EPC Quotation-15th May 2011

ENGCON ENERGY PTE LTD
Company Registration Number: 200301783C N0. 4, Bunga Rampai Place, Singapore 539700 Tel: (65) 62818726 Fax: (65) 68584595 E-mail: albertyap@pacific.net.sg
Mr. Leoncio Tan Managing Director Golden Season Grains Center Inc.
Barangay Dadap, Luna Isabela, Philippines
Date: 15th May 2011
EPC PROPOSAL 6.5MW RICE HUSK FIRED POWER PLANT
EPC Quotation
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Index
1. 2. 3. 4. 5. 6. EQUIPMENT SUPPLY PORTION LOCAL PORTION ENGINEERING AND PROJECT MANAGEMENT EXCLUSION PRICE & PAYMENT TERMS WARRANTY & SCHEDULE
EPC Quotation
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1.
1.1
EQUIPMENT SUPPLY PORTION
One (1) unit rice husk fired boiler and steam generation equipment Please see Annex A for technical specification.
1.2
One (1) unit steam turbine generator and condensing equipment Please see Annex B for technical specification.
1.3
One (1) lot power plant electrical system consist of: a. b. c. d. e. f. g. h. i. j. One (1) unit 15kV, 630amp generator VCB switchgear panel, One (1) unit MV metering and bus PT panel, One (1) unit 1250kVA, 13.2kV / 440V station transformer, One (1) unit 15kV, 630amp station transformer VCB switchgear panel, One (1) unit 15kV, 630amp power plant outgoing feeder VCB switchgear panel, One (1) unit 440V, 2000amp station feeder ACB switchgear panel, One (1) unit boiler & auxiliary equipment MCC panel, One (1) unit black start generator control, synchronizing and ACB switchgear panel, One (1) unit PLC and SCADA (Siemens Step 7). One (1) One (1) unit 75KVA single phase 220V lighting transformer.
1.4
One (1) lot 13.2kV substation equipment consist of: a. b. c. d. e. One (1) unit 15kV, 630amp VCB switchgear panel, One (1) lot system protection & control instruments, One (1) unit metering complete with necessary PTs, CTs, One (1) lot electrical MV, LV and control cables and wires, One (1) lot concrete pole complete with cross-arm, supports, insulators etc.
1.5
One (1) lot water treatment system consist of: a. Three (3) units of 17.5 cu.m/hr each multi media filter & twin softener system each consist of: i. Multi Media Filter Design Flow rate: Feed water Quality: Required Feed Pressure: Product Water Quality: Design Cycle Time: Regeneration: ii. Softener Design flow rate: Feed water quality:
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20 m3 / hr Deepwell water 60 - 80 psi Filtered to less than 20 m 24 operating hours approx. 30 minutes, manual
17.5 cu.m/hr Deepwell water

th
EPC Quotation
15 May 2011

Fee water hardness: Product water hardness: Design cycle time: Regeneration cycle time: iii. Key components
less than 200mg/L as CaCO3 less than 2.0mg/L as CaCO3 approx. 16 hrs approx. 120 minutes
FRP Composite Resin Tank: Manual Operated Valve: Automatic 5-cycle Multiport Softener Valve: Multi-Media Graded Filter Media: Purolite C100 Softener Resin: Top distributor, bottom hub, lateral assembly: Feed water Control Valve: Feed water Variable Flow meter: Liquid filled 2 " SS Pressure gauge: Isolation and bypass valves: Brine tank in polyethylene c/w brine valve: Grundfos Multistage SS Feed Pump: Control Panel: b. One (1) unit water de-mineralizer consists of: i.
3 nos. 1 set 2 set 1 lot 2 lot 3 sets 1 set 1 set 1 lot 2 sets 1 set 1 set 1 set
One (1) unit activated carbon filter as De-mineralizer pretreatment: Design flow rate: Feed water quality: Product water quality: Regeneration cycle time: 5 cu.m/hr Deepwell water Organics free, filtered to less than 50m 30 minutes automatic for MMF and ACF 60 minutes automatic for softener
ii.
One (1) unit 2 bed de-mineralizer: Design flow rate: Feed water TDS: Product water TDS: Product water hardness: Design cycle time: Design throughput: NaOH (as 100%) used per cycle: HCI (as 100%) used per cycle: Effluent generated per regent: 3.5 cu.m/hr 900mg/L < 10mg/L < 0.0mg/L >12 hurs >60 cu.m 35.0 ltr 30.0 ltr 5 cu.m
iii
Key components: Anion and cation narrow bead resin: FRP composite tanks c/w internals airoperated diaphragm valves: 1 lot 1 lot
EPC Quotation
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Flowmeter c/w flow control valves: Pressure gauges: Air pressure regulator c/w solenoid valve assembly: SS multistage pump c/w VSD control: Acid & caustic tanks: Pressure relief valve: Digital conductivity analyzer: PLC based controls with keypad interface, audio & visual alarm, IP55 weather proof control panel: FRP composite resin tank for MMF & ACF: Automatic 3-cycle multiport filter valve: Media for MMF & ACF: Feed water control valve: Top distributor, bottom hub, lateral assembly: Feed water pump: Feed water variable flow meter: Liquid filled 2.5 pressure gauge: Isolating and by-pass valves: Electrical actuated motorized valve: Pressure switchers: PVC SCH 80 plumbing on epoxy coated carbon steel: 1.6 One (1) lot condensate cooling system consists of: a.
1 lot 1 lot 1 lot 2 units 1 lot 1 lot 1 unit
1 set 2 units 2 sets 2 lots 1 set 2 sets 1 unit 1 lot 1 lot 2 sets 2 sets 1 lot 1 lot
Four (4) unit FRP Natural Draft parallel flow cooling tower: i. Design Conditions: Cooling water flow: Hot water temperature: Cold water temperature: Design wet bulb temperature: Evaporation losses: Drift losses: ii. iii. iv. v. vi. 800 cu.m/hr 40C 32C 27.78C approx. 1.35% of water circulation approx. 0.3% of water circulation
Frame Works: Hot dipped galvanized M.S. Louvers: Fiber glass reinforced plastics. Water Distribution Header: Galvanized pipe. Water Distribution Nozzles: PVC / Nylon-6 Bolts, Nut, Misc. Hardware: Electroplated M.S. & PVC
b.
Four (4) units condensate cooling pumps each: Horizontal centrifugal pump, cast iron casing, bronze impeller and stainless steel shaft capable of delivering 800m3/hr against 20mtrs, coupled to 100Hp., 440volts, 3 phase, 60
EPC Quotation
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hz., mounted on a common base-plate and rubber coupling. Suction and discharge size 12 x 10 inches diameter. c. 1.7 One (1) lot isolating valves, strainers and fittings.
One (1) lot power plant auxiliary equipments: a. b. c. d. Two (2) unit air compressor, One (1) unit 750KW Black Start generator (re-conditioned), One (1) unit 10 ton SWL overhead traveling crane (to be installed in Turbine House), Two (2) units 40 cu.m/hr deepwell & pump.
1.8
One (1) lot power plant erection materials: a. b. c. One (1) lot piping and fittings, One (1) lot electrical MV, LV and control cables and wires, One (1) lot steel materials.
EPC Quotation
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2.
BALANCE OF PLANT
The power plant shall be designed and constructed as per attached layouts. 2.1 Mechanical Installation Works a. Boiler and Turbine Generator Installation Works i. ii. iii. iv. v. vi. b. Prepare necessary importation documents & permits, Perform custom clearing, Land transportation from port of discharge to project site. Site assembly & installation works. Jacking, mounting and alignment on foundation blocks. Grouting of turbine generator on foundation block.
Auxiliary Equipment Installation Works i. ii. iii. iv. v. vi. Prepare necessary importation documents & permits, Perform custom clearing, Land transportation from port of discharge to project site. Site assembly & installation works. Mounting and installation of all auxiliary equipment on the foundation. Grouting of all auxiliary equipment using normal non-shrink cement.
c.
Piping Installation works i. Supply of necessary cranes, lifting equipment, welding machines, gas cutters, bending machines, drill press, hand drills, welding electrodes, grinders, hand tools, etc. Fabricate, layout and installation of all system piping in accordance with Approved For Construction Drawings. Fabrication, layout and installation of all steel bracket and support structures for all piping systems. Chemical cleaning, flushing and pickling of piping system including the supply of chemical and anti-corrosion oil if necessary. Pressure testing of piping system in accordance with manufacture requirement. Paintings of all piping systems include supply of paint materials. One coat primer and one coat final finishing. Supply & installation of rockwool insulation and sheet steel cladding.
ii.
iii.
iv.
v. vi.
vii. d.
Supply, fabricate and installation works i. Fabricate and install of 25 meters exhaust chimney.
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EPC Quotation

ii. e.
Drilling and construction of 2 x 35cu.m/hr deepwell.
Supply and installation of the following water tanks: i. ii. iii. One (1) unit approx. 25 cu.m raw water storage tank (elevated tank), One (1) unit 20 cu.m boiler feed water storage tank, One 91) unit 20 cu.m boiler feed water tank with deaerator and steam heating system.
2.2
Electrical Installation Works a. Mounting and installation of all electrical equipment, transformers, panels and switchgears include the supply of anchor bolts and necessary shim plates. Supply, layout and installation of all cable tray systems in accordance with approved plans include the supply of mounting bolts and necessary steel brackets. Supply, layout, installation and termination of all high voltage cables in accordance with approved plans; include the supply of all cables and termination kits. Supply, layout, installation and termination of all low voltage and control cables in accordance with approved plans include the supply of all cables and termination kits.
b.
c.
d.
2.3
Civil Construction Works a. Engineering Design Complete engineering design of Power Plant with control room, foundations, roadwork, storm drainage etc. Engineering work includes: i. ii. iii. iv. v. b. Soil testing and geotechnical evaluation (5 bore holes shall be drilled at site) Architectural drawings, Structural drawings, Material / test certifications for concrete, As-built drawings.
Site Development i. ii. Clearing and leveling, Excavating of foundations and footings.
Note: The site should be backfilled and leveled by Owner before handling over to the contractor. c. Construction of Boiler House i. The Boiler House shall be designed and constructed to house the boiler and associated equipment in accordance with the boiler supplier recommendations and requirements. The floor area of the boiler house shall be approx. 28m x 6.6m.
EPC Quotation
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ii.
Construction 1. 2. 3. 4. 5. 6. 7. Foundation, footings, floors slabs - - Reinforced concrete. Columns, beams, girders, stair ways - - Structural Steel. Masonry - - Combination of steel louvers and ribbed steel sheet. Roof - - Ribbed steel roofing sheets gauge 24 with 25mm thick fiberglass wool thermal insulation and aluminum foil backed. Roof framing - - Structural steel trusses and purling. Lightings and emergency lightings. Lightning protection and earthling system.
d.
Construction of Turbine House i. The Turbine House is a two stories building annex to the Boiler House, the upper level (approx. 6m above ground) shall house the turbine generator and control room, the ground level shall housed the condenser, station transformer & turbine auxiliary equipments The floor area of the rooms are: 1. 2. 3. 4. ii. Turbine Generator Room: MCC panels / Control Room: MV panels & Transformer Room: Condenser & Auxiliary Room: approx. 10m x 18.5m (+8m level) approx. 8m x10m (+8m level) approx. 8m x 10m (+4.5m level) approx. 10m x 18.5m (+0m level)
Construction 1. 2. 3. 4. 5. 6. 7. 8. Foundation, footings, floors slabs - - Reinforced concrete. Columns, beams, girders, stair ways - - Structural Steel. Masonry - - Combination of steel louvers and ribbed steel sheet. Roof - - Ribbed steel roofing sheets gauge 24 with 25mm thick fiberglass wool thermal insulation and aluminum foil backed. Roof framing - - Structural steel trusses and purling. Lightings and emergency lightings. Lightning protection and earthling system Control Room shall be installed with window type or split unit type airconditioner.
iii.
Architectural 1. 2. 3. 4. 5. 6. 7. Masonry (Control Room only) - - Cement plastering on both side with painting. Doors - - Steel or metal doors with painting. Windows - - Double swing glass window with steel or metal casement. Viewing window between Control Room and Turbine generator Room shall be sliding glass panel type size 2m by 1.5m. Floors - - Plain concrete finishing. Washroom - - Unglazed ceramic tiles. Ceilings - - Suspended ceiling with acoustic board and fiberglass wool Insulation in Control Room, no ceiling in other areas.
EPC Quotation
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e.
Construction of 2 stories Workshop / Store & Admin. Office A 2 stories building shall be constructed to house the Workshop / Warehouse on the ground floor and Admin. Office on the 2nd floor. Each floor shall have a floor area of approx. 6m x 18m. Workshop / warehouse: i. Construction 1. 2. 3. 4. 5. 6. ii. Foundation, footings, floors slabs - - Reinforced concrete. Columns, beams, girders, stair ways - - Structural Steel. Roof - - Ribbed steel roofing sheets gauge 24 with 25mm thick fiberglass wool thermal insulation and aluminum foil backed. Roof framing - - Structural steel trusses and purling. Lightings and emergency lightings. Lightning protection and earthling system.
Architectural 1. 2. 3. 4. Masonry - - Cement plastering on both side with painting. Doors - - Steel roller shutter door of 2m x 2.5m with manual operation. Other areas shall be installed with steel or metal doors with painting. Windows - - Double swing glass window with steel or metal casement. Floors - - Plain concrete finishing.
(Workshop equipment, tools, storage facilities, office equipment and stationary are not in the scope of supply). Admin. Office: The admin. office shall be designed and constructed with the following rooms: 1. 2. 3. 4. 5. i. Conference Room, Plant Manager Office, Engineers office, Admin Staff office, Panty / CR / Rest Area:
Construction 1. 2. 3. 4. 5. 6. Foundation, footings, floors slabs - - Reinforced concrete. Columns, beams, girders, stair ways - - Structural Steel. Roof - - Ribbed steel roofing sheets gauge 24 with 25mm thick fiberglass wool thermal insulation and aluminum foil backed. Roof framing - - Structural steel trusses and purling. Lightings and emergency lightings. Lightning protection and earthling system.
EPC Quotation
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7. 8. ii.
CR complete with 1 x toilet, 1 x shower and 1 x wash basin. Office space shall be installed with window type air-conditioner.
Architectural 1. 2. Masonry - - Cement plastering on both side with painting. Doors - - Workshop shall be installed with steel roller shutter door of 2m x 2.5m with manual operation. Other areas shall be installed with steel or metal doors with painting. Windows - - Double swing glass window with steel or metal casement. Floors - - Plain concrete finishing. Washroom - - Unglazed ceramic tiles. Ceilings - - Suspended ceiling with acoustic board and fiberglass wool Insulation in air-conditioned spaces, other areas shall be installed with suspended ceiling with plaster board (gypsum).
3. 4. 5. 6.
(Furniture, telephone, office equipment and stationary are not in the scope of supply).
f.
Foundation & Other Works: i. ii. iii. iv. v. vi. vii. viii. ix. Foundation & Structural Support Works Boiler, Foundation & Structural Support Works Turbine Generator, Foundation & Structural Support Works Chimney, Foundation & Structural Support Works ESP, Foundation & Structural Support Works Water tanks, Foundation & Structural Support Works Cooling tower & pumps, Foundation & Structural Support Works Electrical panels and equipments, Supply and erection of Water Treatment Plant shed, Supply and erection of cooling water pump shed.
g.
Storm Drain System U shape concrete lined canal of various sizes with concrete cover where necessary.
h.
Road Works i. ii. iii. Road - - Road within the power plant to be Portland cement concrete. Curb and gutter - - Concrete. Walkway - - Concrete.
EPC Quotation
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3. ENGINEERING AND PROJECT MANAGEMENT

3.1 Project Management Team Engcon Energy Pte Ltd shall be the leader of the project and shall organize and form a Project Management Team which includes the project teams from the 3 main suppliers. The Project Management team shall be responsible to ensure that the installation of the power generation equipment is completed according to agreed time schedule and meet all technical specifications and performance guarantees as stipulated in this quotation. 3.2 Project Team Organization & Responsibilities The Project Management Team shall be organized based on engineering disciplines and trades. It shall be led by a competent, responsible and experience project manager (PJM) supported by the project manager of the 3 main suppliers and a team of experience engineers, supervisors, specialists and supporting staffs. The PJM shall coordinate with the Owner project team and owners contractors to ensure the smooth execution and timely completion of the project. To ensure the smooth execution of the design, engineering, manufacturing, assembling, packaging, delivery, installation, testing & commissioning of the power generation equipment, the Project Management Team shall: a. Integrate and interface all design and engineering information from the suppliers to prepare necessary engineering drawings for the installation of the power generation equipment; Review all engineering documents to ensure that local requirements, rules and regulations are met; Prepare necessary engineering data, information & drawings for the installation, testing and commissioning of the equipment; Ensure the timely dissemination of engineering and installation information to the suppliers and contractors to ensure the installation of the equipments are done accurately and correctly; Formulate detail equipment delivery schedules to ensure the timely delivery of all equipment to site; Formulate detail construction schedule to ensure the timely completion of the installation work; Formulate necessary installation, QA/QC, safety and security procedures to ensure the smooth and safe execution of the project;
b.
c.
d.
e.
f.
g.
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h.
Ensure the quality of supplies, materials and works comply with approved standards and in compliance with the contract requirements, Coordinate and conduct regular meeting with the Owners project team and owners contractors to ensure all parties are kept updated on the latest status and development of the project; Prepare and submit regular progress report to all concern parties to record the progress, status, developments, certifications etc. on the installation of the power generation equipment.
i.
j.
EPC Quotation
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Project Manager
Engcon Energy Pte Ltd
Engcon Project Tem

1. 2. 3. 4. Design/Engineering Team Procurement Team Packing & Shipment Site Project Team: a. Site Project Manager b. Civil Engineer c. Mechanical Engineer d. Electrical / Instrumentation Engineer e. Piping Engineer f. QA / QC Team g. Safety Engineer 5. Testing & Commissioning Team 1. 2. 3. 4. 5. 6.
IJT Project Tem

Boiler Supplier
Project Manager Design/Engineering Team Procurement Team Factory Assembly Packing & Shipment Site Erection Team a. Erection Supervisor b. Electrical / Instrumentation Supervisor c. Piping Supervisor d. Welding Supervisor e. QA / QC Team f. Safety Engineer g. Local Contractor 7. Testing & Commissioning Team
Triveni Project Tem

Turbine Generator Supplier
Project Tem
69kV Substation Supplier
1. 2. 3. 4. 5. 6.
7.
Project Manager Design/Engineering Team Procurement Team Factory Assembly Packing & Shipment Site Erection Team: a. Installation Supervisor b. Electrical / Instrumentation Supervisor c. Piping Supervisor d. QA / QC Team e. Local Contractor Testing & Commissioning Team
2. 3. 4. 5. 5.
Project manager Design/Engineering Team Procurement Team Packing & Shipment Site Erection Team a. Installation Supervisor b. Electrical / Instrumentation Supervisor c. Local Contractor 6. Testing & Commissioning Team
EPC Quotation
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4.
EXCLUSION
The following are not included in our price and shall be supplied by Owner or others contractors: 1. 2. 3. 4. 5. 6. 7. 8. 9. Construction water and electricity for the whole duration of the project, Pilling works, Clearing, back filling (reasonably compacted) and leveling of the project site with an area of approx. 100m x 100m, Open rice husk storage areas, rice husk weighing and ash disposing facilities, Perimeter fencing, Construction equipment such as bulldozer, excavator, loader, dump-trucks, forklift etc. First fill of lube oil, gear oil, misc. grease and chemical Import tax and duty, VAT and all local government tax and fees, Working VISA for foreign workers and engineers.
5.
5.1
PRICE & PAYMENT TERMS
Price (See attached for details cost breakdown) a. Equipment Supply Portion US$5,850,000.00 (US Dollars Five Million, Eight Hundred and Fifty Thousand Only) b. Balance Of Plant 1. Balance Of Plant #1 Php72,000,000.00 (Philippines Peso Seventy Two Million Only) 2. Balance Of Plant #2 can be handled directly by Golden Season Php36,900,000.00 (Philippines Peso Thirty Six Million and Nine Hundred Thousand Only) The quoted price is net to the Contractor, any local tax such as VAT, income tax and any other government tax shall be paid by the Owner on behalf of the Contractor.
5.2
Payment Terms a. Equipment Supply Portion i. ii. iii. 25% down payment on contract signing by direct bank TT, 65% on shipment covered by LC, 10% on completion of testing and commissioning covered by LC.
EPC Quotation
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b.
Balance Of Plant i. ii. 30% down payment on contract signing by direct bank TT, 70% on monthly progress payment covered by LC.
6
6.1 Warranty
WARRANTY & SCHEDULE
Unless otherwise specified, the warranty period shall be 12 months commencing from the date so certified in the Taking Over Certificate or 240 months after the date of shipment whichever occurs first. 6.2 Project Schedule The project completion schedule shall be 24 months from the received of down payment and LC,
This validity of this quotation is 2 months until 15th July 2011.
Albert Yap Director
EPC Quotation
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EPC PRICE ESTIMATION - 6.5MW

15th May 2011
S/No. 1 Item Description Boiler - Supplied By IJT - CIF Manila a. Main boiler, furnace & traveling grate b. Induce air & combustion air system c. Husk feeding system & service tank d. Ash evacuation system e. Feed water supply system f. Feed water deaeration system g. Turbine control steam supply system h. Feed water chemical dosing & treatment system i. Fly ash filtration system - Electro-Static-Precipitator Turbine Generator - By Triveni India a. Multi stage turbine b. Water cooled AC generator c. Vacuum Condenser & condensage pumps d. Turbine control & PLC panel e. Generator control & syn. panel Electrical System - by Engcon a. Generator switchgear panel b. MV metering and Bus PT panel c. 13.8KV / 440V Station transformer d. 13.8kV Station transformer MV switchgear panel e. 13.8kV Outgoing feeder switchgear panel with metering f. Station main LV feeder switchgear panel g. Boiler MCC and DC starter panel h. PLC / SCADA i. Black start switchgear & syn. panel j. Testing & Commissioning Other Power Plant Equipments & Materials - By Engcon a. Water Treatment System - Demin. (2 x 2.5 cu.m/hr) b. Water Treatment System - MMF & Softener (3x20m3/h) c. Cooling Water Pumps (3 x 1000 m3/hr) d. Cooling Tower (3 x 1000 m3/hr) e. Overhead Crane f. Piping & Fittings - for cooling system only g. Piping & Fittings - for turbine & others h. Electrical cables i. Steel materials 13.2kV Substation a. 15kV Fuel Cutoff Switch with Lightning Arresters b. PTs, CTs & Metering c. Steel pose, insulators, conductors etc. Unit 1 Lot 1 Lot 1 Lot 1 Lot 1 Lot 1 Lot 1 Lot 1 Lot 1 Lot 1 Lot 1 Lot 1 Lot 1 set 1 set 1 set 1 set 1 Lot 1 set 1 set 1 unit 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 Lot 1 set 3 3 3 1 set 1 set 1 set 1 lot 1 lot 1 Lot 1 set 1 lot 1 lot Unit Cost $2,950,000.00 $1,900,000.00 $450,000.00 $550,000.00 $15,000.00 Subtotal: Discount: Discounted Price: Total Cost $2,950,000.00 $1,900,000.00 $450,000.00 $550,000.00 $15,000.00 $5,865,000.00 $15,000.00 $5,850,000.00
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Balance Of Plant #1 - M&E S/No. M&E Installation Works 1 M&E - Boiler 2 M&E - Turbine Generator / cooling system / others 3 Tools, trucks and crane etc (see # 01). 4 Consumables & paint etc. 5 Misc. Equipment & Materials a. Compressor & dryer b. Battery Panel c. Lighting transformer 150kVA
Unit 1 lot 1 lot 1 lot 1 lot 2 units 1 unit 1 unit
Unit Cost (Php) 24,000,000.00 8,000,000.00 4,000,000.00 1,000,000.00 350,000.00 150,000.00 150,000.00 Subtotal:
Total Cost 24,000,000.00 8,000,000.00 4,000,000.00 1,000,000.00 700,000.00 150,000.00 150,000.00 38,000,000.00
Balance Of Plant #2 - Civil S/No. Civil Construction Works 1 Design & Engineering 2 Boiler foundation & firing floor 3 ESP (deduster) foundation & footings 4 ID fan foundation 5 Exhaust chimney, support structure & foundation 6 Turbine generator house & control room
Unit 1 lot 1 lot 1 lot 1 lot 1 lot 1 lot
Unit Cost (Php) 500,000.00 12,000,000.00 2,000,000.00 300,000.00 3,000,000.00 20,000,000.00 Subtotal: Total BOP #1: Discount: Discounted Price:
Total Cost 500,000.00 12,000,000.00 2,000,000.00 300,000.00 3,000,000.00 20,000,000.00 37,800,000.00 75,800,000.00 3,800,000.00 72,000,000.00
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Balance Of Plant #2 S/No. M&E Installation Works 1 Custom clearing & transportation to site (# 01) 2 All risks insurance 3 Equipment Rental (# 03) 4 Black start engine - 1000kw (Reconditioned) 5 Rice husk supply conveyor & elevator 6 Ash conveyor & elevator 7 Deepwell and pump (2 x 35m3/hr) 8 Cooling tower basins 9 Water treatment shed (4m height) 10 Cooling water pump foundation & shed (Roof only) 11 Rick husk storage bunker 12 Ash storage bunker 13 Road, side walk, car park & drainage 14 Deepwell water storage tank, support tower & foundation 15 Admin. Office / Workshop / Warehouse (6m x 18m) 16 O&M staff dormitory
Unit 1 lot 1 lot 1 lot 1 lot 1 lot 1 lot 2 1 lot 1 lot 1 lot 1 lot 1 lot 1 lot 1 lot 1 lot 1 lot
Unit Cost (Php) 5,000,000.00 1,750,000.00 300,000.00 2,500,000.00 1,500,000.00 800,000.00 400,000.00 2,750,000.00 500,000.00 250,000.00 8,500,000.00 1,500,000.00 1,500,000.00 750,000.00 5,000,000.00 3,500,000.00 Subtotal: Total BOP #2: In US$ $5,850,000.00 $1,655,172.41 $848,275.86 $8,353,448.28
Total Cost 5,000,000.00 1,750,000.00 300,000.00 2,500,000.00 1,500,000.00 800,000.00 800,000.00 2,750,000.00 500,000.00 250,000.00 8,500,000.00 1,500,000.00 1,500,000.00 750,000.00 5,000,000.00 3,500,000.00 36,900,000.00 36,900,000.00 In Peso 254,475,000.00 72,000,000.00 36,900,000.00 363,375,000.00
US$ To Php: 43.500
Total Price - Equipment: Total Price - BOP#1: Total Price - BOP#2:
Balance Of Plant #2 (BOP#2) can be handled directly by Golden Season. # 01 # 02 # 03

Use of necessary construction equipment available in Golden Season. Only heavy lift crane need to rent from Manila. Use the empty rice trucks to carry imported or local purchase equipment & materials to site from Manila. Only oversize items shall use special trucks and carriers rental from special transportation contractor. Use necessary construction equipment available in Golden Season.
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6.5MW Rice Husk Fired Power Plant Layout

8th May 2011
Existing 2MW Power Plant
Approx. 80 meters
Admin./Workshop Building
(6m x 18m)
Garden
Water Treatment Plant (6m x 16m)
Cooling Towers
TG Room
Control Room (8 x 10m) (10m x 18.5m)
Approx. 70 meters
Rice Husk Bunker

(2 Days Capacity)
Husk Loading Station
Ash Bunker
1-75
6.5MW Rice Husk Fired Power Plant Layout
Approx. 80 meters
Admin./Workshop Building
(6m x 18m)
Garden
Water Treatment Plant (6m x 16m)
Cooling Towers
Approx. 70 meters
TG Room
Control Room (8 x 10m) (10m x 18.5m)
Rice Husk Bunker

(2 Days Capacity)
Husk Loading Station
Ash Bunker
1-75
Layout Plan - 2 Stories Admin. / Workshop Building
CR
CR
Pantry
Engineer Office
Workshop
Admin. Office
18m
Plant Manager Office
Tool Store / Warehouse
Conference Room
6m
125
O&M Staff Dormitory
4m
1m
4m
4m
4m x 2.5m 4m x 3m
Pool Table
4m x 2.5m 4m x 3m 4m x 2.5m 4m x 3m 16m 4m x 2.5m

Table
Ref.
Cooking Area
4m x 3m 4m x 2.5m CR, Shower Washing Area
4m x 3m
75-1:15
Conceptual Rice Husk Feeding Design
Husk Bunker
30
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18m
14m
75-1:15
Annex A
Boiler Technical Specification & Scope Of Supply
ISGEC John Thompson

Scope Of Supply & Technical Specification For A 40 TPH Rice Husk Fired Traveling Grate Boiler
SECTION SECTION 1 SECTION 2 SECTION 3 SECTION 4 SECTION 5 SECTION 6
DESCRIPTION SALIENT FEATURES OF PROPOSED STEAM GENERATOR DESIGN BASIS SCOPE OF EQUIPMENT SUPPLY AND SERVICES TECHNICAL DATA SHEETS PERFORMANCE GUARANTEES LIST OF MAINTENANCE TOOLS AND TACKLES
1.
ISGEC JOHN THOMPSON (IJT) is amongst India's leading manufacturer of Industrial Boiler, Sugar plant, Raw Syrup Plant for Ethanol. IJT hold a significant market share of our products/projects in India as well as in overseas market. IJT has supplied over 550 boilers and 56 Complete Sugar Plants and major expansions to date in India and several overseas markets. IJT is part of over US$ 450 million turnover Public Limited Company. IJT is ISO 9001-2000 certified. IJT works is amongst the most sophisticated and modern manufacturing facilities in India. IJT has have overseas offices in USA and Germany. Currently IJT is executing a number of contracts overseas, some of which are listed below: USA- 1 No. 70 TPH Gas Fired Boiler for Longview Power Project. Chile- 1 No. 140 TPH Coal Fired Boiler for Methanex Group. Spain- 1 No. 28 TPH biomass fired Boiler for Aldebaran Energy. Brazil- 2 Nos. 100 TPH Oil and gas Fired Boilers for Petroquimicasuape. Senegal 1 No. 150 TPH Travelling Grate Boiler for Compagnie Sucriere Senegalaise Thailand- 1 No. 95 TPH Travelling Grate Boiler for Mid-Siam Sugar Co. Ltd. (Mitr Phol Group) and 2 Nos. 150 TPH Travelling Grate Boilers for Khon Kaen Sugar Power Plant Co. Ltd. 1 No. 10 MW Power Plant with rice husk fired boiler for U thong Biomass project. Page 1 of 24
2.
3.
Philippines - Cane Milling & Raw Syrup Plant of 1650 TCD, Multi-fuel fired boiler on turnkey basis (excluding civil work). This is for a Greenfield Ethanol Plant Project as a Joint Venture with Bronzeoak, U.K. a British Company commissioned in Nov 2008.. Sudan- 4 Nos. 130 TPH bagasse /oil fired Boilers on turnkey basis for While Nile Sugar, Sudan Project. Kenya- Complete Sugar Plant of 1650 TCD capacity to Kibos Sugar & Allied Industries Ltd., Kenya for plantation white sugar by double sulphitation process. Complete Sugar plant of 1650 TCD capacity to Butali Sugar Mills Ltd. for plantation white sugar by double Sulphitation process. 170 TPH, 87 kg/cm2g, 515 Deg C bagasse fired Boiler and Bagasse Handling system for Mumias Sugar, Kenya. Zambia - 31 MW Power Plant which includes a 160 TPH bagasse fired Boiler, TA set and associated works for Nakambala Sugar, Zambia. Expansion of Complete Sugar Plant originally supplied by us at Consolidated Farming Ltd. from 1500 TCD to 2500 TCD capacity. This Plant produces both plantation white and raw Sugar.
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SECTION 1 SALIENT FEATURES OF PROPOSED STEAM GENERATOR I. DESIGN FEATURES: 1. Conservative grate area loading to ensure the efficient combustion of fuel. 2. Temperature elements are provided on the skid bar, cross beam and riddling hoppers with temperature indication in the control room. Also alarm is provided to alert when the temperature reaches around 3000 C. 3. Conservative volumetric loading of furnace. a. Ensures adequate residence time for efficient fuel combustion. b. Ensures lower furnace exit gas temperature to avoid fouling due to alkali content in the fuel. 4. Higher furnace cross section to reduce flue gas velocity in the furnace, hence reduced fuel carry over and less suspension / localized combustion in the upper furnace. 5. Convective Super heater Design. a. Super heater placed in radiant zone faces burning fuel particles. b. Fouling of ash in Super heater due to high temperature in radiant zone. c. Causing overheating of radiant Super heater during boiler start up due to higher metal temperature. All the above problems are eliminated by placing super heater in convective zone. (Refer General Arrangement drawing enclosed). 6. Conservatively designed Steam drum / Water drum a. To keep drum steam loading rate low. b. To enable boiler operation with rapid load swings and fast response to load changes. 7. Efficient drum internals consisting of cyclone separators and demisters to ensure high steam purity at all loads. 8. Single pass, inline boiler bank without baffles, hence lower flue gas velocities, lower tube erosion and less draft loss. 9. Over fire air system with higher secondary air pressure to provide better air penetration across furnace cross section thereby minimizing un burnt carbon loss. The secondary air nozzles are staggered providing turbulence and air curtain to minimize escape of un burnt fuel particles. 10. Optimum steam side pressure drop in superheater circuit to ensure proper steam distribution and cooling of superheater coils. 11. Optimum flue gas velocity levels in pressure parts to minimize erosion due to ash. 12. High circulation ratio at all loads ensuring efficient cooling of water wall tubes and also preventing departure from nucleate boiling.
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II.
CONSTRUCTION FEATURES 1. The material of construction of grate bar is Spheroidal Graphite Iron. This is moderate silicon, low alloy ductile (nodular cast iron with ferrite matrix). 2. Self lubricated graphite bearings (Morganite bearings) are provided for the stoker shaft. The Morganite carbon bearing is self lubricating, chemically inert, dimensionally stable, nonhygroscopic and highly resistant to wear characteristics which makes it ideal for hostile environment. 3. Drum internals of bolted construction for easy removal / replacement. 4. Water-cooled membrane wall construction with optimum fin width. To have maximum absorption of heat. Lower fin tip to base differential temperature. Structural rigidity. 5. Inline, single pass boiler bank tube, hence optimum draft loss, ease in cleaning. 6. Wide pitching of superheater assemblies to minimize fouling. 7. Plain tube economizer with in line arrangement ensures ease of cleaning and inspection. 8. Air heater air side bypass arrangement with manual damper and corten steel tubes will be provided for first 6 rows on air entry side to prevent corrosion during low load operation and start up of the boiler. 9. Adequate soot blowers in superheater, boiler bank and economizer region for efficient onload cleaning of heating surfaces. 10. Pressure parts tubes made of hot finished seamless steel construction to ensure high tube life and hence higher boiler availability. 11. Provision of adequate access doors / observation doors for inspection and repair. 12. Location and arrangement of heating surfaces ensures good accessibility for inspection and repairs. 13. Minimum use of refractory, thereby eliminating cumbersome maintenance.
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SECTION 2 DESIGN BASIS ISGEC JOHN THOMPSON, BI DRUM, NATURAL CIRCULATION, BALANCED DRAUGHT, SEMI OUTDOOR, WATER TUBE TYPE, BOTTOM SUPPORTED, CONTINOUS ASH DISCHARGE TRAVELLING GRATE BOILER suitable for A. BOILER PARAMETERS MCR Evaporation (Gross) Peak Generation ( hour once in a shift of 8 hours ) Steam Pressure at Boiler Main Steam Stop Valve outlet Super heated steam temperature at Main Steam Stop Valve outlet Super heated steam temperature Control range Feed Water Temperature at inlet of Economizer / outlet of deaerator Number of boilers B. SITE CONDITION Ambient Temperature Relative Humidity Seismic Zone Wind velocity Plant elevation Plant location m/s Deg.C % 30 60 Zone IV As per UBC 1997 56 627 m above mean sea level Philippines kg / hr kg / hr 40,000 40,000
bar(g)
38
Deg. C
370 12
% BMCR
60-100
Deg. C
105
Nos.
One
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Area classification * Client to confirm C. DESIGN / PERFORMANCE CODES Pressure part Boiler Integral & External Piping Other auxiliaries and non pressure parts including steel structural Performance testing of the boiler (efficiency)
Safe, Non Hazardous & Non Corrosive
ASME ASME Indian standards.
ASME PTC 4.1-1964 (R1991) by Indirect heat loss method IEC / IS ISA
Electrical Control and Instrumentation D. FUEL Fuel for Load carrying Rice Husk E. UTILITIES 1. Cooling water (Fresh, filtered circulating cooling water) Supply pressure 3.5 bar (g) Supply temperature 30 Quality of water Filtered and Clarified. 2. Instrument air Pressure Temperature Dew Point Quality Plant air Pressure Temperature Quality
100% MCR Rice Husk Natural
6 bar (g) 30 (-) 40 Deg. C Moisture and oil free, clean air.
3.
6 bar (g) 30 Oil free clean air.
4. Electric Power: Motor Voltage Frequency Combined variation Type Instrumentation
440V +/- 10% 60 Hz +/- 5% 10% 3 phase, AC supply
Page 6 of 24
Voltage Frequency Type Field transmitters Voltage Type F.
220 V 60 Hz 1 phase, AC
24 V DC
RECOMMENDED FEED WATER AND BOILER WATER REQUIREMENT As per BS 2486
G.
Drive Turbine Steam Parameters Inlet Steam Condition Pressure Temperature
38 bar (g) 365 0C
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SECTION 3 SCOPE OF EQUIPMENT SUPPLY AND SERVICES Mechanical 1. Pressure parts Steam drum of fusion welded construction provided with necessary nozzle and with dished ends on both side with man ways. Steam drum internals comprising cyclones, scrubbers & demisters. (Drum internals are of carbon steel construction except demister, which is of SS construction). Mud drum of fusion welded construction with dished ends on both side with man ways. Furnace water wall tubes of fin welded water-cooled membrane wall construction together with inlet and outlet manifolds provided with necessary stubs. Necessary openings in the furnace for access doors peep holes and fuel distributor. Single stage Superheater system with all inter connecting piping and headers. Boiler bank tubes of single pass design. Economizer complete with inlet and outlet manifolds and coil support. All pressure parts tube material will be of hot finished seamless tube.
2. Feed Water system Feed water piping from deaerator storage tank outlet to boiler feed pump suction including suction header and from boiler feed pump discharge including discharge header. Feed water piping from boiler feed pump discharge header to feed control station inlet and from feed control station outlet to economizer inlet header. Feed water piping from economizer outlet header to steam drum. Cooling water supply / return piping from terminal point near boiler front row column to all equipment within the boiler island requiring cooling water. Service water supply / return piping from terminal point near boiler front row column to all equipment within the boiler island requiring service water. Boiler initial filling line from terminal point near boiler front row column to the water wall drain header. Spray water piping from boiler feed pump discharge to PRDS for deaerator initial heating. Hangers and supports for piping, as required.
3. Steam system Circulating system including down comers and risers. Saturated steam piping from steam drum to super heater inlet header.
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Steam piping from superheater outlet header to main steam stop along with integral bypass valve. Soot blower steam piping from super heater header outlet to respective soot blowers in superheater, boiler bank and economizer. Upstream piping for deaerator pressure reducing desuperheater station steam line (Max. 5 m length considered). from main
One no. initial heating deaerator steam pressure reducing and de-superheating station (fixed orifice type) including pressure control valve and temperature control valve (1 x 100% pneumatic pressure control valve and 1 x 100% pneumatic temperature control valve with manual isolation valve at inlet & outlet and manual by pass valve). Pressure Reducing & De-Superheater capacity of 4 TPH considered. Steam piping from PRDS outlet to deaerator. (Max. piping length of 50 m considered). Target plate and temporary piping required for steam blowing. Hangers and supports for piping, as required.
4. Drain and Vent piping
Safety valve exhaust & Start up vent piping up to a safe elevation. High pressure boiler blow down piping up to continuous blow down tank. Drain piping from individual drains to drain header and from drain header to intermittent blow down tank. Drain piping from continuous blow down tank to intermittent blow down tank with level control valve. Blow down piping from outlet of intermittent blow down tank to nearest trench in boiler area. Each One no. blow down tank for continuous & intermittent blow down. Flash steam piping from continuous blow down tank to deaerator. Raw water quenching line for Intermittent Blow Down tank from terminal point.
5. Non Pressure parts Tubular Mild Steel airheater (with ERW tubes and gas flow through tubes) to preheat the combustion air and comprising of tube sheet, casing and associated supports and structures. (First 6 rows of tubes at cold end will be of corten steel tubes to avoid cold end corrosion during boiler starting and part load operation). Airheater provided with bypass arrangement with manual damper.
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Over Fire Air nozzle at required elevation in furnace wall along with necessary ducting, if required. Pre dust collector is provided upstream of air heater in the flue gas path to collect the larger unburnt carbon / ash particle from the gas stream and prevent fire hazard in ESP.
Casing & Hoppers: Carbon steel casing (5 mm thick) with stiffeners and supports for economizer. Furnace front ash discharge chute submerged into submerged ash conveyor along with manually operated plate gates. Bottom ash riddling hoppers with manually operated plate gates and rotary air lock valve. Fly ash hoppers below economizer/air preheater and ESP operated isolation plate gate and rotary air lock valve. Boiler Supporting Structures, Plat forms, Stair case & operating floor: Buck stays, tie bars as required. Boiler steel supporting structure from operating floor. The structure up to operating floor and operating floor will be RCC which has to be done by the customer. Galleries, ladders and stairways with hand rails providing access to the essential levels of the boiler, fuel feeders and soot blower etc. Gratings are of open bar type. (Gratings, platforms, handrails, staircase are of Galvanized Iron construction). One no. staircase from firing floor level to steam drum operating floor level as shown in General arrangement drawing. Canopy (Galvanized sheet of 24 SWG thick) over boiler furnace and side cladding (Galvanized sheet of 24 SWG thick) for boiler up to steam drum operating floor level from top. Roof structure and structures for side cladding sheets. G.I weather protection hoods for outdoor motors. Rain water down pipes. Support and suspension steel, access platform for all equipments, piping and ducting. Air and Flue gas ducting: Air ducting with required stiffeners, carbon steel expansion joints, resin bonded mineral wool insulation, cladding and necessary fixing components (plain Aluminium cladding thickness of 24 SWG for hot air ducting) for the following. o Forced draft air fan cold air suction ducting. Page 10 of 24 with manually
o o o o o
Cold air ducting from Forced draft air fan to air heater. Hot air ducting from air heater to furnace bottom. Secondary air fan cold air suction ducting. Cold air ducting from Secondary air fan to air heater. Hot air ducting from Secondary air fan outlet to over fire air nozzle / fuel pneumatic spreader.
Flue gas ducting with required stiffeners, carbon steel expansion joints, resin bonded mineral wool insulation, cladding & necessary fixing components (plain Aluminium cladding thickness of 24 SWG) for the following: o o o o o Flue gas ducting from boiler outlet to economizer. Flue gas ducting from economizer to air heater. Flue gas ducting from air heater to Electrostatic Precipitator. Flue gas ducting from Electrostatic Precipitator to Induced draft fan inlet. Flue gas ducting from Induced draft fan outlet to inlet of chimney.
(All the above duct plate material will confirm to IS2062) Travelling grate: Continuous ash discharge travelling grate complete with variable frequency electric drive, reduction gear box. The grate assembly will include the key, seals, bottom air compartment and tensioning mechanism. Self lubricated bearing (graphite bearings) are provided for the travelling grate stoker shaft. Thermocouples are provided on the skid bar, cross beam and riddling hoppers. Refractory & Insulation: Lightly resin bonded mineral wool Insulation (Designed for 20Deg C differential temperature between ambient and surface temperature with an air velocity of 1.0 m/sec over the surface) and plain aluminum cladding thickness of 24 SWG for electro static precipitator, ducting, piping and other auxiliaries as required along with fixing material. Corrugated aluminum cladding thickness of 24 SWG for boiler furnace. Chimney counter flanges, expansion joint near chimney and fasteners for the connection. Casting for access doors and peep holes.
6. Auxiliaries One no. horizontal, radial and backward curved blade, cold Secondary Air (SA) fan with constant speed electric drive motor including foundation bolts, base frame, coupling, coupling guard, suction silencer ( if required) and suction hood. Fan will be provided with pneumatically operated Inlet Guide Vanes (IGV) / Damper. Speed of the fan will be 1800 rpm. Grease lubrication is provided for the fan bearings.
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One no. horizontal, radial and backward curved blade, Forced draught (FD) fan with constant speed electric drive motor including foundation bolts, base frame, coupling, coupling guard, suction silencer (if required) and suction hood. Fan will be provided with pneumatically operated Inlet Guide Vanes (IGV)/Damper. Speed of the fan will be 1800 rpm. Grease lubrication is provided for the fan bearings. One no. horizontal radial, backward curved blade, simply supported Induced Draught (ID) fan with variable speed electric drive motor & pneumatically operated Inlet Damper Control (IDC) including base frame coupling, coupling guard speed of the fan will be 1200 rpm. Impeller will be provided with hard facing / replaceable liners to minimise erosion. Grease lubrication is provided for the fan bearings. Manual isolation damper at SA/ FD/ ID fan outlet. RTD for measuring the bearing temperature of fans. Individual base frame and foundation bolts for fans & motors. Sample coolers complete with SS coils, sampling piping and cooling water piping for superheated steam, saturated steam, boiler feed water and blow down water. Valves, mountings and fittings including the following: o o o o o o Two nos. Spring loaded safety valves on steam drum and one no safety valve on super heated main steam line. Silencers for startup vent valve and superheater safety valve to limit the noise level to 110 dBA at 1m distance. One x 100% pneumatically operated feed control valves with manual isolation valves at upstream and downstream. One x 100% motorized by pass for feed control valves One no. non return valve in steam line at boiler outlet. Required nos. manual isolation in main steam line.
List of Motorized isolation valves: o o o o One no motorized main steam stop valve with motorized integral bypass at superheater outlet. One no pneumatic start up vent valve (with inching facility) with motorized isolation valve. Two nos. motorized isolation valve at feed pump discharge. Each one no. motorized continuous blow down & intermittent blow down valve.
7. Soot Blowers Electrically operated long retractable soot blowers for superheater zone and rotary soot blowers for boiler bank and economizer zone complete with pressure reducing station
Page 12 of 24
and other accessories, valves/fittings. Sequential operation of soot blowers will be realized in distributed control system. One x 100 % pneumatically operated soot blower pressure control valve with manual isolation valve at upstream and manually operated isolation valve at downstream and one no. 100% manually operated bypass valve.
8. Deaerator cum storage tank, Boiler Feed water pumps ,Feed water storage tank & transfer pumps & Chemical dosing system: Deaerator cum storage tank: o One no. Spray cum tray type deaerator of 48 TPH capacity and De-aerated water tank of 20 minutes storage of MCR generation capacity between NWL to trip level. Deaerator is to be mounted on top of control room. (Refer enclosed General Arrangement drawing for the location of deaerator) One x 100% pneumatically operated deaerator pressure control valve with manual operated isolation valve at up stream and downstream and one no. manual by pass valve. One x 100% pneumatically operated deaerator level control valve with manual operated isolation valve at up stream and downstream and one no. manual by pass valve. Steam piping from pressure control valve to deaerator. Feed water piping from level control valve to deaerator. Condensate piping from terminal point to deaerator. Over flow piping from deaerator terminated near deaerator with level control valve. Ladders or staircases, as required. Lightly resin bonded mineral wool insulation with plain aluminum cladding of 0.80 mm thick. Valves and fittings, as required. Boiler feed water pumps: o 2 x 100% MCR Capacity centrifugal, single section, multistage, ring section type boiler feed pump (1W+1S) along with constant speed drive motor complete with coupling, connection flange, automatic recirculation valve, suction strainer, mechanical seals, lift off device and ring oil lubrication. Upsteam piping for drive turbine from main steam line and exhaust steam piping from turbine exhaust to deaerator.
o o o o
o o
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Minimum re-circulation piping and balance leak-off piping from boiler feed water pumps to inlet of deaerator tank. RTD for measuring the bearing temperature of pumps. Individual base frame and foundation bolts for pump & motor. Chemical Dosing System:
o o
One no Skid mounted Low Pressure dosing system comprising of one no. mixing cum storage tank (stainless steel) with motorized agitator and 2 nos. positive displacement pumps(1W+1S). One no Skid mounted High Pressure dosing system comprising of one no. mixing cum storage tank (stainless steel) with motorized agitator and 2 nos. positive displacement pumps(1W+1S). Low Pressure Dosing piping (stainless steel) from Low Pressure dosing tank to Boiler feed pump suction. High Pressure Dosing piping (stainless steel) from High Pressure dosing tank to Steam drum. Valve and fittings as required. High Pressure / Low Pressure dosing system dilution water line from one point near boiler front row column to respective dosing tanks.
o o
9. Fuel Storage Bunker & feeding system : Rice Husk storage bunker & feeding system: o One no. carbon steel bunker of 50m3 (water volume) capacity for storing Rice husk along with supporting structure, manual plate gates at bunker outlet. Three nos. surge hoppers at feeder inlet. Three nos. of screw feeder with variable frequency drive for feeding the Rice Husk to furnace through pneumatic spreaders along with necessary connecting chutes. Three nos. pneumatic spreaders.
o o
o 10.
Pollution control equipment Electrostatic precipitator: One no. Electrostatic precipitator of single stream type to limit the outlet dust concentration to 150 mg/Nm3 at the outlet of ESP with all fields working. Complete accessories including emitting & collecting electrodes, casing, hoppers, hopper level indicators, hopper heater, rapping mechanism, T/R sets, supporting structures, stairways, walkways, handrails, housing, carbon steel expansion joints, Page 14 of 24
Lightly resin bonded mineral wool insulation with plain aluminium cladding of 24 SWG thick, inlet and outlet funnels, gas distribution screens, electrical and mechanical interlock system, manually operated isolation gates at hopper discharge. Hopper heaters are thermostatically controlled. (Stairways, walkway, handrails are of Galvanized Iron construction). 11. 11.1 Instrumentation Local field instruments Temperature elements to measure 11.2 11.3 Flue gas temp. at furnace outlet (K type thermocouple) Flue gas temp. at superheater outlet (K type thermocouple) Flue gas temp. at outlet of boiler bank (K type thermocouple) Flue gas temp. at outlet of economizer(RTD) Flue gas temp. at outlet of Air preheater (RTD) Flue gas temp. at outlet of ESP(RTD) Air temp. at outlet of Air preheater(RTD) Air temp. at riddling hopper (K type thermocouple) Feed water temp. inlet & outlet of economiser(RTD) Steam temp. after superheater(K type thermocouple) Feed water temp. at Deaerator outlet (RTD)
Pressure gauges to measure Steam pressure at Steam Drum and at the outlet of Super Heater. Feed Water pressure before & after Feed Water control station. Feed water pressure at economiser inlet and outlet. Soot blower pressure Feed pump suction & discharge pressure CBD tank pressure Instrument air pressure
Draught gauges to measure Furnace pressure Flue gas pressure at superheater outlet Flue gas pressure at economiser inlet & outlet Flue gas pressure at outlet of air preheater Flue gas pressure at ESP outlet Flue gas pressure at chimney inlet Air pressure before and after air preheater Air pressure at SA fan discharge
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11.4 11.5
Air pressure at riddling hopper
Temperature gauges to measure Steam temp. at superheater outlet Flue gas temp. at outlet of air preheater Air temp. at SA fan discharge Flue gas temp. after ESP Air temp after air preheater Feed water temp before & after economizer. Feed water 100% control valve (1 no.) De-aerator level control valve. (1 no.) De-aerator pressure control valve. (1 no.) Soot blower pressure control valve. (1 no)
Pneumatically operated control valves
11.6
Pneumatically operated power cylinder FD Fan inlet - 1 no ID Fan inlet - 1 no SA Fan inlet - 1 no
12.0 12.1
Field instruments required for PLC based control system (PLC is quoted optionally) Field instruments required for the following control loops: No. 3 1 1 1 1 1 1 1
12.1.1 Three Element Drum Level Control Drum Level Transmitter(2 out of 3 logic) Drum pressure transmitter Steam Flow Transmitter. Feed flow Transmitter. Nozzle for steam flow Orifice for water flow I / P Convertor for FCV Feed control valve
12.1.2 Furnace Draught Control Furnace Pressure Transmitter I / P Convertor Power Cylinder 2 1 1
12.1.3 Auto Combustion Control Steam pressure Transmitter Air Flow Transmitter Aerofoil meter Page 16 of 24 1 1 1
12.2.
O2 analyser I / P Convertor Power Cylinder
1 1 1
12.1.4 Deaerator level Control Level Transmitter I / P Convertor Level Control valve 1 1 1
12.1.5 Deaerator pressure Control Pressure Transmitter I / P Convertor Pressure Control valve 1 1 1
12.1.6 Blow down tank level control Level Transmitter I / P Convertor Level Control valve 1 1 1
12.1.7 Soot blower steam pressure control Pressure Transmitter I / P Convertor Pressure Control valve 1 1 1
12.1.8 Deaerator initial heating PRDS control Compensating cables from thermocouples to junction boxes (Junction box is located within the boiler house) 12.3 Control and instrumentation cables from field instruments to local junction boxes (junction boxes is located within the boiler house) 12.4 12.5 13. Impulse piping wherever necessary for the items which are under our scope of supply. One no. O2 analyzer in flue gas line placed after economizer Electrical 14. Drive motors of all auxiliaries covered under the scope Variable frequency drive for fuel feeders, stoker drives and ID Fan. Electric actuators for valves as applicable.
General Initial fill of lubricants and grease. Chemicals for alkali boil out.
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Suitable operating mechanism complete in all respect with access for operation of all manual and power cylinder operated dampers. Two coats of red oxide primer painting at shop prior to dispatch. Commissioning spares as required. Special tools and tackles, as per enclosed list. Two years Operational and Maintenance spares, as per enclosed list. (Quoted separately).
15.
Scope of Services. Supervision of Erection / Testing & commissioning of mechanical, Electrical, C&I equipments as included and scope of supply. Performance test of boiler. Training of purchasers operating personal (schedule to be mutually discussed).
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SECTION - 4 TECHNICAL DATA SHEETS Furnace Width Depth Height Type Tube diameter Tube thickness Material Steam Drum Material ID Thickness Water drum Material ID Thickness Water wall headers Material No of Headers Superheater (Counter flow type) OD x T (mm) Material Inlet header material Outlet header material Boiler Bank Type Tube OD x T (mm) Material Economiser Type Location Tube OD x T (mm) Tube material Air heater Type Tube OD Thickness Material : : : : Tubular, gas through tubes. 63.5 mm 2.3 mm BS 6323 ERW & Corten Steel for first 6 rows of tubes at cold end of airheater block. : : : : Inline, horizontal Between boiler bank outlet and Air heater. 38.1 x 4.0 SA 210 Gr A1 : : : Single pass, in line arrangement. 51 x 4.0 SA 192 : : : : 38.1 x 4.0 SA 210 Gr A SA106 Gr B. SA106 Gr B. : : SA 106 Gr. B Six : : : SA 516 Gr 70 914 mm As per ASME : : : SA 516 Gr. 70 1372 mm As per ASME : : : : : : : 4400 mm 4312 mm 13500 mm Membrane wall construction 63.5 mm 4.00 mm SA 210 Gr A1
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Effective Heating Surface Areas (Sq. M.) Furnace (EPRS) Boiler Bank Economiser Superheater Air heater FD Fan No of fans Type Design volume Design head Motor rating Speed Type of Control ID Fan No of fans Type Design volume Design head Motor rating Speed Type of Control SA Fan No of fans Type Design volume m/s Design head mmWC Motor rating KW Speed rpm Type of Control Boiler Feed Water Pumps No. of pumps Type of pump Design Flow Design head Motor rating Speed : : : : : : 2 x 100% (1W + 1 S) Multi Stage, Centrifugal, Ring section 52.20 590 132 3600 : : : : : : : 1 x 100% Centrifugal, Backward curved, simply supported. 8.6 690 90 1800 Inlet guide vane, pneumatically Operated m/s mmwc KW rpm : : : : : : : 1 x 100% Centrifugal, Backward curved, simply supported. 27.00 200 132 1200 VFD / Pneumatically operated inlet damper m/s mmwc KW rpm : : : : : : : 1 x 100% Centrifugal, Backward curved, simply supported. 16.00 200 55 1800 Inlet guide vane, pneumatically operated : : : : : 225 340 365 140 980
m/hr MWC KW rpm
Deaerator cum storage tank Type Deaerator capacity Deaerator storage tank
: : : Page 20 of 24
Spray cum Tray 44 tph (120% MCR) 20 minutes storage between NWL & LWL
LP Dosing System No of dosing pumps Type of pump No. of agitator Dosing chemical HP Dosing system No. of dosing pumps Type of pump No. of agitators Dosing chemical ELECTROSTATIC PRECIPITATOR Design flow Inlet dust concentration Outlet dust concentration m/sec gm/Nm mg/Nm : : : : 26.50 25 150 (with all fields in service) 150 100% MCR Rice Husk : : 38 41 : : : : 2 x 100% (1W +1SB) Positive displacement. 1 (motorised). Trisodium phosphate : : : : 2 x 100% (1 W + 1 SB) Positive displacement 1 (motorised) Hydrazene / Erythorbate
Flue gas outlet temperature Deg.C Predicted Performance Data Flow Superheated steam t/hr Feed water t/hr Temperatures Saturated steam temp. C Superheated steam temp. C Feed water temp. at eco. Inlet C Feed water temp. at eco. Outlet C Ambient air temp. C Air at air heater outlet temp. C Flue gas temp. at combustion chamber C Outlet (FEGT) Flue gas temp. at SH inlet C Flue gas temp. at SH outlet C Flue gas temp. at Boiler Bank inlet C Flue gas temp. at Boiler Bank outlet C Flue gas temp at Eco inlet C Flue gas temp at Eco outlet C Flue gas temp. APH inlet C Flue gas temp at APH outlet C Flue gas temp ID fan inlet C Gas velocities Superheater Boiler bank Economiser Air preheater m/s
: : : : : : : : : : : : : : : :
252 370 12 105 210 30 145 830 830 690 685 455 455 240 240 150 150
: : : : Page 21 of 24
6-7 7-8 7-8 12
Fuel Storage bunker feeding system Type of feeder Number of feeders Type of control Motor rating KW Bunker storage capacity Material of fuel bunker Insulation Type Cladding Density of insulation Ducting Air duct thickness Material Flue gas duct thickness Material : : : : 4 mm IS 2062 (Carbon Steel) 5 mm IS 2062 (Carbon Steel) : : : Lightly resin bonded mineral wool Plain aluminum sheets (24 SWG thick) 100-120 kg/m : : : : : : Screw feeder 3 VFD 2.2 100 IS 2062 (Carbon steel)
m3
Technical data sheets are tentative only and may undergo changes during detailed engineering without affecting performance of the boiler.
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SECTION 5 PERFORMANCE GUARANTEES Performance guarantee for Rice Husk at 100% BMCR We shall guarantee that under test conditions and provided the Boiler is operated and maintained in accordance with our operating and maintenance instructions, the Boiler plant when working with its associated equipment shall be suitable for giving the following performance: BOILER PERFORMANCE GUARANTEE PARAMETERS MCR evaporation (Gross) : 40 TPH 370 12 0C
Superheated Steam Temperature at : main steam stop valve outlet Superheated Steam Pressure at main : steam stop valve outlet Boiler efficiency at 100% BMCR :
38 bar (g)
86% (on LHV basis)
The above guarantee is based on feed water temperature of 1050C at economizer inlet, 300C ambient temperature, 60% relative humidity, feed and boiler water quality and fuel analysis as specified in Design parameters of our technical offer. Performance test shall be carried out to per ASME PTC 4.1 1964 (R 1991) by Indirect heat losses method. Particulate emission at the outlet of Electrostatic Precipitator(with all fields in service) : 150 mg / Nm3
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SECTION 6 LIST OF MAINTENANCE TOOLS AND TACKLES Sl.No. 01. Component Description Tube Expander Set (Mandrel & Ratchet) Quantity 1 Set Application Main bank and air heater Level Guage Tubes, Headers, Pipes Rotary Equipment As required FD / ID / SA Fans Valves, Safety Valves
02. 03.
Torque Wrench D-Meter for measuring thickness
1 Set 1 No.
04. 05. 06. 07.
Portable Noise level meter Set of Spanners Coupling puller Lapping tools
1 Nos. 1 Set 3 Set 1 Set
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Annex B
Turbine Generator Technical Specification & Scope Of Supply
Technical Specification & Scope Of Supply: 6.5MW Full Condensing Turbine Generator
INDEX Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 : : : : : : Scope of Supply Technical Specifications Performance and Guarantee Data Utilities QAP List of Tools and Tackles
Page 1 of 26
CHAPTER 1 SCOPE OF SUPPLY PART-A MECHANICAL
Steam Turbine Multistage, Nozzle governed, Horizontal spindle, two bearings, Impulse fully condensing steam Turbine with: - Hydraulically operated Stop & Emergency Valve with integral steam strainer for inlet - Hydraulically operated Throttle/Governing valves for inlet steam flow control steam flow control. Lubrication System Forced feed lubrication system, combined for Turbine, Gearbox and Generator comprising of: - Lube oil tank cum base plate provided with cleaning doors, air breather and AC motor driven vapour extractor. The provision for connecting oil centrifuge is provided. - Shaft driven Main oil pump (MOP) - AC motor driven Auxiliary oil pump (AOP) with auto cut-in & cut-out facility - DC motor driven Emergency lube oil pump (EOP) with auto cut-in & cut-out facility - Suction strainers for MOP, AOP & EOP - Pressure relief valves for discharge of MOP & AOP lube oil line - Oil coolers (1 working + 1 standby) with on-line change-over arrangement - Oil filters (1 working + 1 standby) with on-line change-over arrangement - Pressure regulating valve to achieve desired lube oil pressure - Interconnecting lube oil piping Governing System Electronic governor (Woodward 505) complete with electro-hydraulic actuator, magnetic speed pick-ups. Hydraulic accumulator of bladder type in the turbine control oil circuit to take care of any surges in control oil line and suitably pre-charged with gas. Control oil filter 10/15 micron size. Control oil pressure-regulating valve to achieve desired control oil pressure in the control oil system. Interconnecting control oil piping.
Safety devices Over speed trip and alarm Low lube oil pressure trip and alarm Low control oil pressure trip and alarm High thrust wear trip and alarm High exhaust/condenser pressure trip and alarm Manual trip (Hand trip) Page 2 of 26
Remote emergency trip (Solenoid trip) DP across lube oil filters high alarm High Vibration trip thru Vibration Monitoring system for high speed train (Turbine front bearing, turbine rear bearing, turbine rotor axial shift, gear box high speed pinion shaft front bearing, gear box high speed pinion shaft rear bearing)
Gearbox Double helical, single reduction Gearbox with hardened & ground gears
Couplings Non-lubricated, steel laminated, flexible type, high speed coupling and low speed couplings with coupling guards.
Accessories Motorised barring gear arrangement Gland sealing system complete with : Gland Vent condenser with motor driven air blower Valves and piping within specified battery limits for header line Common base plate for turbine and gearbox Insulation for Turbine hot parts (lagging & cladding) Set of tools & tackles for maintenance Set of foundation bolts
Condensing System Condensing system comprising of : - Shell & Tube type, horizontal, divided water box type condenser with integral hotwell - Rupture disc for condenser protection - Expansion bellow with spool piece between turbine exhaust and condenser inlet - Stand pipe & flash pipe - Sacrificial Anodes in water boxes - Condensate extraction pump (CEP) with motors (1 working + 1 standby) - Condensate piping from hot well through CEPs & ejector condensers and upto specified battery limits (i.e. upto outlet flange of by-pass line level control valve) complete with pipe supports, strainers, steam traps, drains, vents and isolation provisions. - Dry air/vapor line within specified battery limit. - Steam jet air ejector system complete with : Twin stage main (running) ejectors (1 working + 1 standby) Start up ejector with silencer Inter and after condensers Isolation valves on motive steam inlet and on individual ejector elements. Vent and drain valve Strainers Pressure and temperature gauges
Page 3 of 26
PART-B AC Generator
ELECTRICAL
AC Generator shall be complete with following accessories : Brushless exciter with PMG Air coolers AVR cum Excitation panel Anti-condensation heaters Twin bearings Auxiliaries for Generator protection and control Generator control (Relay, Metering & Synchronizing) Panel Lightning arrestor, Surge capacitor and Potential transformer (LA, SC & PT) panel Neutral grounding resistor (NGR) Panel Battery and Battery Charger cum DC distribution panel.
PART-C - CONTROL & INSTRUMENTATION Turbine Local gauge panel Turbine local Gauge Panel shall house the pressure and temperature gauges for various operating parameters. Impulse piping with fittings shall be supplied loose for interconnection between field tap-off points and gauge panel. Various Transmitters (4-20 mA signals to PLC) and pressure switches (Digital Inputs to PLC) are mounted in this panel and signals are terminated at junction boxes on the panel for connectivity to PLC. Condensing system Condenser hot well level control system complete with : Control valves I-to-P converter Air filter regulators Dial type Pressure gauges for : Motive steam to ejector Condensate to ejector Condensate from ejector First stage ejector condenser Condensate pump discharge Dial type temperature gauges for : Condensate after hotwell Condensate after inter/after condensers of ejectors Motive steam to ejector Cooling water inlet & outlet
Page 4 of 26
Condensate suction Condensate to ejector Pneumatic and impulse piping with fittings for interconnection within battery limits.
Turbine Control cum PLC Panel (Non-redundant PLC) Turbine control panel shall house the following : Electronic governor Vibration Monitor SCADA / PLC based turbine safety interlocks and trip logic Remote controls comprising of selector switches, ammeters, push buttons & indicating lamps for : AOP motor EOP motor Air blower motor CEP motors 1 & 2 Barring gear motor Vapour extractor motor Push buttons for turbine speed raise and lower Turbine remote trip/reset push buttons SCADA / PLC based temperature Monitoring for turbine and gearbox bearing temperature SCADA / PLC based alarm annunciations for Turbine fault monitoring
The panel shall be complete with AC supply & DC supply on /off control switches, indicating lamps and space heater. Stand alone PC with SCADA will provided near the control panel. Turbine Aux. MCC cum DC (EOP) starter panel This Panel shall house: DOL starters for: AOP motor Barring gear motor Air blower motor Vapour extractor motor CEP motors 1 & 2 Feeder & control circuit for EOP motor.
Page 5 of 26
Local push button station Local control stations with on/off push buttons for : AOP motor EOP motor Air Blower motor Barring Gear motor Vapour extractor motor CEP motors 1 & 2 Generator Dial type pressure gauge for lube oil - 1 per bearing
Dial type temperature gauges for : Bearing oil 1 per bearing Hot air & cold air 1 each per cooler - Temperature sensors for : Winding temperature (embedded RTDs) 2 per phase Bearing oil temperature (duplex RTD) 1 per bearing Hot air & cold air 1 each per cooler - SCADA / PLC based Temperature monitoring of Generator winding and bearing oil temperature
Page 6 of 26
CHAPTER 2 TECHNICAL SPECIFICATIONS PART A MECHANICAL STEAM TURBINE Design : Type Casing split Rotor type Shaft seal No. of governing valves Rated speed Rated power Oil system : Oil : Governing oil pressure Lube oil pressure Oil type Oil quantity for initial fill and flushing Oil reservoir capacity Retention time Material of oil reservoir Material of oil piping from Pumps to filters Material of oil piping from Filters to bearings Material of oil piping from Bearings to reservoir Main oil pump : Type Operating speed Capacity Driver Material of body Material of end cover Material of drive gear : : : : : : : Gear (positive displacement) 1800 rpm 540 Liters/minute Gearbox low speed shaft CI CI EN 36 / EN 40 : : : : : : : : : : 5.5 Kg/Cm2g 1.5 Kg/Cm2g Servo prime ISO VG-46 / 57 / 68 5000 Liters 3000 Liters 5 minutes Carbon steel Carbon steel SS Carbon steel : : : : : : : Multistage, impulse, nozzle governed fully condensing type Horizontal Solidly forged & machined rotor with integral disks. Labyrinth Three (Inlet) 7545 RPM 6500 kW
Page 7 of 26
Auxiliary oil pump : Type Operating speed Capacity Driver Material of body Material of end cover Material of drive gear : : : : : : : Gear (positive displacement) 1800 rpm 540 Liters/minute AC motor (15 KW, 440 V, 3 Phase) CI CI EN 36 / EN 40
Emergency oil pump : Type Operating speed Capacity Driver Material of body Material of end cover Material of drive gear : : : : : : : Gear (positive displacement) 1440 rpm 50 Liters/minute DC motor (1.5KW , 110 V) CI CI EN 36 / EN 40
Oil cooler : Design code Type Oil inlet temperature Oil outlet temperature Tube material Tube sheet material Capacity Mounting : : : : : : : : HEI / TEMA Shell and tube / Plate type 60 0C 46 0C Admiralty Brass / SS Plates Carbons steel 540 Liters/minute Saddle support
Lube oil filter : Element type Capacity Oil filtration Capacity Mounting Oil Vapour Extractor : Type Capacity Driver Mounting
: : : :
Micro-felt 540 Liters/minute 10 15 microns Foot
: : : :
Centrifugal 400 m3/Hr AC Motor (0.375 KW, 440 V, 3 Phase) Flange
Bearings : Journal Bearings Type Material : : Tilting pad White metal with steel Babbitt
Page 8 of 26
Thrust Bearings Type Material : : Tilting pad White metal with steel Babbitt
Governing System : Governor: Type Inputs (critical) Control range Control accuracy Speed droop Power supply Accessories : : : : : : : Electronic (Woodward 505) 2 speeds from MPU-1 & 2 0 to 110% of rated speed +/- 2 RPM (steady state speed) 3 to 6% (programmable) 110 V DC 2 Magnetic speed pick-ups (MPU) 1 electro-hydraulic actuator
Hydraulic Accumulator : Type Working fluid Capacity : : : Bladder Pre-charged Nitrogen 20 Litres
Governing oil filter : Element type Oil flow Capacity Oil filtration Capacity : : : Micro-felt 35 Liters/minute 10 15 microns
Safety devices : Over speed trip: Type Low lube oil pressure trip: Type
Eccentric spring loaded oil dump valve
Spring loaded spool valve combined with LP trip
Low control oil pressure trip: Type : High thrust wear trip: Type
Spring loaded spool valve combined with LP trip
Through vibration monitoring system/ Electronic thrust position transmitter with alarm and switch
High exhaust pressure trip: Type Hand trip: Type
Through pressure switch and solenoid trip
Block & dump valve in trip oil line
Page 9 of 26
Operation Solenoid trip: Type Operation
Local hand lever
: :
Solenoid operated block & dump valve De-energise to open & trip
GEARBOX Design : Type Input |Output speed S.F. Accessory Bearings : Journal Bearings Type Material ThrustBearings Type Material
: : : :
Double helical , Single reduction 7545 / 1800 RPM 1.5 AGMA Air breather
: :
Sleeve (offset halves) White metal with steel Babbitt
: :
Sleeve White metal with steel Babbitt
COUPLINGS High Speed Coupling Type Low Speed Coupling Type ACCESSORIES Barring gear : Type Driver Gland vent condenser Design code Type Tube material Shell & end cover material Tube sheet material Accessory Driver for air blower : : Auto engage & auto disengage AC motor (11 kW, 440 V, 3 Phase) : Flexible element with shear pins : Flexible element
: : : : : : :
HEI / TEMA C Shell and tube SA 249 TP 304 ( OD) Carbon Steel Carbon Steel Motor driven centrifugal air blower AC motor (0.375 kW, 440 V, 3 Phase)
Page 10 of 26
GENERAL : Material of construction for major turbine components Steam casings & chest : BS 3100 Gr.B2 / BS 3100 Gr.A2 Rotor shaft : 21CrMoV57 Blades : FV-520B/ X22CrMoV121/X20Cr13/FV-624 / FV-448E Nozzle rings : AISI 410/AISI 304 Shrouds : AISI 410 Laby gland seals : BS 970 416 S21 Diaphragms : IS 2002 / IS 2062 (Mild steel) Steam strainer : SS Material of construction for major gearbox components Casings Pinion and integral shaft Gear wheel Gear wheel shaft : : : : MS Fabricated / CI (BS-1452 Gr.20) 17CrNiMo6 Case carburised 17CrNiMo6 Case carburised BS 970-080M40
Turbine connections : For Inlet steam Exhaust steam CONDENSING SYSTEM STEAM SURFACE CONDENSER Design code Type Capacity Construction Cleanliness factor Hotwell retention time Tube fixing Tube material Tube sheet material Water box & Shell material STEAM JET AIR EJECTORS Design code Suction medium : : HEI Air / Vapour : : : : : : : : : : HEI (Thermal) TEMA (Tube sheet, cover plate & flange) Shell and tube To suit exhaust flow Divided water box 0.85 3 minutes Expanded joints SA 249 TP 304 ( OD) Carbon Steel Carbon Steel Number One One Size Rating Orientation Side Bottom
8 NB ANSI 900 # RF Special
Page 11 of 26
System elements
Accessory Time to reach 66% vacuum with start-up ejector Material of nozzle Material of shell & diffuser Material of tubes Material of tube sheet Material of silencer
: : : : : : :
Twin stage, 2 x 100% main ejectors Single stage, 1 x 100% start-up ejector 1 x 100% inter /after condensers Integral steam strainers 20 minutes SA 479 TP 304 SA 516 Gr. 70 / SA 105 SA 249 TP 304 Carbon Steel Carbon Steel
CONDENSATE EXTRACTION PUMPS Type Mounting Suction pressure Discharge pressure Operating speed Driver Type of bearings Type of seal Type of coupling Type of lubrication Material of casing Material of impeller Material of shaft Material of shaft sleeve RUPTURE DISC Type End connection Material of diaphragm Material of flanges EXPANSION BELLOW Type Design code Material of bellows element Material of liner Material of flanges : : : : : Round / Rectangular Universal type rectangular expansion joints SS-304 SS-304 IS-2062 (Carbon steel) : : : : Diaphragm Flanged SS CS : : : : : : : : : : : : : : Centrifugal Horizontal Same as condenser pressure 80 MWC 2900 RPM AC motor (440 V, 3 Phase) Anti-friction Mechanical Flexible Oil CI CF8M C45 AISI 316
Page 12 of 26
PART B ELECTRICAL AC GENERATOR Design : Rated output Rated voltage Rated frequency Combined variation of voltage & frequency Rated p.f. No. of phases No. of terminals Connection Rated speed / No. of pole Ambient temperature Excitation Rotor Cooling method Mounting Insulation Temperature rise Enclosure Duty Rotation Terminal box Bearings : Type Accessory Lube oil system : Type Source Air coolers : Cooling method Capacity Cooler tube material Mounting Anti condensation heaters: Type Power supply : : : : CACW 2x 60%(or as per manufacturers standard) Admiralty brass Top : : Forced feed Turbine lube oil system : : Sleeve Temperature gauge : : : : : : : : : : : : : : : : : : : : 6500 kW / 8125 kVA 13.8 kV +/- 5% 60 Hz + / - 3% +/-5% 0.80 (lag) 3 phase, 3 wire system 3 for phase & 3 for neutral Star 1800 rpm / 4 pole 40 Deg.C Brushless with PMG Cylindrical CACW Horizontal Class F (both rotor and stator) Class B limits (both rotor and stator) IP-54 (Stator) & IP-23 (Exciter) Continuous and suitable for parallel operation To suit driver output To suit HT cable connection
: :
Resistance heating 230 V, Single phase
Page 13 of 26
Water leakage detector: Location Quantity AVR CUM EXCITATION PANEL Design: Control type Control modes Voltage adj. Range Regulation Dead time Features : -
: :
Bottom of cooler 1 No. per cooler
: : : : :
Thyristor based Digital 1 auto + 1 manual +/- 10% +/- 0.5% Less than 30 mS
Compounding Diode failure detector Auto PF controller Remote voltage control Auto-Manual follow-up Under frequency protection Field flashing provision
AVR cum excitation panel shall be complete with generator voltmeter, field voltmeter, field ammeter, PF meter, null meter, Auto/Manual selector switch, AC supply & DC supply on /off control switches, indicating lamps and space heater with thermostat. GENERATOR CONTROL PANEL (RELAY, METERING & SYNCHRONISING) Generator control panel for generator protection shall house the following Numeric relay (with MODBUS RS-485 and/or Digital outputs for connectivity to PLC): DESCRIPTION Voltage controlled over current protection relay Stator earth fault protection relay Differential protection relay Over voltage protection relay Timer for over voltage protection relay Under voltage protection relay Reverse active power protection relay Under frequency protection relay Over frequency protection relay PT fuse failure sensing relays TAG NO. 51 V 51 N 87 59 2-59 27 32 P 81 0 81 U 60 A 60 B 60 C
Page 14 of 26
Loss of excitation (Field failure) protection relay Auxiliary relays & timers for loss of excitation protection relay
40 G 40 X 27/40 G T1/40 G T2/40 G 95 46 80 86G 86T
Trip circuit supervision relay Negative phase sequence protection relay DC supply supervision relay Generator master trip relay Turbine master trip relay Meters
System : 3 phase, 4 wire, unbalanced load Digital Trivector meter : 1 No. (to indicate Current, Voltage, Power factor, Frequency, kVA, kW, kVAR, kWH & kVAH) (with MODBUS RS-485 port for connectivity to clients PLC) Synchroscope : 1 No. Check synchronizing Relay : 1 No. Aux. relays for Synchronising scheme : 1 Set Auto Synchroniser : 1 No. (Woodward SPMD) Temperature monitoring for generator winding and bearing temperatures thru RTD inputs to PLC. Alarm Annunciations for generator fault monitoring Thru Numeric relay (Digital inputs to PLC) The panel shall be complete with synchronising selector switches, breaker control (T/N/C) switches, push buttons, AC supply & DC supply on /off control switches, indicating lamps and panel space heater with thermostat. General : Type LA, SC & PT PANEL LA, SC & PT panel shall house the following : Lightning arrestor Discharge current Quantity : Desk & free standing
: :
10 KA 3 Nos. (1 per phase)
Page 15 of 26
Surge capacitor Capacitance per phase Quantity Potential transformers For Protection Metering Excitation Quantity 3 Nos. 3 Nos. 1 No.
: :
0.25 F 3 Nos. (1 per phase)
Secondary output 110 V 110 V 400 / 220 V
Class 3P 1 3
Burden 100 VA 100 VA 4000 VA
General : Type Terminal box : : Simplex, modular & free standing To suit HT cable connection
NEUTRAL GROUNDING RESISTOR PANEL NGR panel shall house the following: Resistor Type Rated current Duty rating Resistor grid type Temperature rise Mounting & fixing of Resistor units Neutral isolator Operation No. of poles Limit switches Earth connection Type Quantity Current Transformers For Differential protection Earth Fault Protection Quantity 3 Nos. 1 No. Secondary output 1A 1A Class PS 5 P 20 Burden N/A 10 VA : : Porcelain insulated 12 mm terminal studs Two Nos. : : : Motorised One 2 Nos. (for on / off positions) : : : : : : Naturally air cooled 100 A 10 seconds Punched steel 3750 C over ambient (max.) Mounted on grid rods; fixed and assembled in tiers separated by porcelain insulators
Page 16 of 26
Neutral Current CT
1 No.
1A
0.5
10 VA
General : Type Terminal box Material of busbars BATTERY Type Capacity Rating Volt per cell No. of cells : : : : : Maintenance free, VRLA 100 AH 110 V, DC 2 V, DC 55 : : : Simplex, dead front & free standing To suit HT cable connection Copper
BATTERY CHARGER CUM DC DISTRIBUTION PANEL Battery charger cum DC distribution panel shall house the following : Battery charger Quantity Input Output Voltage regulation Operation mode : : : : : One float & one float cum boost charger 440 V, 1 phase, 60 Hz, AC supply 15 A, 110 V DC (Float charger) 20 A, 110 V DC (Float cum boost charger) +/- 1% from no-load to full load Auto / Manual
Charger panel shall be provided with alarm for following faults : Float charger failed Float cum boost charger failed DC voltage high DC voltage low AC supply failed Batter earth fault Charger panel shall house following meters : AC Voltmeter DC Voltmeter with selector for load/charger/battery DC Ammeter for load DC Ammeter for charger DC Ammeter for battery
Page 17 of 26
DC distribution system Panel shall be provided with feeders for : DC motor starter panel HT Breaker panel Generator control panel AVR cum excitation panel Turbine control panel Spare : : : : : : 1 No. 1 No. 1 No. 1 No. 1 No. 2 Nos.
General : Type AC MOTORS Type Winding connection Duty Enclosure Cooling Insulation Power supply Speed / No. of poles DC MOTOR Type Duty Enclosure Cooling Insulation Power supply Speed : : : : : : : Shunt field Continuous IP-55 TEFC Class F 110 V 1440 RPM : : : : : : : : Induction Delta Continuous IP-55 TEFC Class F 440 V, 3 Phase, 60 Hz To suit driven equipment : Simplex, dead front & free standing
Page 18 of 26
PART C CONTROL & INSTRUMENTATION TURBINE LOCAL GAUGE PANEL Turbine gauge panel shall house the following : Pressure gauges for : Inlet steam HP Wheel case Exhaust steam Lube oil Control oil Temperature gauges for : Inlet steam Exhaust steam Pressure switches for : Turbine inlet steam pressure high alarm Turbine inlet steam pressure very high trip Lube oil pressure low alarm Lube oil pressure very low trip Control oil pressure low alarm Control oil pressure very low trip AOP auto cut-in & cut-out EOP auto cut-in & cut-out Condensate header pressure control & CEP auto-start interlock Condenser pressure high alarm (1 No.) Condenser pressure high trip (2 Nos.) Temperature switch for : Turbine inlet steam temperature low alarm Turbine inlet steam temperature very low trip Level switch for Condenser hotwell level low alarm and CEP dry run interlock Level indicator cum controller (for Condenser) Pressure transmitters for : (for Connectivity to PLC) Turbine Inlet steam Turbine wheel case Turbine Exhaust / condenser steam Turbine Lube oil Turbine Control oil Differential pressure transmitter for monitoring DP across lube oil filters Main oil pump (MOP) discharge Auxiliary oil pump (AOP) discharge Emergency oil pump (EOP) discharge Page 19 of 26
Motive steam to ejector Condensate to ejector Condensate from ejector Condensate pump 1 (CEP1) discharge Condensate pump 1 (CEP2) discharge
Temperature transmitters for : (for Connectivity to PLC) : Turbine Inlet steam Turbine exhaust steam Condensate after hotwell Motive steam to ejector Level transmitter (for Condenser) RTDs for (for connectivity to PLC) : Turbine bearing oil Gearbox bearing oil Turbine oil cooler inlet Turbine oil cooler outlet Turbine oil cooler outlet Vibration Monitoring System for high-speed train (Turbine front bearing, turbine rear bearing, turbine rotor axial shift, gear box high speed pinion shaft front bearing, gear box high speed pinion shaft rear bearing)
Note: The Transmitters (4-20 mA signals to PLC) and pressure switches (Digital input to PLC) are mounted in this panel and signals are terminated at junction boxes on the panel for connectivity to PLC. GENERAL : Type : Simplex, dead front & free standing
TURBINE CONTROL CUM PLC PANEL Turbine control panel shall house the following : - Electronic governor (4-20 mA signals to PLC) - Vibration Monitor (4-20 mA signals to PLC) - SCADA / PLC based turbine safety interlocks and trip logic - Remote controls comprising of selector switches, ammeters, push buttons & indicating lamps for : AOP motor EOP motor CEP-1 & 2 motors Barring gear motor Air blower motor Vapour extractor motor
Page 20 of 26
Push buttons for turbine speed raise and lower Turbine remote trip/reset push buttons SCADA / PLC based temperature Monitoring for turbine and gearbox bearing temperature SCADA / PLC based alarm annunciations for Turbine fault monitoring
The panel shall be complete with AC supply & Dc supply on /off control switches, indicating lamps and space heater. Stand alone PC with SCADA will provided near the control panel. Turbine Aux. MCC cum DC (EOP) starter panel This panel shall house the following : Incoming feeder complete with MCCB unit, voltmeter, CT operated ammeter, indicating lamps & bus bars DOL starter complete with switch-fuse unit, contactor, overload relay, CT operated ammeter, indicating lamps & pushbuttons for : AOP motor CEP-1 & 2 motors Barring gear motor Air blower motor Vapour extractor motor Incoming feeder complete with switch-fuse unit, voltmeter, ammeter and indicating lamps for DC motor 2 step resistance starter for EOP motor complete with switch-fuse unit, contactor, overload relay, ammeter, indicating lamps & pushbuttons.
GENERAL SPECIFICATIONS OF INSTRUMENTS Pressure and temperature gauges Dial Scale Type Accuracy Over range protection Accessories Pressure switch Sensor type Material of case Material of bellows : : : Bellows Die cast aluminium SS-316 : : : : : : 150 mm circular 270 Deg. arc with black pointer Bourdon (pressure gauge) Mercury in steel (temperature gauge) +/- 1 % 125 % Shatter proof safety glass
Page 21 of 26
Resistance temperature detectors : Element type Solenoid valve Power supply Operation Type : : : 110 V DC De-energise to open 2 way, universal ports : PT-100, 3 wire
Current to pneumatic converter Supply Input Output Enclosure Accessory Air filter regulator Filter element Element material Body material : : : 5 microns Sintered bronze Cast aluminium : : : : : Air at 1.5 Kg/cm2.G 4 20 mA 0.2 to 1.0 Kg/cm2.G (air) Die-cast aluminum alloy body Pressure gauges for supply & output
Vibration monitoring system : Type of detectors Type of display Accessories : : : Magnetic probes Bargraph display (LCD) through panel mounted dual channel monitors Power supply module System Monitor Proximitors and extension cables
Page 22 of 26
CHAPTER 3 PERFORMANCE AND GUARANTEE DATA Performance (Fully condensing) Parameter Turbine Inlet Steam Pressure (bara) Turbine Inlet Steam Temperature (oC) Turbine Inlet Steam Flow (kg/hr) Turbine Exhaust Steam pressure (bara) Turbine Exhaust Steam Temperature (oC) Turbine Exhaust steam flow Approx (kg/hr) Electrical Output at Generator terminals @ 13.8 kV, 60 Hz
37 360 33,500 0.11 47.7 33,500 6500
Page 23 of 26
CHAPTER 4 UTILITIES A. STEAM CONSUMER / PURPOSE Turbine gland sealing system at 11 bara Ejector system At 11 bara B. COOLING WATER Inlet pressure Inlet temperature Temperature rise (T) : : : 1.5 barg 33 Deg. C 8 Deg. C CONTINUOUS DEMAND 60 M3/Hr 30 M3/Hr 70 M3/Hr 2305 M3/Hr INTERMITTENT DEMAND 250 Kg/Hr (during start-up) 350 kg/hr (during start-up) CONTINUOUS DEMAND N/A 300 Kg/hr
CONSUMER / PURPOSE
Turbine oil cooler Gland Vent Condenser Generator air cooler Surface Condenser C. INSTRUMENTATION AIR For control purpose D. AC POWER Power supply CONSUMER AOP Motor Vapour Extr. Motor Air blower motor Barring Gear Motor CEP Motor : :
5 SCFM at 7.0 Kg/cm2g
440 V, 50 Hz, TP & N CONTINUOUS DEMAND N/A 0.375 KW 0.375 kW N/A 15 kW
INTERMITTENT DEMAND 15 kW (during start-up & shut-down) N/A N/A 11 kW (during shut-down) N/A
Note: All utility figures mentioned above are indicative only. The actual requirement shall be furnished during detailed engineering.
Page 24 of 26
CHAPTER 5 Q A PLAN EQUIPMENT DESCRIPTION Complete assembled turbine 1. 2. 3. 4. 5. 1. 2. 1. 2. 3. 4. 5. 6. 7. 8. 1. 2. 3. 4. 1. 2. 1. 2. 3. TESTS Visual & dimensional checks No-load run test & functional check on safety devices Vibration check Noise level check Open inspection & dynamic rotor balancing (after noload run test) Visual & dimensional checks Operational & functional tests Visual & dimensional checks OCC & SCC test Over speed test Vibration check Noise level check HV test Measurement of winding resistance and insulation resistance Measurement of shaft voltage Visual & dimensional checks Operational & functional tests HV test Measurement of insulation resistances Visual & dimensional checks Range calibration Visual & dimensional checks Operational & functional tests Range calibration
GVC with air blower Complete assembled generator
NGR panel /AVR panel / Generator panel / Aux. MCC
Turbine Gauge Panel Instruments
NOTE :
1. Material test certificates from manufacturers shall be submitted for major components of turbine and other bought-out items along with supply. 2. We have not envisaged any customer hold point in QAP and delivery & price quoted are on the same basis.
Page 25 of 26
CHAPTER 6 LIST OF TOOLS AND TACKLES EQUIPMENT DESCRIPTION TURBINE Overspeed trip cap removal bolt Fixture for putting oil seals with cover Allen keys 1/16 to Circlip plier (internal & external) 6 Double end spanner x 5/16 Double end spanner 3/8 x 7/16 Double end spanner x 9/16 Double end spanner 5/8 x Double end spanner 7/8 x 1 Double end spanner 24/27 mm & 30/32 mm Double end spanner 1 x 1-1/8 Single end spanner 1- Ring spanner 1 x 1-1/8 Ring spanner 1 x 1 Ring spanner 24/27 mm & 30/32 mm Open end spanner 1- & 1- Screw driver 6 & 12 Adjustable spanner 6 QUANTITY
1 No. 1 No. 1 Set 1 No. each 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. each 1 No. 1 No. 1 No. 1 No. 1 No. each 1 No. each 1 No. each 1 No.
Page 26 of 26

EPC Quotation-15th May 2011

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EPC Quotation-15th May 2011

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ENGCON ENERGY PTE LTD

Date: 15th May 2011

EPC PROPOSAL 6.5MW RICE HUSK FIRED POWER PLANT

ENGCON ENERGY PTE LTD

ENGCON ENERGY PTE LTD

EQUIPMENT SUPPLY PORTION

17.5 cu.m/hr Deepwell water

ENGCON ENERGY PTE LTD

ENGCON ENERGY PTE LTD

1 lot 1 lot 1 lot 2 units 1 lot 1 lot 1 unit

ENGCON ENERGY PTE LTD

ENGCON ENERGY PTE LTD

ENGCON ENERGY PTE LTD

Drilling and construction of 2 x 35cu.m/hr deepwell.

ENGCON ENERGY PTE LTD

ENGCON ENERGY PTE LTD

ENGCON ENERGY PTE LTD

ENGCON ENERGY PTE LTD

3. ENGINEERING AND PROJECT MANAGEMENT

ENGCON ENERGY PTE LTD

ENGCON ENERGY PTE LTD

Engcon Project Tem

IJT Project Tem

Triveni Project Tem

ENGCON ENERGY PTE LTD

PRICE & PAYMENT TERMS

ENGCON ENERGY PTE LTD

WARRANTY & SCHEDULE

This validity of this quotation is 2 months until 15th July 2011.

Albert Yap Director

EPC PRICE ESTIMATION - 6.5MW

Unit 1 lot 1 lot 1 lot 1 lot 2 units 1 unit 1 unit

Unit 1 lot 1 lot 1 lot 1 lot 1 lot 1 lot

US$ To Php: 43.500

Total Price - Equipment: Total Price - BOP#1: Total Price - BOP#2:

Balance Of Plant #2 (BOP#2) can be handled directly by Golden Season. # 01 # 02 # 03

6.5MW Rice Husk Fired Power Plant Layout

Existing 2MW Power Plant

Water Treatment Plant (6m x 16m)

Rice Husk Bunker

Husk Loading Station

6.5MW Rice Husk Fired Power Plant Layout

Water Treatment Plant (6m x 16m)

Rice Husk Bunker

Husk Loading Station

Layout Plan - 2 Stories Admin. / Workshop Building

Plant Manager Office

Tool Store / Warehouse

O&M Staff Dormitory

4m x 2.5m 4m x 3m 4m x 2.5m 4m x 3m 16m 4m x 2.5m

4m x 3m 4m x 2.5m CR, Shower Washing Area

Conceptual Rice Husk Feeding Design

PDF created with pdfFactory trial version www.pdffactory.com

PDF created with pdfFactory trial version www.pdffactory.com

Boiler Technical Specification & Scope Of Supply

ISGEC John Thompson

SECTION SECTION 1 SECTION 2 SECTION 3 SECTION 4 SECTION 5 SECTION 6

Safe, Non Hazardous & Non Corrosive

ASME ASME Indian standards.

100% MCR Rice Husk Natural

6 bar (g) 30 Oil free clean air.

4. Electric Power: Motor Voltage Frequency Combined variation Type Instrumentation

440V +/- 10% 60 Hz +/- 5% 10% 3 phase, AC supply

Voltage Frequency Type Field transmitters Voltage Type F.