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CONTENTS

CHAPTER

TITLE

PAGE NO.

INTRODUCTION

01

II

EXECUTIVE SUMMARY

03

III

NEED AND JUSTIFICATION FOR THE PROJECT

10

IV

15

BASIC POWER STATION REQUIREMENTS AND SITE

FEATURES
FUEL SOURCE AND TRANSPORTATION TO SITE

VI

PLANT LAYOUT AND CIVIL ENGINEERING ASPECTS

19

VII

MAIN PLANT EQUIPMENT AND SYSTEMS

24

VIII

INSTRUMENTATION AND CONTROL SYSTEM

32

IX

WATER SYSTEMS

38

COAL HANDLING SYSTEM

47

XI

ASH HANDLING SYSTEM

51

XII

MISCELLANEOUS SYSTEMS

58

XIII

ELECTRICAL SYSTEMS

60

XIV

ENVIRONMENTAL PROTECTION AND WASTE

MANAGEMENT

79

XV

PROJECT SCHEDULE AND IMPLEMENTATION

89

XVI

PROJECT COST ESTIMATES AND TARIFF

18

91

LIST OF APPENDICES

APPENDIX
NO.

TITLE

1.

Project Site Details

2.

Basic Information for Environmental Appraisal

3.

Raw Water Analysis

4.

Analysis of Coal

5.

Analysis of Fuel Oil

6.

Project Cost Estimate

7.

Abstract of Project Cost

8.

Estimated Cost of Generation

9.

Water allocation letter

10

Financial Analysis

LIST OF EXHIBITS
EXHIBIT NO.

TITLE

1.

GRID MAP OF MADHYA PRADESH

2.

VICINITY PLAN

3.

PLOT PLAN

4.

TG BUILDING OPERATING PLAN: AT EL 17.0 M

GENERAL ARRANGEMENT

5.

TG AND BOILER CROSS SECTION GENERAL

ARRANGEMENT

6.

HEAT BALANCE DIAGRAM

7.

WATER SYSTEM SCHEME AND MATERIAL

BALANCE

8.

COAL HANDLING SYSTEM FLOW DIAGRAM

9.

BOTTOM ASH HANDLING SYSTEM - FLOW

DIAGRAM

10.

FLY ASH HANDLING SYSTEM - FLOW DIAGRAM

11.

KEY ONE LINE DIAGRAM

12.

PROJECT MILESTONE SCHEDULE

13.

ORGANISATION CHART OPERATION &

MAINTENANCE

CHAPTER I
INTRODUCTION
1.

Essar Power M.P. Limited (EPMPL) is a wholly owned subsidiary of Essar

Power Ltd. It proposes to install a 1,200 MW coal fired pit head based thermal
power station near Mahan coal blocks, in Sidhi district of Madhya Pradesh
(M.P). It is proposed to supply around 400 MW net power to M.P. State and
balance around 700 MW power will be sold to Essar Steel Limited for its steel
plant at Hazira in Surat District of Gujrat.
EPMPL has been allotted the Mahan Coal Block in Singrauli Coalfields for
captive mining. The Mahan Coal Block has reported reserves of 144 million
tones.
EPMPL would take up extension of power project in second stage as and
when opportunity is available in getting nearby mines in Singrauli coalfield
allotted. These new coal blocks would be used for the second phase. EPMPL
has retained the services of TCE Consulting Engineers Limited (TCE),
Bangalore for preparing a Detailed Project Report (DPR) for the proposed
2,000 MW thermal power station.

2.

Terms of Reference

3.1

Following are the terms of reference of the DPR :

(a)

Power Demand Analysis and justification of project

(b)

Study of topographical survey and other data for locating the project
considering all pertinent factors including the rehabilitated area

(c)

Study of water requirement and finalization of water system.

(d)

Study of fuel (coal) requirement, mode of transportation, storage and

handling system.

(e)

Study of power evacuation and connection with the grid.

(f)

Property / Plot plan and preliminary layout of the main plant showing
major equipments, coal and ash handling facilities and services
corridors etc.

(g)

Technical description of all major equipment and systems along with

process flow diagrams.

(h)

Civil & Structural engineering aspects.

(i)

Environmental considerations & adoption of suitable measures as

required in accordance with the Pollution Control stipulations.

(j)

Project implementation schedule showing key milestone activities.

3.2

3.

(k)

Estimation of the project cost with broad and detailed breakup under
major heads and phased expenditure over the period of project
execution.

(l)

Computation of the cost of generation at power station bus.

(m)

Operation and Maintenance Philosophy

requirement, training & organizational set up.

including

manpower

The scope of services of TCE does not include:

(a)

Site survey and soil investigation. (The report would be based on

topo-sheet of Survey of India and assumed soil data)

(b)

Environmental
Impact Assessment
management Plan (EMP) study.

(c)

Obtaining clearances and arranging for infrastructure linkages such as

fuel linkage, water linkage, land availability, power evacuation etc.

(EIA)

Environmental

The DPR is finalized based on the following :

(a)

Report of Central Mine Planning & Design Institute Ltd. (CMPDI)

dated March 2004 submitted to Central Electricity Authority (CEA)
which identified potential sites for pit-head, coal based thermal power
stations in Singrauli Coalfield based on remote sensing data.

(b)

Site visit by a team of engineers, discussions held with Madhya

Pradesh Electricity Board (MPEB) officials and the information
available with TCE.

CHAPTER II
EXECUTIVE SUMMARY
PURPOSE

1.

The purpose of this report is to present the techno-economic details of the

proposed installation of 1200 MW (Phase I of ultimate capacity of approx.
2000 MW) coal fired thermal power project near Mahan coal blocks near
Bandhaura, Khairahi and Karsualal & Nagwa villages, in Singrauli Tehasil of
Sidhi District of Madhya Pradesh (M.P).

2.

This report highlights the details of the selected site, availability of coal and
water, evacuation of power, features of the main plant equipment including
raw and cooling water system, coal and ash handling systems, electrical
systems, environmental aspects, estimates of project cost, schedule for
project implementation and organization structure for operation and
maintenance.
SCOPE

3.

The scope of this Detailed Project Report (DPR) covers the following:
(a)

Need for installation of two phases, totaling to ultimate capacity of

approximately 2000 MW, coal fired thermal power station

(b)

Study of the selected site considering topography, soil conditions,

accessibility by road and rail, availability of water for condenser
cooling and other requirements, power evacuation plans, transport of
fuel required for the plant from the nearby mine, space availability for
ash disposal and general environmental aspects

(c)

Preparation of plant layout keeping in view the ultimate capacity of

2000 MW power plant.

(d)

Details of the major aspects of the proposed plant, general design

philosophy and salient technical specifications of the following major
equipment/systems for the proposed first phase of 1,050 MW unit
installation in addition to power plant configuration :
(i) Steam-generator and auxiliary systems
(ii) Steam turbine-generator and auxiliary systems
(iii) Water systems
(iv) Coal handling system
(v) Ash handling system including ash disposal system and a brief
outline of possible schemes for utilization of ash generated in
the plant

(vi) Fuel oil supply system

(vii)Other mechanical balance of plant systems
(viii)

Electrical systems and power evacuation system

(ix) Instrumentation and control systems

(x) Civil, structural and architectural aspects
(e)

Environmental aspects

(f)

Preparation of project implementation schedule

(g)

Project cost estimates and financial analysis.

PROJECT FEATURES

4.

Land
(a)

Land required for setting up two phases, totaling to ultimate capacity

of approximately 2000 MW, coal based power station is of the order of
1790 acres (725 hectares) for both the phases including power plant
and its all auxiliary systems, ash disposal area and colony.

(b)

Land close to Mahan coal blocks, about 4 km from the mine has been
identified for power station. Adequate area for setting up of Phase I
and Phase II is available. Land for around 725 Ha has been identified
in four villages i.e. Khairahi, Kharsualal, Bandhara and Nagwa. The
area of the villages have been identified to accommodate main plant,
ash pond area, Local township/colony in such a manner that no. of
PAF is kept at bare minimum.

(c)

Primarily the land is consisting of waste land with/without scrubs

(about 50%) and agricultural land (about 50%). Settlement of around
250-300 households is expected to require resettlement and M/s.
EPOL has already initiated a detailed R&R study, being conducted by
TCE to assess and implement the R&R plan. Discussions are already
going on with District Collector regarding R&R policy.

(d)

Two railway stations are situated near the proposed site: (i) Singrauli:
on the Katni- Chopan Section which is about 35 km away and (ii)
Shaktinagar: in U.P at a distance of 35 km. The nearest air port is
varanasi (280 km).

(e)

The site is located west of Govind Vallabh Pant Sagar (GVPS) at

about a distance of 37 km.

5.

Water
The source of water required for the proposed thermal power plant is Govind
Vallabh Pant Sagar (GVPS) reservoir, which is estimated to be at a distance
of 37 km from the site. Government of M.P was approached for confirming
availability and allocation of 71.45 million cu. m (80 Cusecs/0.058 MAF) water
which would be sufficient for the ultimate capacity of 2,000 MW power plant.
On the basis of present consumption of 0.227 MAF out of M.P.s share of 0.78
MAF from the reservoir basin, the Govt. of M.P has allocated the said quantity
of water from the reservoir.

6.

Coal
Power plant would get coal from Mahan coalfield which is located in main
Singrauli coalfield basin. Mahan Coal block has been allocated jointly to
Essar Power & Hindalco Industries by Ministry of Coal, GOI. Mahan coal mine
is situated at about 4 km (North-West)from the proposed plant site.
The coal bearing area of the Mahan block lies in the main basin of Singrauli
Coalfield and has a reserve of 144 Million Tonnes. The area of the coal block
is about 9.2 sq. kms. Total average coal thickness is about 11 m. Depth range
of coal seam is upto 150 m.

7.

Power Evacuation
The Power generated from the proposed station will be stepped up to 400KV
and power will be evacuated to the 400KV Substation at Sipat-Pooling Point
(around 215 Km approx. away). In addition to that there will be LILO with two
nos. SC 400 KV line from Vindhyachala-Korba at Mahan. Thus the project will
have connectivity with WR pooling point at Sipat, Vindhyachal STPS and
Korba STPS at 400 KV. In addition to that the necessary augmentation and
strengthening of the PGCIL grid for further power evacuation will be made
after due discussion with the WR constituents/CEA and PGCIL.

8.

Power Utilization and Sale of Power

It is planned that around 400 MW power will be supplied to the state of M.P in
line with the MoU signed with them and rest 700 MW power will be used for
Essar Steel Ltd at Hazira in Surat District of Gujrat.

9.

Main Plant Equipment

9.1

Based on the analysis, it is recommended to install two (2) units each of

approximately 600 MW capacity in each phase. Other configuration options
would be studied during detailed Engg stage.

9.2

The steam generators would be 100% coal fired and would be rated to
generate about 2028 t / hr of superheated steam at 179 ata pressure and
540C temperature when supplied with feed water at a temperature of 252 o C
at the economizer inlet. The reheat steam temperature would also be 540C.

9.3

The steam turbine generator (STG) would be rated for 600 MW maximum
continuous output at the generator terminals, with throttle steam conditions of
170 bar and 537oC steam temperature and 0.1 bar (a) back pressure.

9.4

The steam turbine would be a reheat extraction and condensing type turbine.
The STG output, at valve wide open (VWO) condition could be 630 MW.
Steam turbine would be a two / three cylinder reheat, extraction and
condensing turbine. The parameters indicated above are preliminary and
subject to confirmation by the selected main equipment suppliers.

10.

Coal Handling System

It is envisaged that run off mine coal for this project would be received from
Mahan coal fields belonging to Essars captive coal mines. The annual
requirement of coal for the power plant would be about 5.0 million tonnes
considering a plant load factor of 80% and coal GCV of 4,100 k Cal / kg.
However it may be noted here for the purpose of designing the boiler and all
other auxiliaries a GCV of 3800 Kcal/kg is considered. The coal handling
system envisaged would be capable of handling coal at the rate of 1,600
tonnes / hour and would consist of two streams of conveyors, one operating
and the second one being standby.

11.

Ash Handling System

11.1

The bottom ash handling system proposed envisages evacuation and

transportation to a storage silo in wet form and from thereon for onward
disposal by jet pumps to the ash disposal area.

11.2

Fly ash from the respective hoppers of ESP, Eco/AH of each boiler will be
evacuated in dry form through dense phase pressurized pneumatic system to
the fly ash silos for storage and subsequent evacuation. Fly ash from silo will
be sent to cement/brick plant manufacturers to the maximum extent possible
and the bottom ash will be utilised for development of low lying area. The rest
of fly ash plus the bottom ash will be disposed off in slurry form to the ash
pond to be located nearby. There would be water recovery plant at ash pond
through a clarifier/pump house to send back the clear water for re-use. The
make-up water for ash slurry disposal system will be met from cooling water
blow down system. Also the ash pond will be provided with a HDPE
Protective layer if required to avoid any contamination of ash water with
ground water.

12.

Condenser Cooling and Make-up Water

12.1

The source of consumptive water for the thermal power plant would be
Govind Vallabh Pant Sagar (GVPS) reservoir, which is at about a distance of
37 km from the power plant. The total requirement of raw water make-up is of
the order of 48 cusecs for the 1,200 MW power plant capacity and 80 cusecs
(42 MGD) for 2,000 MW capacity. Raw water is proposed to be pumped from
the river water pump house to a raw water pond (buffer to cater for 2 days
storage).

12.2

For the condenser cooling, closed circuit re-circulation system with clarified
water make-up using natural draft cooling towers has been proposed. The
make up water for the condenser cooling would be drawn from the clarifier by

gravity and gets discharged into the common CW forebay. From the CW
pump house the cooling water would be pumped to the condenser through
individual MS conduits. The discharge would be led to the cooling tower
through similar MS conduits.
12.3

Raw water required for other services viz. DM plant, fire protection system,
cooling water make up for air-conditioning & ventilation system and plant
potable water system, service water, auxiliary cooling (bearing cooling) etc.
would be pumped from a common clarified water tank.

12.4

Feed cycle makeup and cooling water for steam generator and turbine
generator auxiliaries would be met from the DM plant output.

13.

Environmental Aspects

13.1

The power plant is proposed to use coal brought from Mahan captive mine
blocks located in Singrauli Coal Fields having low Sulphur content. One (1)
twin-flue 275 m high RCC chimneys (stacks) is proposed to be provided
common for two steam generator units to meet the requirements of the
environmental regulations. The steam generators would be provided with low
NOx burners and hence the emission of oxides of Nitrogen from the steam
generator would be minimum.

13.2

The steam generators would be provided with electrostatic precipitators to

limit the particulate matter in the flue gas to 100 mg / N cu m as per the Good
Utility Practices which is better than the current pollution control norms.

13.3

Adequate provisions are proposed for neutralizing the effluents from the water
treatment plant. Effluents from the entire power plant are proposed to be
treated and reused in the power plant to minimize the make-up water
requirement.

14.

Project Cost and Tariff

14.1

The estimated capital cost of the proposed project in stage I of 1200 MW

capacity based on prevailing rates in Mar 2007 is Rs. 4860 crores including
interest during construction (IDC) and financial charges. The above cost is
based on in-house data and budgetary costs. The cost per MW of installed
capacity works out to Rs. 4.05 crores / MW.

14.2

The cost of generation at 80 % PLF works out to Rs. 2.16 per kWh including
return on equity. The levellised tariff works out to Rs. 1.82 per kWh for the
net energy from the 1st stage of the proposed super thermal power station of
1200 MW capacity.

15.

Project Schedule and Implementation

15.1

The Commercial Operation Date (COD) for the 1 st stage of the power station
of 1200 MW capacity will be as below:
First unit of 600 MW capacity (Unit # 1) is envisaged in 36 months reckoned
from the date of financial closure followed by the other unit within three
months. Financial closure is anticipated to be achieved by 30th June 07.

15.2

The project is proposed to be executed through a number of separate

package contracts finalized through competitive bidding.

15.3

The time period between the Phase I and Phase II would be about 2 Years,
subject to allotment of new coal blocks.
CONCLUSIONS

1.

Based on demand-supply gap in India, it is concluded that setting up of a

2,000 MW capacity coal fired power station in two stages in Sidhi district of
M.P state is viable from the technical and economical points of view.

2.

The proposed power plant has all the basic requirements essential for a
thermal power plant viz. land, water, fuel (coal) and power evacuation
facilities.
RECOMMENDATIONS

3.

To ensure timely completion of the proposed project, it is recommended that

early action on the following activities may be initiated by EPMPL and arrange
for the following expeditiously to realize the advantage of first entrant in the
State of M.P in the recent past :
(a)

To conduct detailed topographic survey of the identified land and the

land in the vicinity so as to firm up actual coordinates and extent of
land to initiate acquisition.

(b)

To carryout detailed soil and geo-technical investigations to ascertain

load bearing capacity and to conclude type of foundations viz. open
type foundations or pile foundations.

(c)

Discussion with MP govt, other beneficiary states/users, PGCIL and

other state utilities for power purchase agreement and wheeling of
power

(d)

Initiate action to obtain necessary clearances for raw water intake

pipeline corridor and coal conveyor corridor from mines.

(e)

Approval of Civil Aviation Authority for installing 275 m high chimneys.

(f)Initiate discussions with prospective Indian Financial Institutions, Foreign

Financial Institutions, external commercial borrowing agencies, Indian
commercial banks and reputed main plant equipment suppliers
(g)

Appointment of Project Consultant for carrying out detail engineering.

CHAPTER III
NEED AND JUSTIFICATION FOR THE PROJECT
1.

Essar Steel Limited is having an integrated Steel Plant of 4.6 mtpa capacity at
Hazira in Surat Dist of Gujarat. Presently its demand is being met from the 515
MW Combined Cycle Power Plant of Essar Power Limited located adjacent to it.
In addition to that demand also is being met from a 505 MW plant of Bhander
Power Limited (a Subsidiary of Essar Power Limited) which is under construction
and located adjacent to the 515 MW plant. Out of 500 MW capacity, around 355
MW is already commissioned and balance 150 MW is scheduled to be
commissioned in next few months time.

2.

Essar Steel (Hazira) Limited is a subsidiary of Essar Steel Limited and is in

advanced stage of putting up a 3.9 mtpa Corex gas fired steel plant at Hazira.

3.

It is a well known fact that steel plant is highly energy intensive and needs
continuous uninterrupted power. The cost of power is one of the major cost
contributor and hence the availability of low cost power becomes the key for
production of steel.

4.

In view of present scarcity and high cost of natural gas and liquid fuel (Naptha)
Essar Steel Limited shall be supplied around 400 MW power from Proposed
Mahan pit head power project, while transmitting the same through EHV lines of
400/765 KV.

5.

Further Essar Steel (Hazira) Limited also intends to source power to the rune of
320 MW from Mahan pit head STPP for its new steel plant of 3.9 mtpa capacity.

6.

EPMPL has signed a MoU with the Govt of M.P for setting-up the Mahan Power
project. As per the terms of agreement EPMPL has agreed to supply 7.5% of net
generated power on real time basis at variable cost. In addition to that the
authorised agency of Govt of M.P reserves the first right of refusal for 30% power
from Mahan STPP.

7.

EPMPL has already qualified for bidding for power procurement by M.P SEB
through which the tariff will be finalised and subsequent to that the PPA will be
signed for 25 years for supply of the power to the state.

8.

The State of Madhya Pradesh is part of the Western Region comprising the
states of Goa, Gujarat, Maharastra, Chattisgarh, Daman & Diu etc. The installed /
available generation capacity in Madhya Pradesh is 2991 MW, as on Dec2005.

9.

The Ministry of Power (MoP) of Govt. of India has projected the following peak
demand and energy requirements at National level and in particular western
region as follows :
Table-III.1
Projection

All India

Energy Requirement in MU
2006-07

2011-12

719,097

975,222

Peak Load ( MW)

2006-07
115,705

2011-12
157,107

Western
Region

669,034

898,135

106,465

149,365

224,927

299,075

35,223

46, 825

232,742

321,578

35,968

50,747

349, 179

- Projections AS per 16th EPS

- Revised Projections based on actual figures of 2004-05 and actual growth

measured between 1992-2005, plus anticipated demand from additional Rural
Electrification.

- Modified demand projections for the purpose of planning future capacity

addition by readjusting for unreported Power cuts/disruptions on regional basis
keeping All India Projections as per 16th EPS.

53,377

Note: 1. C for All India level is same as figures for A.

2. Source National Electricity Plan.
10.

The installed / available generating capacity of the existing power stations,

projects under execution, projects under planning as well as the share from the
Central Sector projects for the period 2006-07 to 2011-12 for M.P. State are
shown in Table - III.1. The installed capacity of the existing plants, the data on
projects under execution and planning furnished in this Table is based on the
information obtained from Madhya Pradesh Electricity Board (MPEB)

Table-III.2
List of Projects existing, Under Implementation / Planning
Sl.
No.

I.

Project

i) State owned
(Amarkantak extn.)
ii) Lanco
Amarkantaka

MW

2,148

210

180

360+
166

166

166

500

500
843

v) Medhikheda

20
40

vi) Indira Sagar

1000

vii) Sardar Sarovar

743

119

viii) Omkareshwar
(8X65)
II

300

iii) Birsinghpur extn.

iv) Hydel ( Ban
sagar)-IV

Expected year of availability and MW

20062007- 20082009201020112007
2008
2009
2010
2011
2012

520

Central sector
Share

III

1,733

273+
500

Non conventional
Nil

IV

Total of additional
planned capacity

1452

910

826

166

166

500

Existing plants, non

conventional
including share
from central
projects

6,467

7919

8829

9655

9821

9987

10487

Total expected
capacity by the
year wise in MW

6,467

7919

8829

9655

9821

9987

10487

VI

DEMAND FOR ELECTRICAL POWER AND ENERGY

11.

The demand for electrical energy has been steadily increasing in the State of
Madhya Pradesh due to rapid industrialization and agricultural growth. The
existing peak power demand in the year 2005-06 was 8 GW, which is 68.4% of
the projected peak load for the same year. The peak load and the expected
energy requirement as projected in the Sixteenth Electric Power Survey of India

for the State of Madhya Pradesh for the period 2005-06 to 2011-12 is shown in
Table III.2 (X plan-2006-07, XI plan-2011-12).
AVAILABILITY OF POWER
12.

The Power Survey of India recognized that while computing the available peak
power from the installed capacity, the following factors need to be considered:
(a)
(b)
(c)
(d)
(e)

Planned outage due to maintenance

Forced outage
Spinning reserve
Auxiliary power consumption
Other factors relevant to the aspect of peak power availability.

Considering the above-mentioned factors, the peak power available is

estimated in Table III.2. For energy availability, 70% load factor is considered
for Thermal plants. The energy availability is taken as per the data collected
from MPEB.
Table-III.2
Peak Power Demand Requirements

200506

2006
07

200708

200809

200910

201011

2011-12

Total Installed capacity

MW

6467

7919

8829

9655

9821

9987

10487

Peak Demand Forecast

MW

8186

8661

9155

9677

10230

10814

11431

Average Demand forecast

(16th EPS)

MW

5649

5977

6318

6679

7060

7463

7889

Our conservative peak

demand forecast

MW

5243

5558

5891

6244

6619

7016

7437

Our conservative avg demand

forecast

MW

4294

4552

4825

5114

5421

5746

6091

Estimated peak generation

available

MW

3835

4755

5301

5797

5897

5997

6297

Estimated avg generation

available

MW

3196

3962

4418

4831

4914

4998

5248

Peak demand shortfall

MW

1408

803

590

447

722

1019

1140

Avg demand shortfall

MW

1098

589

407

283

507

749

843

th

(16 EPS)*

*As per Sixteenth Annual Power Survey of India

NEED FOR THE POWER PROJECT

13.

As may be noted from the above Table III.2, there would be deficit in generation
capacity. The estimated deficit by the 11th Five year plan are of the order of 1
GW for generation capacity.

14.

Further, the availability of power depends on the number of plants under

execution / planning as indicated in Table III.1 getting commissioned in time. Any
delay in the implementation of power projects, due to reasons such as lack of
clearances, financial constraints, etc. would result in much larger deficit in
subsequent years. Considering this scenario, there would be a large deficit in
peak availability and energy availability.

15.

Considering the above scenario of power requirement by the group

companies and the persisting power shortage in Western region, Mahan
Super Thermal Power Project is well justified.

CHAPTER IV
BASIC POWER STATION REQUIREMENTS AND SITE FEATURES
BASIC STATION REQUIREMENTS
1.

The estimated requirements of land, fuel and water for the proposed power
plant installation of two phases, totaling to ultimate capacity of 2000 MW, coal
fired thermal power station are presented in Table - IV.1below :
TABLE - IV.1
Estimated Requirements of Land, Fuel and Water for a 2000 MW Coal
Fired Thermal Power Station
Land for power plant with the
facility for ultimate expansion
to 2,000 MW
Annual coal requirement
(With annual load factor of
80%) for 1st phase of 1200
MW)
Total raw water requirement

427.8Ha (1057 acres) for the power plant

including main plant etc. 267.6 Ha (661
acres) for ash disposal area and 30.2 Ha
(75 acres) for colony.
5.0 million tones

48 Cusec for 1st stage of 1200 MW and

80 cusecs (or 196,000 cu.m / day) for
ultimate capacity of 2000 MW capacity

SITE FEATURES
2.

Site Location
The proposed site is located near Mahan coal blocks near Bandhaura,
Khairahi, Karsualal and Nagwa villages, in Singrauli tehasil of Sidhi District of
Madhya Pradesh (M.P). The latitude and longitudes of the main power project
location are 240 0 0 / 820 25 0. The land identified for the project is shown in
Exhibit-2.

3.

Basis of site selection

Central Mine Planning & Design Institute Ltd. (CMPDI), in its Report dated
March 2004 submitted to Central Electricity Authority (CEA) had identified
potential sites for pit-head, coal based thermal power stations near Singrauli
coal fields based on remote sensing data. Out of these, EPMPL preferred the
Site which is located near Mahan coal blocks near Bandhaura, Khairahi and
Karsua village, Sidhi district in M.P from various technical considerations.
TCE also studied the Report and concurred with EPMPLs choice.

4.

This Site is about 37 km away from Govind Vallabh Pant Sagar reservoir from
where consumptive water is proposed to be drawn for the proposed power
project.

5.

Primarily, the identified area consists of waste land with / without scrubs
(about 50%) and agricultural land (about 50%).The plant will be located in
such a manner to minimize the resettlement of the villagers.

6.

The layout of the power station shall be finalized duly considering the exact
coordinates of the power lines which is possible only after a detailed
topographical survey.

7.

Characteristics of Location and Land

Terrain for the proposed main plant is almost flat with elevations ranging
around 338 M above MSL in the main plant area (Kharahi/Kharsuaal). In the
absence of soil characteristics, it is assumed that the foundations of the
structures do not require piles and good soil bearing capacity is expected to be
available even at lower depths. The water table is also assumed to be
relatively high (about 4-5 M below ground level) in this area. However, all
these assumptions are to be validated after suitable surveys / studies /
investigations.

8.

Resettlement and Rehabilitation (R&R)

Settlement of around 771 families is expected as per the R&R study carried
out. The R&R plan will be in line with the policies of the state government.

9.

AVAILABILITY OF WATER
The source of water required for the proposed thermal power plant is Govind
Vallabh Pant Sagar (GVPS) reservoir, which is estimated to be at a distance
of 37 km from the site.

10.

COAL SOURCE AND TRANSPORTATION

Power plant would get coal from Mahan coalfield which is located in main
Singrauli main basin. Mahan Coal block has been allocated jointly to Essar
Power & Hindalco Industries by Ministry of Coal , GOI. Low grade coal from
Mahan coal mines situated at about 4 km is proposed to be used for this
project.

11.

POWER EVACUATION
EPMPL initiated a study for augmenting/strengthening the PGCIL grid
including the connectivity of the proposed station with the nearest 400KV
substation. As per study a double circuit line at 400 KV will have to be laid to
the WR Pooling point at Sipat over 215 Km distance. In addition to that a LILO
is proposed with two nos. single circuit 400 KV line connecting Vindhyachal
STPS Korba STPS at Mahan 400 KV switchyard. Further to that a 400 KV

double circuit line will be laid from Gandhar to a new 400 KV switchyard at
Hazira. The long term open access application is made to PGCIL for finalizing
these schemes in addition to the augmentation of the PGCIL network. The
same will be finalised with due discussion and consultation with PGCIL/CEA
and other WR constituent members.
12.

ENVIRONMENTAL ASPECTS
There is no metropolitan city or eco-sensitive spots including national parks,
wild life sanctuary, biosphere reserve, historical and cultural sites present in
the vicinity of the proposed site as per Ministry of Environment and Forests
(MoEF) guidelines. Further, super thermal power plants existing in the nearby
vicinity viz. Vindhyanchal STPS, Singrauli STPS, Rihand STPS and Anpara
STPS. are more than 25Km away from the proposed station.

13.

Also, all necessary pollution control measures are being proposed for the
power plant. Thus, the site has all the infrastructural requirements for the
proposed power plant expansion. It is therefore, considered that this site is
suitable for the installation of the proposed power plant expansion units.

CHAPTER V
FUEL SOURCE AND TRANSPORTATION TO SITE

TYPE OF FUEL
1.

The steam generators would be designed primarily for coal firing. Light Diesel
oil would be used for start-up and HFO for flame stabilisation at low loads.
SOURCE OF FUEL AND QUALITY

2.

Coal for the project would be indigenous, supplied from the Mahan coal fields
belonging to Essars captive coal mines located in main Singrauli Coal Fields
in the State of M.P. The expected Run-off-Mine (ROM) coal analysis is
expected to be as furnished in Appendix - 4. ROM coal is planned to be fired
in boilers directly which would be having a maximum of 40% ash content and
a gross calorific value (GCV) of about 4,100 k Cal / kg.

3.

The secondary fuel would be HFO as per IS:1593. Fuel oil for the power plant
would be made available from Essar / HPCL / BPCL / IOC.
ANNUAL COAL REQUIREMENT

4.

The annual coal consumption for the proposed first phase of power plant is
estimated as 5.0 million tonnes duly considering average GCV value of ROM
coal as 4,100 k Cal / kg and annual plant load factor (PLF) of 80%. However
as for as plant design is concerned, a calorific value of 3800 kcal/kg is
considered.
MODE OF TRANSPORT OF COAL TO SITE

5.

Coal from the mines is envisaged to be transported to power plant by

conveyors.

6.

The coal handling system envisaged would be capable of handling coal at the
rate of 1,600 tonnes / hour for the 1 st stage of 1200 MW power plant and
would consist of two streams of conveyors, one operating and one being
standby.
FUEL OIL REQUIREMENT AND MODE OF TRANSPORT OF FUEL OIL TO
SITE

7.

The fuel oil system would be designed for the use of Light Diesel Oil (LDO) for
start up and HFO for flame stabilization purposes.
The HFO/LDO requirement to the tune of 1800KL/month for 1 st stage of
2000MW Project.

8.

Oil is envisaged to be supplied from nearest terminal by using road tankers to

the site. 7 days of oil storage is considered adequate during trial operation.
Hence, a total HFO storage capacity of 5000 m3 has been envisaged.

CHAPTER VI
PLANT LAYOUT AND CIVIL ENGINEERING ASPECTS
PLANT LAYOUT
1.

The layout of the main plant along with all the auxiliary systems has been
shown in Plot Plan (Exhibit - 3). In laying out various facilities consideration
has been given to the following general principles :
(a)

Least disturbance to existing habitation and vegetation, if any.

(b)

Flexibility to have future expansion units with particular reference to

the switch yard

(c)

Predominant wind directions as gathered from the wind rose to

minimize pollution, fire risk, etc.

(d)

Power evacuation corridor for connection to state grid

(e)

Raw water intake facilities

(f)

Approach road to the power plant from the main highway

(g)

Availability of
equipment.

(h)

Availability of adequate space for labour colony during construction

stage.

adequate

space

for

fabrication

construction

2.

All facilities of the plant are laid out in close proximity to each other to the
extent practicable so as to minimise the extent of land required. The layout
also facilitates communication of men and movement of materials between the
various facilities both during initial construction and also during subsequent
operation and maintenance.

3.

Fuel oil would be received by road tankers.

CIVIL ENGINEERING ASPECTS
Site Topography And Grade Level

4.

Site terrain is almost flat without significant undulations and the elevations is
around 337 M above MSL. The main plant, auxiliary buildings and coal
stockyard etc. would be located at suitably higher level of than the general
grade level.

Station Building : General Arrangement

5.

General arrangement plan of the station building is shown in Exhibit 4 and

sectional view is indicated in Exhibit 5. The steam turbine generator and
auxiliary equipment would be located in the AB bay of the building having 34.0
span. Each unit is accommodated in a length of 10.5 x 9 bays. Total length of
station building for both the units would be 210 m which includes two
unloading / maintenance bays each of 10.5 m wide at the end of the station
building. The heaters are accommodated in the BC bay ( Heater bay) having a
span of 10.0 m. The control room / electrical building is located on the side ot
the station building to accommodate switch gear, electronic panels and control
room in a space of 63.0 m x 21.0 m.

6.

The turbine - generator bay would be serviced by three floors - ground floor at
0.0 M level, mezzanine floor at 8.5 M level and operating floor at 17 M level.
Localised O&M platforms at required levels would be provided. The deaerator
would be located at EL 31.75 M in the BC bay (heater bay). Road access
would be provided to the unloading and maintenance bays for unloading TG
components and auxiliary equipment.

7.

The superstructure would be of structural steel framing with RCC floor slabs.
The roof of the TG bay would consist of pre-cast concrete panels supported
on steel trusses. The turbine generator pedestal would be reinforced concrete
and would be isolated from the building foundations and super structure. All
structures would be designed to cater to applicable wind/seismic forces in the
area as per relevant Indian Standards.
Steam Generator Area and Mill Bay

8.

The mill bay would be of structural steel-framed construction, supporting the

steel bunkers. The 12 m wide bay would have blower room at ground level
and floors for the feeders and for the bunker feeding conveyors provided with
trippers. The bunker bay would be located at the front side between the
furnace in the steam generator area and the T-G building. Concrete paving
would be provided in the steam generator area with necessary drains and
trenches. Pipes and cables in this area would, in general, be routed on
overhead pipe / cable racks.

9.

The general arrangement plan of the steam generator cross section is shown
in Exhibit 5.
Chimney

10.

Twin-flue chimney with common wind shield for the two units has been
envisaged for the proposed thermal power plant. The total height of reinforced
concrete chimney is 275 m with 6.5m diameter at exit. This would meet the
requirement of Indian Emission Regulation. The chimney windshield shall be
of RCC slipform construction.

Miscellaneous Buildings
11.

Table - VI.1 below indicates list of major buildings / structures planned in the
power plant and type of construction :
Table -VI.1
Major Buildings / Structures
Sl.
No.
1.

2.

3.

4.

5.

6.
7.
8.

9.

Building / Structure

Remarks / Type of Construction

ESP control room

Ground plus one floor; common for two

units. Structural steel construction with
brick walls. Floors and roof would be of
RCC.
Air washer rooms
Two per unit; Each having ground plus
one floor. Structural steel construction
with brick walls. Floors and roof would
be of RCC.
Ware
house
and Structural steel columns with bricks for
Workshop
side cladding. Pre-coated galvalume
sheet supported on structural steel
would be provided for roof.
D.G house
Structural steel construction with precoated galvalume sheet for roof. Sides
are kept open.
Hydrogen cylinder shed Structural steel construction with precoated galvalume sheet for roof with 1.8
m high brick dwarf walls for the sides.
CW pump house &
MCC room
Clarified water pump
house
D.M Plant

Structural steel construction with brick

walls
Structural steel construction with brick
walls.
Structural steel columns with pre-coated
galvalume sheets for roof.
Roof is
supported on structural steel trusses.
Sides are kept open.
Coal handling switch Structural steel construction with brick
gear cum control room
walls

10.

Switch
room

yard

control Structural steel construction with brick

walls

11.

DM plant control room Concrete construction with brick walls

cum switch gear room

12.
13.

Ash handling
compressor room +
MCC room
Admin Building

Compressors would be provided with

metallic containers and covered shed
would be provided for protection.
Concrete construction with brick walls

14.

Canteen Building

Concrete construction with brick walls

15.

Service Building

16.

Fire Station Building

17.

Car / Scooter parking

Structural steel construction with brick

walls. Floors and roof would be of RCC.
Structural steel construction with precoated galvalume sheet for roof. Sides
are kept open. Fire office space would
be of concrete construction with Brick
walls
Structural steel construction with precoated galvalume sheet for roof. Sides
are kept open.

Soil Profile and Foundations

12.

Details would be furnished after the detailed geo-technical investigation of the

proposed area is carried out. However the net safe bearing capacity of 25 t/m2
at 4.0 m below the existing ground level is considered for cost estimation
purposes.
Machine Foundations

13.

All equipment would be supported on conventional block / framed type RC

foundations and would be separated from the building foundations and
superstructure. All variable speed machines would be supported on vibration
isolation system with springs and viscous dampers.
Roads, Drains & Boundary Wall

14.

The roads would initially be of water-bound macadam type with shoulders on

either side of carriage width. After major construction activities are completed,
these would be surfaced with bituminous carpet. All major roads would be 7.0
m wide and other approach roads would be 4.0 m wide. Storm water drains
would be provided on either side of the roads. The storm water drains would
be of RCC construction. The storm water drains would be connected to the
nearest water body or would be treated suitably and reused for gardening and
other purposes. The power plant boundary wall of 3.0 m height with anticlimbing device would be constructed from locally available stones.
Design Basis

15.

Dead and live loads would be considered as per relevant IS codes and
standard engineering practices. The basic wind speed of 50 m / s is
considered for design of buildings / structures as per IS : 875 : Part III. The
power plant is located in Seismic Zone III as per IS : 1893 and seismic forces
would be considered accordingly for the structures / buildings. All designs
would be carried out in SI units and would be as per relevant IS codes.
Sewage Disposal

16.

Sewage from various buildings would be lead to septic tanks located close to
the buildings by means of CI pipes laid underground. The overflow from
septic tanks would be led to the dispersion trenches or soak pits.

Landscaping
17.

The various services / utility areas within the plant would be suitably graded to
different elevations. Natural features of the plant site would be retained as far
as possible to integrate with the buildings to form a harmonious / pleasant
environment. Areas in front of various buildings and the entrance of power
plant would be landscaped with ground cover, plants, trees based on factors
like climate, adaptability etc. The green belt would consist of native perennial
green and fast growing trees. Trees would also be planted around the coal
stock pile area and ash disposal area to minimise the dust pollution.

CHAPTER VII
MAIN PLANT EQUIPMENT AND SYSTEMS
PLANT CAPACITY AND SELECTION OF UNIT(S) SIZES
Plant Capacity
1.

1,200 MW capacity coal based thermal power plant has been proposed at
selected site to be implemented in first phase. Accordingly, all the plant
facilities / equipment / systems would be designed and selected for a plant
capacity of 1,200 MW only.
Selection Of Unit Sizes

2.

The following alternative plant configurations are feasible for the proposed
1,200 MW thermal power plant in 1st stage :
(a)

4 x 300 MW units

(b)

2 x 500 MW units plus one unit of 210 MW.

(c)

2 X 600 MW Units

3.

A number of 500 MW units are already operating in the country since 1979,
with first 500 MW unit installation at Trombay Thermal Power Station, Tata
Electric Companies, Mumbai, followed many installations in NTPCs super
thermal power stations at Ramagundam, Korba, Singrauli, Talcher and
MSEBs Chandrapur and UPSEBs Anpara Thermal Power Station. So far the
performance of these 500 MW units have been quite satisfactory.

4.

Similarly, the first set of 2 x 250 MW units were commissioned in 1995 at

Dahanu thermal power station followed by other units at Kothagudam and
Suratgargh. These units have also demonstrated proven performances over
their respective operating periods.

5.

Many no. of 600/300 MW units are running in China and their performance
also have been reported to be good.

Merits of 1 x 500 (600) MW Unit Vs 2 x 250 (300) MW Units

Installation
6.

From the Tables VII.1 and VII.2, it may be concluded that 1 x 500 MW unit has
the following merits over 2 x 250 MW units configuration :

6.1

Heat rate of 500 MW unit is lower than 250 MW unit by 24.78 k Cal / kWh
resulting in annual fuel saving of about 26,819 tonnes and hence reduction in
annual fuel charges by Rs. 2.68 crores.

6.2.

Station building volume for 500 MW unit is less than 2 x 250 MW units
requirement by 24,000 M3 resulting in substantial saving in civil works which
is estimated at Rs.5.28 crores.

6.3.

1 x 500 MW unit configuration being a single unit installation, the O & M staff
requirement in the main plant area practically reduces one half of 2 x 250 MW
units configuration. Further inventory of spares would also reduce
substantially as the number of equipment / components in 1 x 500 MW unit is
about one half of 2 x 250 MW units. Hence, there would be substantial
reduction in O & M costs.

6.4.

Overall space requirement for the main plant area i.e. Steam turbine, Steam
generator and switchyard area in case of 1 x 500 MW unit is 80,000 M2 as
against 90,000 M2 for 2 x 250 MW units.

6.5.

From the thermal power plant performance data published by CEA in the
past, the availability and plant utilisation factor of 500 MW units (86.61 &
78.14) is substantially higher than 200 / 250 MW sets (81.79 & 72.94)
respectively.

6.6.

The comparison between 1 X 600 MW with 2 X 300 MW units are in similar

with 1 X 500 MW with 2 X 250 MW.
Demerits of 1 x 500 (600) MW Unit Vs. 2 x 250 (300) MW Units Installation

7.

The only demerit of 1 x 500 MW unit installation vs 2 x 250 MW units is that in

the event of failure of the unit, there will be total loss of generation of 500MW
as against only 250 MW generation in case of 2 x 250 MW installations.. The
comparison between 1 X 600 MW with 2 X 300 MW units are in similar with 1
X 500 MW with 2 X 250 MW.
Recommendation

8.

In view of the above discussions and duly considering the advantages such as
lesser O&M staff, lesser space, better heat rate, Installation of 500 MW/ 600
MW units for the 1st stage are recommended. However configuration would be
ultimately left for EPC contractor who would quote least capital cost and
running cost including heat rate. The selection would include 2 x 500 MW, 2 x
600 MW and 2 x 660 MW. Choice of subcritical or supercritical parameters
would be left to EPC bidders.

9.

The forthcoming paras of this Chapter briefly describe the salient features of
main plant equipment viz. Steam generator, Steam turbine generator and their
auxiliaries. It may be appreciated of the fact that 600 MW unit size is
considered as bench mark capacity. The actual gross capacity may be in 500,
600, 660 MW sets depending upon the suppliers standard rating. Such a
flexible gross capacity would be specified in the RFP as and when issued to
take the full advantage of manufacturers standard range of main plant
equipment.

STEAM GENERATOR AND ACCESSORIES

10.

The steam generator (SG) would be designed for firing 100% coal and would
be with assisted circulation and drum type. The SG would be of two pass
design, radiant, single reheat, balanced draft, semi-outdoor type, rated to
deliver 2028 t / hr of superheated steam at 179 ata, 540C when supplied with
feed water at a temperature of 252C at the economiser inlet. The reheat
steam temperature would also be 540C.

11.

The steam generator would be provided with coal mills on either side of the
furnace, along with individual raw coal gravimetric feeders and coal bunkers.
Sampling arrangement at mill outlet would be provided for purpose of
establishing the average gross calorific value of coal as well as coal fineness.
The coal mills would be provided with steam blanketing system for the
purpose of fire protection. The SG would be designed to handle and burn HFO
as secondary fuel up to 22.5 % MCR (maximum continuous rating) capacity
and flame stabilisation during low-load operation. For unit light up and warm
up purposes LDO would be used with air atomization. The required fuel oil
pressurizing units and fuel oil heating equipment would be provided. Highenergy electric arc ignitors would be provided to ignite the fuel oil guns.

12.

The steam generator would consist of water cooled furnace, radiant and
convection super-heaters, re-heaters, economizer, regenerative air heaters,
steam coil pre-heaters, etc. Soot blowers would be provided at strategic
locations and would be designed for sequential fully automatic operation from
the unit control room.

13.

The draft plant would comprise of primary air fans, forced draft fans, and
induced draft fans. Electrostatic precipitator (ESP) and fly ash hoppers would
be provided for the collection of fly ash. The ESP would be designed with one
field standby for design coal firing and with no field standby for worst coal
firing, to achieve an outlet dust concentration of 100 mg / Nm (Max) as
stipulated by State / Central Pollution Control Board.

STEAM TURBINE GENERATOR AND ACCESSORIES

14.

The steam turbine generators (STG) would be rated for 600 MW maximum
continuous output at the generator terminals, with throttle steam conditions of
170 bar (a) and 5370 C steam temperature and 0.1 bar (a) back pressure. The
steam turbine would be a reheat extraction condensing turbine. The STG
output, at valve wide-open (VWO) condition could be 630 MW. Steam turbine
would be a two/three/ cylinder reheat, extraction and condensing turbine.

15.

The turbine-generator would be complete with all accessories such as

protection system, lube and control oil systems, seal oil system, jacking oil
system, seal steam system, turbine drain system, 60% MCR HP / LP bypass
system, electro-hydraulic control system, automatic turbine run-up system, online automatic turbine test system and turbine supervisory instrumentation.
The turbine-generator would also have all necessary indicating and control
devices to permit the unit to be placed on turning gear, rolled, accelerated and
synchronised automatically from the control room. Other accessories of the
turbine-generator would include an oil purification unit with transfer pumps and
clean and dirty oil storage tanks of adequate capacity.

16.

Plant Cycle

16.1. The preliminary heat balance diagrams at (100% MCR with 0% make-up) for
the turbine cycle system are furnished in Exhibit - 6.
16.2. The condensing plant would comprise a surface type condenser with two pass
design of single shell construction. The condenser would be suitable for use of
river /raw water for condenser cooling. The condenser would have stainless
steel tubes rolled in to carbon steel tube sheets. 2 x 100% capacity vacuum
pumps would be provided to create vacuum in the condenser during start-up
and to remove the non-condensable gases liberated during normal operation.
16.3. The regenerative cycle would consist of three low-pressure heaters, a variable
pressure de-aerator, two high pressure heaters, one drain cooler and one
gland steam condenser. The heat balance diagrams of turbine cycle are
presented in Exhibit - 6.
16.4. Under normal operating conditions, drains from the high-pressure heater
would be cascaded to the next lower pressure heater and finally to the deaerator. Drains from low pressure heaters would be cascaded successively to
the next lower pressure heater and finally to the condenser hot well. Heaters
would be provided with drain level controls to maintain the drain level
automatically throughout the range of operation of the heaters. The system
would consist of split-range control valves to take the drain to a lower pressure
heater or to the condenser through a flash box.
16.5. The unit would be provided with a 60% HP-LP bypass system:
(a)

To prevent a steam-generator trip in the event of a full export load

throw-off and to maintain the unit in operation at house load.

(b)

To prevent a steam-generator trip following a turbine trip and enable

quick restart of the turbine generator set.

(c)

To minimize warm restart duration of the unit after a trip.

(d)

To conserve condensate during start-up.

(e)

To facilitate quick load changes in both directions without affecting the

steam generator operation during start-ups.

FEED CYCLE EQUIPMENT

Condensate Pumps
17.

The condensate from the condensate hot well would be pumped by 2 x 100%
capacity condensate pumps, one working and one standby to the de-aerator,
through the gland steam condenser, drain cooler and low pressure heaters.
Two pumps would be provided for each 600 MW unit. The pumps would be
vertical, cannister type, multistage centrifugal pumps driven by AC motors.

Boiler Feed Pumps

18.

Feed water would be pumped from the de-aerator to the steam generator
through the high pressure heaters by means of 3 x 50% capacity boiler feed
pumps (Two working steam turbine driven pumps and one AC motor driven
standby pump). The boiler feed pumps would be horizontal, multistage,
centrifugal pumps of barrel type with variable speed hydraulic coupling. Motor
drive BFP will be used during start-up.
Low Pressure Heaters

19.

The low pressure heaters would be of shell & tube type with U-shaped
stainless steel tubes, with their ends rolled in carbon steel tube sheets.
Deaerator

20.

The de-aerating feed water heater would be a direct contact, variable pressure
type heater with spray-tray type or spray type of de-aeration arrangement.
The feed water storage tank would have a storage capacity adequate to feed
the steam-generator for 6 minutes when operating at MCR conditions.
High Pressure Heaters

21.

The high pressure heaters would be of shell & tube type with carbon steel Utubes welded into carbon steel tube sheets. The HP heaters would be
provided with a de-superheating zone and a drain cooling zone in addition to
the condensing zone.
Gland Steam Condenser

22.

A surface type gland steam condenser would be used to condense the gland
steam exhausted from the turbine glands. The gland steam condenser would
be of single-pass type with the main condensate flowing through the tubes to
condense the steam. Exhausters would be provided to evacuate the air from
the shell side and maintain the shell at the required negative pressure.
TURBINE LUBE OIL AND CONTROL FLUID SYSTEM

23.

A complete lubricating oil system would be provided for the steam turbine
generator unit. The control fluid system may be fully separated from the
lubricating oil system or integrated with the lube oil system as per the turbine
manufacturers standard. The lube oil system would be comprising of lube oil
pumps, main oil tank, lube oil coolers, lube oil filters, piping, valves fittings etc.
The control fluid system would have its own pumps, motors, coolers, strainers,
piping, valves and fittings.

TURBINE LUBE OIL PURIFICATION SYSTEM

24.

In the lubrication cycle for the turbine-generator, the lube oil comes in contact
with water, air and metal particles which cause deterioration of the lube oil. In
order to prolong the life of the lubricating oil and the parts served by the lube
oil, suitable purification equipment is required to be provided to remove the
contamination and restore the oil to acceptable conditions.

25.

The continuous bypass method of lube oil purification is proposed to be

adopted. In this method, about 20% of the total oil in the turbine oil system is
circulated continuously through the lube oil purifier. Since the condition of a
portion of the oil is being restored continuously, impurities are controlled to
within permissible values.
The lube oil purification system would be
Centrifuge-type lube oil purifier.

26.

Each lube oil purifier would be capable of purifying lube oil at the rate of 20%
of the total charge per hour.
CONDENSATE POLISHING UNIT

27.

Since fresh water is proposed to be used for this power plant, condensate
polishing unit is not envisaged. However, necessity of the same may be
examined at the time of detailed engineering.
FUEL OIL SYSTEM

28.

The fuel oil system would be designed for the use of LDO for start-up & heavy
fuel oil (HFO) for load carrying & flame stabilisation purposes.

29.

The HFO requirement would be about 720 m 3/day during peak demand. The
peak demand is envisaged when the unit is under trial operation. During
normal operation the HFO requirement is expected to be about 60 m 3/day.
Based on statistical average oil consumption of 2 ml per kWh and PLF of 80
%, the annual HFO requirement would be about 16,500 KL.

30.

Oil is envisaged to be supplied from nearest terminal by using road tankers to

the site. 7 days of oil storage is considered adequate during trial operation.
Hence, a total HFO storage capacity of 5000 m3 has been envisaged.
CHEMICAL DOSING SYSTEM

31.

Phosphate dosing system would be provided to ensure chemical conditioning

of the steam generator drum water so as to prevent scale formation. In
addition, hydrazine / ammonia dosing system would be provided to ensure
chemical conditioning of the feed water by removing the dissolved oxygen and
carbon dioxide present in the feed water. The phosphate solution would be
added directly into the steam-generator drum. The hydrazine / ammonia
solution would be injected into the feed water at the feed water pumps suction
(continuous basis) and at the condensate extraction pumps discharge (only
during start up).

32.

Both high pressure phosphate dosing system and low pressure hydrazine /
ammonia dosing system would comprise solution preparation-cum-metering
tanks with motorised agitators, two positive displacement type dosing pumps,
piping, valves, instruments and local control panel. Each dosing pump would
be sized to cater to the 100% dosing requirements of each of the 250 MW
unit.

CHAPTER VIII
INSTRUMENTATION AND CONTROL SYSTEM
DISTRIBUTED MICROPROCESSOR BASED CONTROL & MONITORING
SYSTEM
1.

Microprocessor based distributed control system with state of art Man Machine Interface (MMI) is proposed to provide a comprehensive integrated
instrumentation and control system including the functions of Data Acquisition
System (DAS) to operate, control and monitor the steam generator and
auxiliaries, steam turbine generator and auxiliaries and the balance of plant
systems with a hierarchically distributed structure.

2.

The Distributed control system (DCS) would use the state of the art technique
of functional distribution of control and monitoring to reduce the risks
associated with failure of any single controlling unit. The DCS has complete
control capabilities that include closed loop control, open loop control,
computation and interfacing for data acquisition, graphic displays, logging,
annunciation, data storage, retrieval, performance calculations and
management information system. The system allows for CRT operation from
the control desk. The communication from the control desk operators interface
to the electronic hardware is over a data highway. The system is provided with
redundancy at various levels thereby ensuring reliability of the system.

3.

The distributed microprocessor based system proposed is functionally

distributed. In the functionally distributed microprocessor based system,
electronic cubicles would be located in a centralised location with centralised
operation from the control room. Remote I / O modules are envisaged for
acquiring switchyard signals in the main control room.

4.

The instrumentation and control system would integrate the functions of plant
monitoring, control and information systems. The system functions would be
distributed in a hierarchical system structure to facilitate the task of integration,
co-ordination and autonomous operation of plant sub-systems / equipment
depending on the plant operation mode. The plant information system would
perform the functions of data logging, operation reports, unit performance
monitoring and plant start-up and shutdown guidance. All equipment and
processes in the unit would be controlled and monitored from central unit
control room. The unit control room houses unit control desk and related
power supply and system cabinets.

5.

A dedicated Microprocessor based DCS of uniform hardware with state-of-the

art MMI covering the following is envisaged :
(a)

SG integral controls like burner management system, secondary air

damper control, soot blowing, high pressure by-pass system and
steam temperature control.

(b)

TG integral controls like automatic steam turbine run-up system

(ATRS), turbine protection electro-hydraulic turbine controls (EHTC),
automatic turbine tester (ATT), turbine stress evaluator, low pressure
by-pass system and gland steam controls

(c)

Balance of plant controls including regenerative cycle controls

The DCS envisaged is independent for each unit except at Management

Information System (MIS) level and at the shift charge engineers level which
is common for both the units.
UTILITY PACKAGES
6.

Utility packages like coal handling system, ash handling system, DM Plant, Air
Compressors and Fuel oil system are proposed with dedicated stand-alone
I&C system. Air conditioning system would be microprocessor-based system.
Chemical dosing system would be relay based. The control of the packages
located in a control room nearer to the respective equipment. Suitable
interface (hardwired and /or serial) would be provided with the plant I & C
system in the main control room.
UNIT CONTROL DESK

7.

The unit, functional group / drive level control and operation of all main plant
equipment including generators, transformers and auxiliaries would be from a
set of monitors mounted on a control desk.

8.

The unit control desk (UCD) would house the following items :

9.

(a)

Monitors for operation, control and monitoring of steam generator,

turbine generator and auxiliaries.

(b)

Alarm monitors

(c)

Telephone handsets

All these monitors are supported by the following peripherals which are
located in the control room :
(a)

Graphic printers (colour)

(b)

LaserJet printers

(c)

Character printer (Operators action)

10.

11.

The operator can perform the following operations of main plant and balance
of plant from monitors in the UCD through key boards. Emergency stop LPBs
would be provided for all drives :
(a)

Operation of all control valves, control dampers, motor operated

valves, interlocked isolating valves and dampers, non-interlocked
isolating valves & dampers, motor operated bypass valves of control
valves, warm-up valves, drain valves and vent valves in the steam
generator, turbine generator and auxiliaries and auxiliary electrical
systems.

(b)

Operation of pumps and fans associated with the steam generator,

turbine generator, feed cycle and other auxiliary systems.

(c)

Call for plant overview, group display, individual loop display, etc. and
carry out associated control operations.

A separate monitor with keyboard common for 2 units would be provided for
the Shift Charge Engineer. However, plant operations from this monitor would
be inhibited.
Electrical Control Panel (ECP)

12.

The ECP would comprise of the generator controls including the monitoring,
control and annunciation for the electrical auxiliary system. The mimic of the
electrical system would be represented up to 415V PMCC level. The 415V
normal/emergency switchgear would also be represented.

13.

All breakers with synchronizing / check synchronization facility would be

controlled from ECP. This would include the GT breakers, 6.6 kV incomers and
bus coupler and the 415 V PMCC incomers and bus coupler and the 415 V
normal/emergency switchgear incomers. Additionally the SST HT side
breakers and tie feeders from the 6.6 kV station switchgear would be
controlled from the ECP.

14.

In addition, all the above controls would be provided in the main plant DCS.
CONTROL ROOM

15.

A control room is proposed to be located on the side of station building. This

control room is partitioned into different rooms to house the following
equipment :
(a)

Unit Control Desk (UCD) and printers in the main control room
(common)

(b)

Electrical control room in main control room

(c)

The I&C system cabinets, electrical auxiliary cabinets, steam

generator and turbine auxiliaries system cabinets in the electronic
cubicle room (separate)

(d)

Shift charge Engineers monitor with key board and printers in Shift
Charge Engineers room (common)

(e)

Maintenance Engineers monitor with key board in MEE room and

printers of I&C, steam generator and turbine system in auxiliary
electronics room (common)

(f)

Uninterrupted Power Supply System (UPS) in UPS room (separate).

FEATURES OF THE I&C SYSTEM

Sequence of Events Recording System
16.

Sequence of events recording system (SER) with adequate capacity would be

provided as an integral part of DCS to log trips, cause of trips and other
important faults to diagnose the cause of plant trip with a resolution of one
millisecond. This would also include switchyard inputs The system would be
provided with a dedicated printer located in the main control room.
Annunciation System

17.

A Stand alone microprocessor based annunciation system (AS) would be

provided with ISA sequence ring back feature. The system has the features of
standard ISA sequences. A limited number of annunciation windows of
important alarms are proposed to be provided in the unit control desk. Alarm
prioritisation is also envisaged. A set of annunciation push buttons would be
provided in the unit control desk.
Analytical Instruments

18.

Adequate number of analytical instruments would be provided for continuous

monitoring of de-mineralised water, condensate, feed water and steam. The
analysis would include pH, conductivity, dissolved oxygen, hydrazine and
silica measurements.
STEAM AND WATER SAMPLING SYSTEM

19.

Various steam and water samples would be routed to a centralised place and
cooled to the required temperature before entering analysers / cells. The
complete hardware associated with this sampling system and cells is mounted
in a sampling rack with facility for grab sample. The analysers are located in a
separate panel near the sampling rack in an air-conditioned environment. Both
the sample rack and analysers are located in a central place with the analyser
panel section partitioned for air-conditioning.
CONTROL VALVES

20.

All control valves would have 15% excess capacity over and above the design
flow value.

FINAL CONTROL ELEMENT ACTUATORS

21.

All final control elements (control valves and control dampers) would have
actuators of pneumatic / hydraulic type. The control valve design would be
suitable for the required fail-safe conditions of process / equipment.

22.

All actuators would be sized so that the final control elements operate properly
even when the upstream pressure exceeds 110% of maximum value.
Pneumatic actuators would be provided with air failure lock and remote
release, limit switches, adjustable minimum and maximum stops, load position
indicators, positioners, electronic position transmitters and solenoid valves in
accordance with the system requirements.
FIELD INSTRUMENTS

23.

Field transmitters, switches and temperature elements with adequate

redundancy would be provided to meet he interlock/control requirements of
the power plant. Minimum number of local instruments/indicators would be
provided to enable local operators to supervise and monitor equipment /
process operation.
AIR SUPPLY FOR PNEUMATIC EQUIPMENT

24.

Oil free, dry instrument air from instrument air header at a pressure of
6 - 8 bar (g) would be drawn for various instrument auxiliaries like control
valve positioners, control damper positioners, I/P converters, etc. Each of
these pneumatic equipment which requires air supply at different levels would
be provided with an air-filter regulator.
POWER SUPPLY

25.

An uninterrupted power supply (UPS) system would be provided to cater to

240 V AC, single phase, 50 Hz, 2 wire power supply requirements of
instrumentation and control systems viz. man-machine interface equipment,
analysers, receiver instruments, and annunciation system. 24 V DC system
would be provided for the control cabinets housing processor, communication
modules and I/O modules.
TESTING AND CALIBRATION INSTRUMENTS

26.

Testing and calibration instruments as required for maintenance of the field

instruments would be provided.
CABLES

27.

Individual pair shielded and overall shielded twisted pair copper cables would
be used for analog signals and overall shielded cables would be used for
digital signals. All these cables are armoured. The overall sheath would be of
FRLS. The size of the wire would be 0.5 sq.mm FRLS, 1.5 sq.mm copper
control cable would be used for cabling between MCC and Control system.
Compensating cables would be provided for connecting the thermocouple
inputs to the control system. The interconnecting cables between any two
cabinets and between cabinets and panels would be of prefabricated type.

INSTRUMENTATION PIPES / TUBES AND FITTINGS

28.

For all pipe mounted instruments, pipes and fittings of appropriate material
would be used. For all high pressure and temperature services (above 62 bar
(g) or 4250C), two isolating valves of NB25 size would be used. For level and
flow instruments NB25 size isolating valves would be used. For other services
and measurements NB15 size valves would be used.

29.

For remote located instruments like transmitters, tubes and fittings of

appropriate material and rating would be used. Open type transmitter racks
would be provided to group and mount all pressure, flow and level
transmitters. Temperature transmitters would be head mounted. Junction
boxes would be provided for termination of all field switches like pressure,
temperature and level.
CONDITION MONITORING SYSTEM

30.

A microprocessor based diagnostic and data management system complete

with vibration and other sensors would be provided for the steam turbine and
all HT (6.6 kV) drives/ motors of boiler and turbine islands and CW pumps.
POLLUTION MONITORING

31.

Continuous SO2 / NOx and particulate monitoring is envisaged in the stack, to

meet the statutory requirements. Oxygen and CO measurements are
envisaged in the flue gas duct.
EARTHING

32.

Separate electronic earthing system with dedicated pits would be envisaged

as part of DCS system.
MASTER CLOCK

33.

A stand-alone master clock system with suitable time formats for

synchronising DCS system clock and a chain of clock system to be located at
strategic locations in the entire plant with satellite time would be envisaged.

CHAPTER IX
WATER SYSTEMS

PLANT WATER REQUIREMENT

The total plant water requirement for the 2 x 600 MW power station is indicated for
the 1st stage of 1200 MW capacity in Table IX-1 as below. The total water
consumption for the ultimate capacity of 2000 MW plant will be proportionately
increased.
TABLE-IX.1
Plant Water Requirements

Sl.
No.

Item

Estimated Quantity
M3/hr

1.

Make up water for condenser

and other auxiliaries

2.

Service Water

3.

Plant and colony

water

M3/day
3840

92160

240

5760

180

4320

potable

4.

DM water for SG make-up .

120

2880

6.

Miscellaneous
(for
filter
backwash,
DM
plant
regeneration, clarifier blow
down and evaporation loss
from Raw water storage tank)

300

7200

Miscellaneous
(including
evaporation loss in pits)

120

2880

4,800

115,200

7.

Total water requirement

1.

It is assumed that requirement of water for ash handling and coal handling
systems would be met from condenser cooling water system blowdown.

2.

The proposed scheme of water systems for the 2 x 600 MW units for stage I
of the proposed power plant is shown in Exhibit - 07. The water systems
consists of various sub-systems listed below and discussed in the subsequent
paragraphs of this chapter :
(a)

Raw water supply and pre-treatment system

(b)

Condenser cooling water (CW) system

(c)

CW Make up water system

(d)

Auxiliary cooling water (ACW) system (DM Water)

(e)

Water treatment (Demineralised water (DM) system)

(f)

Service & potable water system

(g)

Fire protection system

(h)

Effluent treatment Plant

RAW WATER SUPPLY SYSTEM

3.

Proposed System
Raw water is envisaged to be drawn from Govind Vallabh Pant Sagar (GVPS)
located at about 37 km from the plant site. The river water is pumped to the
power plant premises into a raw water pond having about 2 days water
storage capacity to take care of any vagaries of water flow through pipeline
due to unforeseen maintenance etc. Intake structure at GVPS would be
designed for ultimate capacity of plant. However pumps and transport pipes
would be installed in stages.

4.

Raw Water Storage and Treatment

The raw water (which is basically river water) is expected to have high
turbidity / suspended solids especially during monsoon. Since the quality of
influent water required for the various systems in the plant is clarified water
(with turbidity and suspended solids less than 50 ppm), it is proposed to
provide clariflocculator / type clarifiers two (2) nos. for CW make-up /
service water and one (1) no. for DM plant.

5.

Raw Water Distribution

From the clarifiers, raw water would be transmitted by gravity to clarified
water storage tank. This tank would be supplying raw water to various
consuming points such as condenser cooling make-up, DM plant, Service
water, Fire protection water etc.

6.

Clarified Water Storage Tank and Pump House.

The clarified water from the clarifier would be stored in a clarified water
storage tank of capacity 9,600 cu.m which would be in two (2) compartments
feeding to a common sump to facilitate cleaning and maintenance. The
clarified water storage tank would have reserve storage for fire protection
system, which is about 1,500 cu.m capacity. Separate storage tank of 600
cu.m capacity would be provided for DM plant.

7.

Supply of Clarified Water to Various Consuming Points

The required condenser cooling water make-up would be flowing by gravity to
the CW pump house forebay. Requirement of other consuming points would
be pumped by the following pumps :
(i)

DM plant supply pumps

(ii)

Fire water pumps

(iii)

Service water pumps.

CONDENSER COOLING WATER (CW) SYSTEM

8.

Cooling Towers
Recirculation type cooling system with either forced draft or Natural draught
cooling towers (NDCT) 2 Nos. 1 for each unit is proposed for CW system for
each stage of the proposed station. The cooling tower would be designed for
a cooling range of about 10 deg C and an approach of 4.5 deg C. Tower
construction would be of RCC with PVC film type fills.

9.

Cooling Water (CW) Pumps

Five (5) CW pumps each of 50% capacity are proposed for the 2 x 600 MW
power station (2 pumps meeting the CW requirement of each unit and one
common standby) for each stage of the proposed station. These pumps
would be installed in individual chambers connected to a common CW fore
bay. Each pump chamber would have provision for installing coarse screens
and stoplogs. The CW pumps would be located in the pump house. An EOT
crane of suitable capacity would be provided in the pump house for handling
the pumps and motors during maintenance.

10.

RC Channels
The CW flow from the cooling tower basins is proposed to be conveyed by
gravity to the common CW forebay and pump house of RC rectangular open
channels. The channels are designed to resist maximum level fluctuations
expected under transient flow condition.

11.

CW Forebay and Pumphouse

The total CW flow proposed to be discharged from the open channel to a
common forebay and pump house. The forebay is designed to ensure equidistribution of flow to the CW pumps as well as to limit the entrance velocity at
the CW pump house.

12.

CW Inlet and Outlet Conduits

From the CW pump house, the CW discharge is proposed to be conveyed to
the condensers located in the station building, through CW inlet conduits.
These conduits would be either of mild steel construction or of RCC tunnels.
The hot water from the condensers is proposed to be conveyed back to the
cooling towers through CW outlet conduits which would also be either mild
steel or RCC tunnels.

13.

Valves and Specialties

Motor operated butterfly valves would be provided at the discharge of the CW
pumps and the condenser inlet / outlet piping to facilitate isolation and control.
Expansion joints are proposed in the CW pump discharge lines and
condenser inlet and outlet lines to take care of any misalignment, thermal
expansion, etc., and to facilitate erection and maintenance. The CW pumps
and their discharge valves would be suitably interlocked to result in a
co-ordinated operation.

14.

CW Blowdown and Make-Up Water Requirements

Make-up water requirement of CW system is obtained as the sum of drift and
evaporation losses from the cooling tower and blowdown from the CW system
(by way of water drained from the hot water conduit of the CW system). In
order to conserve water, the blowdown would be utilised to meet the water
requirement of the ash handling and coal handling systems.

15.

The assumed analysis of raw water (make up water) is presented in

Appendix-3. Based on this water analysis, a cycle of concentration (COC) of
5.0 has been adopted for CW system. The CW blowdown would be taken
from the condenser outlet. The blow down water from the condenser outlet
would be utilised in the ash / coal handling systems, horticulture purpose and
excess blow down water is led to guard pond.

16.

To prevent scaling arising due to the operation of CW system with a higher

COC, chemical dosing system (with scale inhibitor / dispersant) is envisaged.
In order to prevent /minimise growth of algae in the CW system, Chlorine
dosing system is envisaged. Side stream filtration plant is also envisaged for
the CW system.

17.

Raw Water System Chlorination

In order to prevent / minimise the growth of algae in the raw water system,
chlorine dosing is proposed. Provision would be made for shock dosing and
continuous dosing. However, the continuous dosing rate would be adjusted
during operation phase to meet the chlorine demand.
AUXILIARY COOLING WATER (ACW) SYSTEM

18.

The ACW system meets the cooling water requirements of all the auxiliary
equipment of the TG and SG units such as turbine lube oil coolers, generator
air cooler, vacuum pump, ash cooler, exciter air coolers, Seal Pot, combustor
spies valves, ID / SA / PA fan bearing oil coolers, BFP auxiliaries such as lube
oil coolers, working oil coolers, drive motors, etc., condensate pump bearings,
sample coolers, emergency DG sets and air compressors.

19.

For the ACW system, a closed loop system using passivated DM water as a
cooling medium is proposed. The DM water is circulated through the auxiliary
coolers by three (3) 50% capacity (2 working + 1 standby) ACW pumps. The
hot water from these auxiliaries is cooled in the plate type heat exchangers 2
Nos. by the circulating water tapped from the main CW circuit and pumped by
CCW pumps.

20.

An ACW overhead tank of 20 cu.m capacity is proposed to ensure positive

suction to the ACW pumps and also serve as the source of make-up to the
ACW system.
WATER TREATMENT PLANT

21.

The water treatment plant broadly consists of DM pre-treatment plant,

filtration and DM plant.

22.

The DM pre-treatment consists of :

(a)

Chlorination system in the form of sodium hypochlorite to destroy

organic matter and algae.

(b)

Alum / polyelectro type dosing system for the purpose of coagulation.

23.

The filtration plant consists of three (3) vertical pressure sand filters to remove
turbidity and suspended solids. Back-washing of filters would be done by
means of gravity flow from filtered water storage tank. Part of the filtered
water would be stored in filtered water storage tank which would be located
on the roof of water treatment plant building. This tank would supply water for
filter backwash and potable water system. Water would be supplied to the
filtration plant by means of three (3) nos. (two working + one standby) WT
plant supply pumps. The WT plant supply pumps would take suction from the
clarified water storage tank and would be located in the clarified water pump
house.

24.

De-chlorination Equipment
Activated carbon filters would be used for dechlorination. These filters would
also remove any organic, grease, oil etc. present in the water.
DM Plant

25.

The DM plant would meet the requirements of steam generator (SG) feed
water make up, ACW system make-up and plant / colony potable water. It
would be designed for a total output of about 3,000 m3 / day of DM water
based on SG feed water make up at 3% MCR. It is proposed to provide three
(3) (two (2) working + one (1) standby) streams DM plant, each stream
designed for an output of about 1500 m3 / day with 16 hours productive run
time. Each stream of the DM plant would consist of the following:

26.

Cation Unit
Filtered and dechlorinated water would pass through the cation units. The
cation unit would be designed to limit the sodium slip within 1.0 ppm as
CaCO3.

27.

Degasser System
The effluent from SAC units would then pass through a forced draft degasser
tower to limit the CO2 to 5 ppm as CO 2. For the degasser tower two (2) nos.,
100% capacity degasser air blowers would be provided. The degassed water
would be stored in degassed water storage tank. Three (3)( two working +
one standby) degassed water transfer pumps would be provided for
transferring the degassed water to the anion units.

28.

Anion Units
The degassed water transfer pumps would pump degassed water through
strong base anion (SBA) unit. SBA unit would be designed to restrict the
silica slip within 0.1 ppm as CaCO3.

29.

Mixed Bed (MB) unit

The final polishing of DM water would be done in MB unit. The MB unit would
be designed to limit the silica less than 0.02 ppm as SiO 2 and conductivity
would be restricted to 0.1 micro mho / cm at 250C.
30.

DM water from the mixed bed units would be led to the two DM water storage
tanks. The DM water from the DM plant storage tanks would be pumped to
condensate storage tank by three nos.(3)( 2 working +1 stand by) DM water
transfer pumps.

31.

Regeneration System
30 % Hydrochloric acid and 48% sodium hydroxide would be used as
regenerants for the purpose of regeneration of cation and anion resins
respectively. The equipment of regeneration system would comprise bulk
acid and alkali storage tanks, acid / alkali transfer pumps, acid / alkali solution
preparation and measuring tanks, ejectors and all associated piping / valves,
etc. two (2) nos., each bulk acid and alkali storage tanks would be provided to
meet the requirement of both the streams. Each of the tank would be sized to
hold 15 tonnes of respective chemical.

32.

Neutralising System
The acidic and alkaline effluents from DM plant and the filter backwash would
be led to a neutralising pit. The pit would be in two equal compartments. Acid
or alkali would be added to the neutralising pit depending on nature of
effluents from DM plant. Two (2) nos., pumps, (one working + one standby)
to handle effluents are proposed to re-circulate and dispose the neutralised
effluents into the guard pond.

33.

Mode of Operation of DM Plant / Filtration Plant

The complete mode of operation of DM plant and filtration plant would be
semi-automatic for which a PLC based control system v be provided.
SERVICE AND POTABLE WATER SYSTEMS

34.

Water required for plant washing and air conditioning and ventilation system
make-up would be taken from the service water overhead tank. Water for the
service water overhead tank would be pumped from clarified water storage
tank.

35.

Requirements of potable water for the power plant as well as the colony
would be met from the potable water pumps in the DM plant which would
pump potable water from filter water storage tank to the potable water over
head tank located at a suitable location. Further distribution of potable water
to various consumer points would be by gravity.

FIRE PROTECTION SYSTEM

36.

This system would consist of the following sub-systems :

(a)

Hydrant system covering all areas of the plant and coal stockpile area.

37.

(b)

High velocity water spray (HVWS) system for the protection of

generator transformers, turbine oil tanks, lube oil system equipment,
unit auxiliary transformers

(c)

Automatic deluge (medium velocity water spray) system

protection of cable galleries

for

the

The system would be designed to conform generally to the rules and

regulations of the Tariff Advisory Committee (TAC) / LPA of the Insurance
Association of India. Three (3) firewater pumps (two motor-driven and one
diesel engine-driven) of horizontal, centrifugal type would be provided for the
system. One jockey pump (motor-driven) of horizontal, centrifugal type would
be provided to keep the system pressurised. All the above pumps would be
located in the clarified water pump house. The clarified water storage tank
would have a dead storage of 1,500 cu.m of water for the fire protection
system in line with the regulations of the TAC/LPA.
CHEMICAL LABORATORY EQUIPMENT

38.

A chemical laboratory with all facilities including furniture, testing equipment,

meters, glassware etc. would be established for the power plant to enable
testing of fuel, water, flue gas, etc. as required for normal operation of the
power plant.
EFFLUENT DISPOSAL AND RE-USE SYSTEM

39.

The effluent recycling / reuse system would be designed for maximum reuse
of all the plant effluents. This system would not include storm water / rain
water reuse in the plant during monsoon seasons.

40.

The sources of plant effluent are mainly :

(a)

CW blowdown

(b)

Effluent from WT plant

(c)

Coal pile area run off water

(d)

Plant drains

41.

Part of the CW blowdown would be utilized for meeting the requirement of

ash / coal handling systems and horticulture. Excess blowdown would be led
to guard pond.

42.

Water treatment plant effluent comprises mainly of WT plant regeneration

waste and filter backwash. These effluents would be pumped to the guard
pond through a neutralising pit.

43.

The drains from the coal handling area run off (during rainy season) would be
led to a pond. Coal particles would settle down in the pond and clear water
from the pond would overflow to the storm water drain.

44.

Plant drains from SG / TG area would be led to a sump which would also
collect wastes from transformer area and fuel oil farm area. These oily
effluents would be further treated in an oil water separator for removal of oil

traces. The clear water would be led to the guard pond and the dirty oil would
be disposed off in drums separately.
45.

Provision for suitable treatment would be made in the guard pond to control
the effluent constituents within the limits stipulated by the concerned
authorities. The water from the guard pond would be led to the river
(downstream of in-take pump house)

46.

The clarifier sludge from the CW clarifier and DM plant clarifier which is
intermittent would be pumped to the sludge handling system with thickener
and centrifuge.

CHAPTER X
COAL HANDLING SYSTEM
GENERAL
1.

This chapter covers the provisions for the coal handling system for the
proposed power plant. It covers proposed facilities for transport of coal from
mines to power plant by conveyors, unloading, screening, crushing,
conveying coal up to the steam generator (SG) bunkers or stockyard and
reclaiming from the stockyard and conveying same to SG bunkers.
DESIGN CRITERIA AND ASSUMPTIONS

2.

The design criteria for coal receipt by conveyors, stacking, reclaiming,

screening and conveying is based on the following functional requirements
and assumptions :
(a)

Coal required for each unit at maximum continuous rating (MCR)

condition based on coal from Mahan coal mine having a gross calorific
value of 3,800 k Cal / kg would be about 775 t / hr for stage I of
1200MW.

(b)

The maximum lump size of the coal received at power plant would be
around 250 mm.

(c)

Crushing of coal is considered as the maximum lump size of coal

received at site would be about 250 mm.

(d)

A coal stockyard for stacking of coal required for a minimum period 7

days has been considered.

(e)

Coal would be received at plant site by conveyors.

(f)

Coal handling system would be designed for the proposed 2 x 600

MW units for each stage of the proposed station.

(g)

Two (2) streams of conveyors are proposed throughout the power

plant except for the emergency reclaim conveyor.

SYSTEM CAPACITY
3.

The maximum daily requirement of coal for two units would be about 18,500
tonnes for first stage of the proposed station. The required capacity of the
coal unloading and conveying system is calculated as about 1,600 t/hr based
on 16 hrs operation of the system per day for first stage of the proposed
station.

SYSTEM DESCRIPTION
4.

The system description furnished below is to be read with reference to exhibit

no 3 and 8 (Plot plan and flow diagram).
COAL CONVEYING TO SG BUNKERS

5.

Coal received from mine conveyors is fed to crusher in the crusher house by
conveyor. Coal from crusher house would be conveyed to boiler bunkers
through series of belt conveyors and trippers.

6.

Two (2) sets of screens and crushers would be provided (one operating and
one standby) each of 1,600 TPH capacity.
COAL STORAGE

7.

For the proposed units, space provision has been made in the coal stockyard
to store about 7 days requirement of coal for two units. Since the proposed
power plant is a pit-head based power station and the coal is supplied from
captive mines belonging to EPMPL whish is located close to proposed power
plant by cross country conveyors, storage of 7 days is considered to be
adequate. To enable stacking and reclaiming of coal, Two (2) unidirectional
stacker-cum- reclaimers are considered. The height of the stockpile would be
about 8.75 M. The cross section of the stockpile would be triangular. As a
back-up, there would be facility to store raw coal by trucks. For this, a
separate storage yard and reclaiming facilities would be provided.

8.

Four (4) stock piles, two each on either side of the two stacker cum
reclaimers would be provided with a total storage capacity of about 1,17,600
tonnes of coal. The stacker on the trunk conveyor would stack coal on both
sides of the track. The rated capacity of the stacker would be 1,600 TPH and
the rated reclaiming capacity would also be same. The bucket wheel on the
boom conveyor of the stacker- cum-reclaimer would reclaim the coal from the
stockyard and feed on to the trunk conveyor for onward conveying to bunkers
through a series of conveyors and travelling trippers. During emergency
when both stacker-cum-reclaimers are under maintenance, coal would be
reclaimed from the stock pile by dozing same into the under-ground
emergency reclaim hopper.

SALIENT FEATURES OF THE SYSTEM

The following are the salient features of the coal handling system :
Belt Conveyors from coal mines to Coal Stockyard / SG Bunkers
9.

The rated capacity of all belt conveyors would be 1,600 TPH. All conveyors
would be provided with Nylon-Nylon belting with fire retardant (FR) grade
covers of 5mm thickness at top and 3 mm thickness at bottom. The belt width
would be 1600 mm with a troughing angle of 35o. The belt speed would be
about 2.3 m / sec.
Conveyor Galleries

10.

All above-ground conveyors would be provided with enclosed galleries with

sheeting on side and top. Seal plates at required locations like road & rail
track crossings, above buildings, etc. would be provided. Above ground
conveyors near the station building area would be provided with completely
enclosed galleries.
Screens and Crushers

11.

There would be two screens and two (2) crushers. The Screens would be of
triangular / eccentric disc type with a capacity of 1,600 TPH each. This type of
screen is quite effective for screening sticky coal. Crushers would be of ring
granulator type having capacity of 1600 TPH.
Junction Towers and Crusher / Screen house

12.

All junction towers and screen house would be of structural steel with
chequered plate covered floors. Side cladding and roof would be provided
with corrugated GI sheets.
Feeding of Coal to Bunkers and Bunker Ventilation System

13.

Coal would be fed to the bunkers from conveyors through motorised travelling
trippers. The coal bunkers would be of circular type and the openings on the
top would be covered with bunker sealing belt to avoid dust nuisance. The
bunkers would be adequately ventilated so as to keep the bunkers free from
accumulation of volatile gases, thereby eliminating fire hazard and also
avoiding dust nuisance in the tripper floor. The dust lader air would be
passed through bag filters before being let out into atmosphere.
Stacker-cum- Reclaimer

14.

Two (2) traveling and slewing type stacker-cum-reclaimers would be provided

for stacking and reclaiming of coal in the stock yard. The rated stacking and
reclaiming capacity would be 1,600 TPH. The coal would be stacked on both
sides of each of both the trunk conveyors.

Metering of Coal
15.

Adequate number of electronic belt scales would be provided on conveyors at

appropriate places to monitor the inflow of coal quantity into the plant and the
coal feed to the bunkers.
Tramp Iron Detection and Removal

16.

Tramp iron and other magnetic materials would be removed by means of inline magnetic separators provided on the head pulleys of conveyors leading
to the crusher houses. Metal detectors would be provided on other conveyors
at appropriate locations to detect non-magnetic metal pieces and heavy iron
pieces that may be present in the coal being conveyed.
Dust Control

17.

Plain water spray dust suppression system would be provided for crusher
houses & junction towers. Plain water type dust suppression system would be
provided all around the stockpile to suppress the dust generated and to keep
dust nuisance to the minimum. The bunker ventilation system would be
provided with bag filters to trap the dust generated while loading coal into
bunkers and to vent out dust free gases/air.
Fire Protection

18.

Fire hydrants would be provided at all tunnel entry points, junction towers /
screen house, bunker gallery and along the overhead conveyors. Fire
hydrants would also be placed along the periphery of the coal stock pile for
fire fighting.
Coal Yard Drainage

19.

Around the coal stock yard, drainage channels would be constructed to take
all the effluent from the coal stock yard (sprinkling water, rain / leach water)
which would be ultimately led to a sump. A sump pump would be provided to
pump the leach water to the adjacent ash disposal area.
Controls

20.

Operation of the complete coal handling system, except travelling trippers on

bunkers and stacker-cum-reclaimer would be monitored from the coal
handling control room. Travelling trippers and stacker-cum-reclaimers would
be controlled locally.
The control and protection system would be
microprocessor based with redundant CPU and colour monitor. Telemetered
integrated readings would be provided for accounting of coal consumed by
the SG units. Also, annunciation would be provided in the Unit control room to
indicate low level of each bunker.

CHAPTER XI
ASH HANDLING SYSTEM
GENERAL
1.

This chapter covers the design criteria and salient features of the ash
handling system for the proposed power plant. The following data have been
considered for design of ash handling system for first stage of the proposed
station for each steam generating unit:
(a)
(b)

Hourly coal firing rate at MCR condition

per unit for indigenous coal

387 TPH

Ash content in coal considered for the design

40 %

:
:

20 %
90 %

1 cu.m

of ash handling system

(c)

(d)

Distribution of total ash produced as

Bottom ash
Fly ash
Volume occupied by one tonne of ash in storage
area

(e)

The system adopted for bottom ash removal

would be scraper
conveyor system and for fly ash removal, pressure type pneumatic
system

(f)

Fly ash conveying would be in dry mode and the bottom ash would be
either in dry form or wet slurry form in view of the present environment
regulations.

(g)

The water required for slurry formation would be drawn from

condenser cooling water blowdown. Service water would be used for
refractory cooling and fly ash dust conditioners and auxiliary cooling
water (bearing cooling water) would be used for jacket cooling of air
compressors, silo / ESP aeration blowers cooling etc.

CAPACITY AND TIME CYCLE

2.

Bottom ash removal from the bottom ash hopper would be carried out
continuously at the rate of about 42 TPH per unit. Similarly, the fly ash formed
in one shift would be evacuated from the fly ash hoppers of the steam
generator unit up to ash storage silo with a system capacity of 150 TPH per
Unit under continuous running and 210 TPH during emergency (i.e.
evacuation of ash collected in 8 hours in 6 hours time). Fly ash and bottom
ash from their respective silos would be disposed off in slurry form or dry form
in about 12 hours per day.

SYSTEM DESCRIPTION
Bottom Ash Handling (Refer Exhibit - 9)
3.

Refractory lined dry bottom ash hopper (BAH) having a capacity to store
about four hours bottom ash collection would be provided below the furnace.
Normally the bottom ash generated would be directly discharged into the
submerged scraper chain conveyor (SCC) provided below the BAH. A double
/ single roll type heavy duty clinker grinder would be provided at the head end
of SCC to crush the ash clinkers to (-) 25mm size. The ash clinker form the
clinker grinder would be conveyed to BA storage silo through series of belt
conveyors. The BAH gates would be closed during the maintenance of
scraper chain conveyor.
Disposal of Bottom Ash From Silo

4.

There would be one common BA storage silos for two. Storage silo would be
designed to have a storage capacity of 24 hours of BA generation by two
units. The BA would be disposed off either in wet slurry form or in dry form
using trucks. A reversible belt feeder would be provided below the silo outlet
which would feed BA either to trucks or to wetting unit and jet pump for slurry
disposal.
FLY ASH HANDLING SYSTEM (Refer Exhibit - 10)

5.

The fly ash (FA) system would be designed to evacuate fly ash in dry form
from fly ash hoppers using pressure type pneumatic conveying system as
described below :
The fly ash collected at various hoppers would be conveyed pneumatically to
FA storage silos. The fly ash conveying system would operate continuously
but with time gaps between cycles. The fly ash removal system would be
designed on a continuous basis with 20 cycles per hour and during
emergency with 30 cycles per hour.
Disposal of Fly Ash From Silo

6.

Dry fly ash from the air pre-heater, economiser, stack and ESP hoppers would
be collected in the FA storage silos. The fly ash conveying air would be
vented to the atmosphere through vent bag filter to mitigate the
environmental pollution.

7.

There would be eight FA storage silos, four for each unit. Each storage silo
would be designed to have a storage capacity of 6 hours of FA generation.
The fly ash collected in the storage silo would be either disposed in wet slurry
form or in dry form using trucks. There would be four outlets provided for each

silo, two for wet slurry disposal, one for unloading of ash in conditioned form
in open trucks and one for unloading of ash in closed container trucks.
MAJOR EQUIPMENT
BA Hopper
8.

The BA hopper would have a capacity to store 4 hours of bottom ash

generation. It would be made of MS welded construction having external
supports. A seal trough would be provided around the top periphery of the BA
hopper for furnace sealing and to prevent ingress of air into the furnace. The
hopper would be lined with monolithic refractory.
Clinker Grinders

9.

Two (one working and one standby) single/ double roll type clinker grinder
housed in steel enclosure with suitable liners would be provided at the
discharge end of scraper chain conveyor for each unit. The grinders would
crush the ash clinkers to (-) 25mm size.

Fly Ash Transmitter Vessels

10.

The fly ash transmitters would be designed to operate on the principle of

dense phase pressure type pneumatic system. The size of the transmitter
vessel below fly ash hoppers would be selected based on number of cycles
per hour to be limited to twenty on continuous operation basis or it would be
based on evacuation of ash collected in a shift of 8 hours in 6 hours time, with
30 cycles per hour whichever gives higher size of vessel.
Conveying Air Compressors

11.

The requirement of compressed air for conveying fly ash from ESP hoppers,
APH hoppers, Economiser hoppers and stack hopper to fly ash storage silo
would be met by three (3) (one operating for each unit and one common
standby) screw compressors of suitable capacity with adequately sized air
receivers. Each compressor would be sized for evacuation of fly ash from one
unit under emergency conditions. The requirement of compressed air for
instruments, operation of pneumatic valves in the system and bag filter
cleaning would be met by the plant air compressor.
ESP Hopper Fluidising Blowers and FA Silo Fluidising Blowers

12.

The requirement of fly ash hopper fluidising air would be met by three (3) air
blowers (one operating for each unit and the third one as common standby).
Similarly, silo aeration requirement would be met by three (3) blowers (one
operating for each unit and the third one as common standby).

Jet Pumps for Fly Ash

13.

Two (2) working jet pumps would be provided below each fly ash silo. The
capacity of each jet pump would be about 120TPH. Hence, two working jet
pumps will unload each Fly ash silo in about 4 hours time.
Fly Ash Conditioners

14.

Fly ash from the FA silos would be disposed into covered road trucks via fly
ash conditioners. There would be two fly ash conditioner of suitable capacity
below each fly ash silo. The capacity of fly ash conditioner would about 120
TPH. Two fly ash conditioner would unload each Fly ash silo in conditioned
form in about 4 hours time.
High Pressure (HP) and Low Pressure (LP) Water Pumps

15.

Two (2) HP water pumps (one operating for both units and one standby)
would be provided to meet the water requirement of jet pumps provided below
the bottom ash and fly ash silos of both units. Two (2) LP water pumps (one
operating for both units and one standby) would be provided to meet the
water requirement of the refractory cooling, seal trough makeup, bottom ash
hopper filling and makeup, clinker grinder sealing and fly ash conditioners.
The HP and LP water pumps would be of horizontal centrifugal type.
Ash Slurry Disposal Pumps

16.

Ash slurry discharged into the sumps would be disposed to the ash disposal
area by means of slurry pumps and transport piping. The slurry pumps would
of non-clog, horizontal, centrifugal and single stage type. There would be two
(2) series of ash slurry disposal pumps in which one series of pumps would
be operating and other series would serve as a standby. One series of slurry
pumps would operate continuously for 24 hours per day, 6 hours for bottom
ash disposal and 18 hours each for fly ash disposal from both units.
Automatic Sequential Controls for Ash Removal System

17.

Operation of complete ash evacuation and conveying up to storage silos

(bottom ash as well as fly ash) would be controlled from the control panel
(PLC) located in the unit control room for control / sequential operation and
monitoring.
ASH DISPOSAL AREA

18.

The area identified for ash disposal is about 175 hectares, which is adequate
to store about 40% of ash generated from the entire 1,050 MW power plant
for a period of about 9 years. As per the MOEF, the fly ash generated should
be utilized fully at the end of 9 years. EPMPL would look for prospective
buyers for utilizing the fly ash produced.
Dust Control in the Ash Disposal Area

19.

After disposing ash for a specific period (say 6 months or one year), when the
ash dump reaches certain height, it would be covered with a layer of earth.
This would be continued till the ash pond is full with ash.
Growth of Vegetation

20.

During the disposal of ash, the vegetation would be grown on the ash dump.
Tree plant nursery and trial planting area would be set up near the ash
disposal area for effective growth of vegetation in and around the ash
disposal area in order to prevent wind carrying away the exposed ash. the
type of vegetation should be tolerant to the fly ash characteristics to achieve
growth on ash.
FLY ASH UTILISATION

21.

The fly ash is proposed to be collected in silos and most of it would be utilized
/ marketed in dry form. The fly ash which cannot be utilised / marketed would
be disposed to the ash dump area in slurry form or disposed by trucks.

22.

The fly ash generated in thermal power stations has commercial value
because of its usage in cement and construction industries. Fly ash
generated from the proposed power plant would be commercially utilised in
one or more of the following industries, to the extent possible :
(a)

Cement industry

(b)

Brick industry

(c)

Fly ash aggregate making industry

(d)

Road making / paving

Cement Industry
23.

Fly ash is used in the production of Pozzolona cement by intergrinding

Portland cement clinkers and fly ash or by blending intimately and uniformly
Portland cement and fly ash. Indian Standard specifications limit the
Pozzolona (fly ash or similar material) component upto 25% by weight
whereas in other countries it varies from 15 to 50%.
The advantages of fly ash in the manufacture of Portland Pozzolona Cement
(PPC) as compared to other Pozzolonic materials are two-fold.
(a)

Better hydraulic properties of fly ash.

(b)

Cement retains its natural and accepted grey colour instead of

becoming mud-red in case bricks / tiles are used as Pozzolonic
materials.

Brick Industry
24.

Fly ash produced in modern thermal power stations can be used in making
bricks. The Cement Association of India has conducted research and
experiments for making hollow bricks using fly ash. The Central Building
Research Institute (CBRI), Roorkee has also conducted experiments in
making bricks by using fly ash as an admixture with black cotton soil. In this
project, bricks of minimum 105 kg/sq.cm strength were produced by CBRI.
It is reported from Kolaghat thermal station that bricks are being
manufactured by local brick manufacturers with 70% fly ash and 30% clay
which give higher strength than conventional bricks.
Concrete / Building Industry

25.

Fly ash is used in the building industry largely as a concrete additive. Fly ash
can also be sintered into pellets for use as light weight aggregate.
Laboratory and pilot plant trials carried out at CBRI, Roorkee have
established that sintered light weight aggregate can be successfully produced
from Indian fly ash and used for producing plain concrete as well as
reinforced concrete beams and slabs. Laboratory investigations and factory
trials have shown the technical feasibility of manufacture of cellular concrete
from lime and fly ash. It is more economical to produce this cellular concrete
than the cement-sand cellular concrete, which is being produced in the
country at present.
Fly ash can also be used as masonry mortar. The work done at CBRI
suggests that mixtures would be thicker than 1:6 (by volume) to enable them
to be used as mortar. As a masonry mortar, fly ash is used in place of Surkhi
and prepared in a way similar to Lime-Surkhi mortar. Lime fly ash mortars are
cheaper and better in performance and strength than Lime-Sand mortars.
Roads / Paving

26.

It has been reported from the laboratory tests conducted by the Cement
Association of India that fly ash with other ingredients can be used for paving
roads and airport runways. Fly ash mixed with sand and hydrated lime is
used as a base course of asphalt pavement. The breaking strength of such a
pavement is calculated to be as high as 68 kg/sq.cm (1000 psi). As a result
of a series of experiments, the mixtures of ingredients added in the following
recommended proportions gave a good paving material with adequate
strength and reasonable setting time.
Ingredients
Fly ash
Lime
Portland Cement
Sand

Composition by Weight (%)

12 14
2.8 3.6
0.7 0.9
80 84.5

The above mixture developed a strength from 54 to 95 kg/sq.cm (800-1400

psi) in about 90 days at a temperature of 18 deg. C to 21 deg. C. Further, the
experiments have shown that 30% of crushed stones (instead of sand)
established a strength of 102 136 kg/sq.cm (1500-2000 psi). The total cost
of manufacturing the paving mixture comes to about one and half that of
ordinary road stone which has much less strength and to less than one third
the cost of lime concrete which has good strength. Even the extra strength
obtained by using 30% crushed stones as a substitute for sand, the cost is
not expected to exceed that of conventional materials.
Fly Ash Aggregate
27.

The fly ash can be converted to light weight aggregate which can substitute
the presently used conventional aggregate, in concrete blocks, flooring and
non-load bearing structures such as compound walls, canals, pavements, etc.
The main components of the process are fly ash, calcium oxide, fresh water
quenched bottom ash (optional), sand, water and chemically bonding
additives. The calcium from lime reacts with silica and alumina in fly ash to
produce calcium / aluminium materials in a reaction similar to that of Portland
Cement. These minerals bond the fly ash particles tightly so that hard, strong
and practically unleachable pellets are formed. These pellets are heated at
low temperature to cure them.

28.

It may be noted that proportions of different ingredients to make bricks /

cellular concrete / briquettes with fly ash chiefly depends on the constituents
of the particular fly ash. Therefore, the particular type of fly ash is to be
analysed for the properties of its constituents and checked for suitability or
otherwise and suitable proportions of ingredients are to be determined by
laboratory tests / pilot plant tests.

CHAPTER XII
MISCELLANEOUS SYSTEMS
COMPRESSED AIR SYSTEM
1.

Three (3) screw compressors (2 working and 1 stand by), each having a
capacity of 2,500 Nm3 / hr and a discharge pressure of 8.5 kg / cm2 (g) would
be provided for a set of two units. Thus, there would be six (6) air
compressors for the plant. The screw compressors proposed would meet the
instrument and service air requirements of the plant. The requirement of the
compressed air for the fly ash conveying would be met through separate
dedicated compressors.

2.

The compressed air system would include accessories such as moisture

separators and air receivers. The discharge lines of all the three compressors
would be headered. Two air driers (one operating and the other stand by) for
each unit of suitable capacity would be provided.

AIR CONDITIONING SYSTEM

3.

It is proposed to air-condition the unit control room, electronic cubicle room,

shift charge engineers room, printer room, maintenance engineers room,
ESP control room, static excitation cubicle room, analyser panel room, coal
handling control room, DM plant control room and switchyard control room.
Inside design conditions of 24.5 1.50C dry bulb temperature and relative
humidity not exceeding 60% would be maintained in all air-conditioned areas.

4.

Two independent centralised chilled water systems are envisaged for airconditioning the unit control room / electronic cubicle rooms and ESP control
rooms. Each centralised system would consist of three (two working and one
standby) water chilling units. The system also consists of chilled water
pumps, condenser cooling water pumps, induced draft FRP cooling towers,
adequate number of air handling units for circulating the conditioned air
through air distribution system to the room.

5.

For air conditioning of all other rooms, packaged air conditioners or room air
conditioners of suitable capacity would be provided.
VENTILATION SYSTEM

6.

For the ventilation of the station building, evaporative cooling system (Air
washer type) is envisaged. This system consists of air washers, supply air
fans, air washer circulating water pumps, centrifugal fans and air distribution
system for distributing the supply air inside the station building. The exhaust
of hot air out of the station building would be achieved by provision of roof
extractors and wall mounted exhaust fans.

7.

For ventilation of other buildings, supply air fans, exhaust air fans, roof
extractors or a suitable combination of these would be provided.
HYDROGEN GAS SYSTEM

8.

Hydrogen gas with a purity of 99.9% (by volume) is required for cooling of the
generators. it would be required for the initial filling and continuous make-up
during normal operation for maintaining the required purity in the generator.
The normal Hydrogen gas requirement for two units is about 24 N cu. m / day.
This requirement would be met by procuring the Hydrogen gas cylinders from
the external sources.
CRANES AND HOISTS
Station Building EOT Cranes

9.

One (1) overhead, cabin operated electric overhead travelling (EOT) cranes,
each of 110/20 tonnes capacity would be installed in the turbine hall of the
station building for handling various equipment except generator stator, during
erection and maintenance. The generator stator would be erected by cribbing
or by employing temporary erection facilities such as derrick / hydraulic jacks,
or by mobile cranes.
Miscellaneous Lifting Tackles / Hoists

10.

For the equipment which weighs above 1000 kg, electrically operated type of
hoists and trolleys would be provided. For the equipment weighing less than
1000 kg, manually operated hoists and trolleys would be provided.

11.

The areas / equipment for which the lifting tackles are proposed to be
provided are ware house, all equipment in the station building which are not
accessible to station building EOT crane, steam generator area (all fans, gear
boxes, mill components etc.), DM plant ( to load the chemicals in to the
tanks), coal handling junction towers and crusher / screen house, ash
handling building, cooling tower area, ESPs, , clarified water pump house,
chlorine cylinder area, etc.
WORKSHOP EQUIPMENT

12.

It is proposed to install the work shop equipment in the power plant. Also,
maintenance and measuring tools are proposed to be procured for the
proposed units.

CHAPTER XIII
ELECTRICAL SYSTEMS
GENERATOR
1.

The generators would be rated to deliver 600 MW, at 21 kV, 50 Hz, 0.85power factor, at 3000 rpm. The generator winding would be star connected
with the phase and neutral terminals brought out to an accessible point. The
generator will deliver rated MVA output under + 5% variation in voltage and
+3 to -5% variation in frequency. The star point of the generator would be
connected to earth through an earthing transformer, the secondary of which
will be loaded by a resistance.

2.

The generators would have water-cooled stator windings, stator core and
hydrogen cooled rotor. Hydrogen coolers would be built into the stator frame
of the generator and would be sized to ensure at least 80% of the rated
output when one hydrogen cooler is taken out for maintenance.

3.

The generator would be provided with either brush less or static excitation
system. Suitable fast acting non-dead band type continuous acting voltage
regulator would be provided and mounted in sheet steel clad cubicles. The
excitation cubicles will have necessary sections to house the apparatus and
accessories required for field flashing and control.

4.

The generator would be provided with ClassF insulation.

temperature rise would be limited to that of ClassB.

However,

GENERATOR BUSDUCT
5.

The terminals of the generator will be connected to the generator transformer

through Isolated Phase Bus Duct (IPBD) of adequate short circuit withstand
capability with suitably rated tap-offs to the unit transformers. The bus duct
will be natural air-cooled and will run partly indoor and partly outdoor.

6.

The bus duct installation will be complete with generator line side and neutral
side current transformers and line side voltage transformers required for
protection, metering, voltage regulation and automatic turbine run-up system.
Surge protection equipment consisting of lightning arresters with suitable
discharge characteristics to suit the generator basic insulation level will be
provided.

7.

The rating of the generator bus duct will be as furnished in TableXIII.1.

TableXIII.1
Generator Isolated Phase Bus Duct (IPBD)
Sl.
No.

Particulars

Rating

1.

Type of Bus Duct

IPBD / Natural air cooled

2.

Nominal Service Voltage / frequency

21 kV / 50 Hz

3.

Rated voltage

24 kV

4.

Continuous current rating

24,000 A

TableXIII.1 (Cont'd)
Sl.
No.

Particulars

Rating

5.

Basic impulse insulation level (1.2/50 125 kV peak.

micro-sec)

6.

Bus bar conductor material

7.

(a) VT & SP cubicle

8.

Aluminium

(b) Voltage transformer

24000 / 3 kV / 110 / 3 V / 110 /

3 V, 3 nos., 100 VA / ph.

(c) Lightning Arrestor

24 kV Metal oxide type, with nominal

discharge current of 10 kA.

Bus bar material as per

IS 5082

GENERATOR TRANSFORMERS
6.

The generators will be connected to the 400 kV switchyard through the

generator transformers (GTs). The GT will be rated for 705 MVA with 3 Nos.
single-phase banks each rated 235 MVA, 2 winding with unit coolers. The
transformer will be provided with on-load taps in steps of 1.25%. One spare
limb (single-phase bank) will be procured and kept energised by applying low
voltage. The BIL of the transformer will be 1300 kV. The transformer will be
connected in vector group of YNd1. The HV side neutral will be solidly
earthed. Lightning arresters will be provided on the HV side near the
generator transformer. The HV terminals of the transformers will be
connected to the associated bay in the 400 kV switchyard by overhead lines.

7.

The rating and details of the generator transformers are as in TableXIII.2:

TableXIII.2
Generator Transformers
Sl.
No.

Particulars

Rating

1.

Type of cooling

2.

Rating

235 MVA, 3 Nos. single phase

3.

No load voltage ratio

21 kV / 420 kV

4.

Vector group

YNd1

TableXIII.2 (Contd)

5.

Percentage impedance

15% (Typical)

6.

Type of tap changer

On-load

7.

Tap range

+5% to -10 % in steps of 1.25%

8.

BIL

1300 kV peak.

9.

Terminal connections:

10.

HV Side

HV side Terminals on bushings for

overhead line connection.

LV Side

Throat type with matching flanges for

connection to IPBD.

Applicable standard

IS 2026

STATION TRANSFORMERS
8.

Two station transformers of three winding, three phase, 75/37.5/37.5 MVA,

400kV /11.5kV/11.5 kV, with on load tap changer + 10 % in steps of 1.25% will
be provided. These STs will be connected to the 400 kV switchyard. Each ST
will be sized to cater to 100% station loads + outage of one UAT + starting
load of one unit.

9.

The ratings and details of the station transformers are as in TableXIII.3

TableXIII.3
Station Transformer
Sl.
No.

Particulars

Station Transformer

1.

Type of cooling

ONAN/ONAF

2.

Rating

75/37.5/37.5 MVA

3.

No load voltage ratio

220kV/11.5kV/11.5kV

4.

Vector group

YN yno yno

5.

Type of tap changer

On-load

7.

Tap range

+10% in steps of 1.25%

8.

BIL

950 kV peak

9.

Terminal connections:
HV Side

HV side Terminals on bushings for

overhead line connection.

LV Side

Throat type with matching flanges for

connection to SPBD.

10.

Applicable standard

IS 2026

EVACUATION OF POWER
10.

For power evacuation, 400 kV switchyard will be provided. The proposed

scheme for power evacuation is shown in enclosed single line diagram as
Exhibit-13. The units will be connected to the 400 kV switchyard through
generator transformers. The generator transformers will step up generator
voltage of 21 kV to the switchyard voltage of 400 kV. The proposed one and
half breaker scheme is reliable and provides continuity in power supply even
during outage of a bus or circuit.
The 400 kV switchyard will have the following circuits:
(a)

Two generator transformers

(b)

Two lines for LILO with Vindhyachal Korba Line

(c)

Two Lines for connectivity with WR pooling point at Sipat

(d)

Two station transformers

Space shall be provided in the proposed power plant switchyard for one
additional bay for future use.
400 kV SWITCHYARD
11.

One and half breaker-switching scheme is proposed for the 400 kV

switchyard. The details of the switching scheme are shown in enclosed one
line diagram. The switchyard equipment i.e., breakers, isolators, lightning
arrestors, current transformers and buses would be rated for a short circuit
current rating of 40 kA for one second. The technical parameters of 400 kV
switchyard is given in Table-XIII.4.

12.

For each of the two outgoing lines, precision energy metering will be provided.
The metering panel will be located near the CVTs such that the length of the
metering cable is kept to a minimum to reduce errors in energy recording.
Space will be provided adjacent to this metering panel to enable MSTCL to
install check metering for their verification. The metering panel will have
active and reactive energy and active, reactive/apparent power meters with
0.2 accuracy class.
Table-XIII.4
400 kV Switchyard
Sl.No.

Parameters

400 kV Switchyard

1.0

Technical Data

1.1

Design Voltage Levels

(a)

Nominal Voltage

400 kV

(b)

Highest system voltage

420 kV

Sl.No.

Parameters

400 kV Switchyard

(c)

Basic impulse level

1425 kV peak.

(d)

Fault level (kA rms for 1 sec)

40 kA rms

1.2

Minimum Clearances

(a)

Phase to Phase

2850 mm

(b)

Phase to Earth

2850 mm

(c)

Section Clearance

6500 mm

(d)

Ground Clearance

8000 mm

1.3

Minimum creepage distance

31 mm /kV

2.0

Circuit Breakers

2.1

Type of breaker

2.2

Short circuit breaking and making 40 kA rms / 100 kA

current
peak.

2.3

Applicable standards

SF6

IEC - 56

Table-XIII.4 (Contd)
Sl.No.

Parameters

400 kV Switchyard

3.0

Isolators

3.1

Type of mounting and execution

Centre break, horizontal

upright

3.2

Applicable Standards

IS 9721

4.0

Current Transformers

4.1

Type

Outdoor, oil immersed.

4.2

Accuracy class - metering cores

0.2 for revenue

metering & 0.5 for other

4.3

No. of cores per CT

4.5

Applicable standards

IS 2705

5.0

Capacitor Voltage Transformer

5.1

Type

Capacitor, outdoor, oil

immersed

5.2

Rated voltage factor

1.2 continuous
1.5 for 30 secs.

5.3

Method of connection

Star

5.4

Accuracy class - metering cores

0.2

5.5

Applicable standards

IS 3156

Sl.No.

Parameters

400 kV Switchyard

6.0

Lightning Arrestor

6.1

Type

Zinc oxide, gap less

6.2

Rated voltage

360 kV

6.3

Nominal discharge current

10 kA

6.4

Low current / long duration class

III

6.5

Pressure relief class

6.6

Applicable standards

IEC 99

7.0

Line traps

7.1

Continuous current rating

1600A

7.2

Quantity

Two for each line

7.3

Applicable standards

IEC 353

8.0

Coupling devices

8.1

CVT will serve this purpose.

IEC 481

AUXILIARY POWER SUPPLY SYSTEM

13.

The proposed auxiliary power supply system is shown in enclosed single line
diagram. Various auxiliaries will be supplied at the following nominal voltages
depending upon their ratings and functions :
(a)

11000 V, 10%, 50 Hz 5%, 3 phase, 3 wire, medium resistance

grounded AC supply for motors rated above 1500 kW

(b)

3300 V, 10%, 50 Hz 5%, 3 phase, 3 wire, medium resistance

grounded AC supply for motors rated above 200KW and up to
1500KW

(c)

415 V, 10%, 50 Hz 5%, 3 phase, 3 wire, solidly grounded AC

supply for motors rated 200 kW and below and other L.T. services

(d)

240 V, 10%, 50 Hz 5%, 1 phase AC supply for lighting, space

heating of motors and panels, single phase motors, etc.

(e)

220 V, ungrounded DC supply for protection, control and indication

(f)

110 V, 1 phase, grounded AC supply for AC control circuits

(g)

24 V DC supply for instrumentation and control systems such as

closed loop controls, sequence controls, automatic turbine run-up
system, protection and interlock system, sequence-of-events
recording system and annunciation system

(h)

110 V, 1 phase AC uninterruptible power supply for panel-mounted

recorders, CRT units, printers, analysers, etc., forming a part of the
plant instrumentation and control system.

(i)

As per design concepts, one Motor driven BFP and two turbine driven
BFPs will be provided for each 600MW unit. The Motor driven BFP
will be connected to the Station Bus.

14.

The loads will be segregated as unit loads and common station service loads.
Unit Transformers (UTs) will cater the unit loads whereas the Station
Transformers will cater the station loads under normal operating conditions.
The unit loads will be supplied through two numbers transformers connected
directly to the generator through isolated phase bus duct. Start-up power for
the auxiliaries will be supplied through station transformers. Once the unit is
started and the generator picks up rated speed and voltage, the unit will be
synchronised with grid supply. Tie feeders will be provided between station
switch gear and unit switch gears so that during non availability of one unit
transformer, the station transformer will feed the loads connected to that unit
transformer.
UNIT TRANSFORMERS (UT)

15.

Two (2)-unit transformers will be provided for each unit to feed unit loads.
These will be 38 MVA, 21/11.5 kV, 3 phase, 50 Hz, with + 5% off-circuit taps in
steps of 2.5% on the HV side. The transformers will be ONAN/ONAF cooled
with a vector group of Dyn11. The LV will be medium resistance earthed
through a resistance to limit the earth-fault current to 400A. The details of UT
are indicated in TableXIII.5.

16.

The unit transformers will supply power to the 11kV unit switchgears as
shown in the enclosed single line diagram. As far as possible, the unit loads
will be distributed equally on each 11kV unit switch gear so that in case of
outage of any one bus, it would still be possible to operate the unit at partial
load.
UNIT AUXILIARY TRANSFORMERS

17

Two (2) unit auxiliary transformers will be provided for each unit to feed 3.3kV
unit auxiliary motor loads. These will be 20 MVA, 11/3.5 kV, 3 phase, 50 Hz,
with + 5% off-circuit taps in steps of 2.5% on the HV side. The transformers
will be ONAN/ONAF cooled with a vector group of Dyn11. The 3.3kV system
would be medium resistance earthed through a resistance to limit the earthfault current to 400A.
STATION AUXILIARY TRANSFORMERS

18

Two (2) station auxiliary transformers will be provided to feed 3.3 kV station
auxiliary motor loads. These will be 20 MVA, 11/3.5 kV, 3 phase, 50 Hz, with +
5% off-circuit taps in steps of 2.5% on the HV side. The transformers will be
ONAN/ONAF cooled with a vector group of Dyn11. The 3.3kV system would
be medium resistance earthed through a resistance to limit the earth-fault
current to 400A.
SERVICE TRANSFORMERS

19

The required number of transformers will be provided depending on

service/location of the loads.
These transformers will be rated at
2000/1600/1000kVA, 11kV/433V with a vector group of Dyn11. They will
supply power to the 415 V auxiliaries of the unit and station loads. The
neutral of these transformers will be solidly earthed. The transformers will be

provided with + 5% off-circuit taps in steps of 2.5% on the HV side. The

details of service transformers are indicated in TableXIII.5.
Table-XIII.5
Unit Auxiliary Transformer / Service Transformers
SN

Particulars

Unit
Transformer

Unit/Station
Auxiliary
Transformer

Unit/Station
Service
Transformer

Other Service
Transformers

1.

MVA rating

38

20/9

2/1.6/1.0

As per SLD

2.

Type of cooling

ONAN/ONAF

ONAN/ONAF

ONAN

ONAN

3.

No-load Voltage
ratio

21kV/11.5kV

11kV/3.5kV

11kV/433V

3.3kV/433V

4.

Vector group

Dyn11

Dyn11

Dyn11

Dyn1

6.

Tap changer

Off-circuit

Off-circuit

Off-circuit

Off-circuit

7.

Tap Range

+5% in steps
of 2.5%

+5% in steps
of 2.5%

+5% in steps
of 2.5%

+5% in steps
of 2.5%

8.

Impulse withstand
(1.2/50 micro-sec)

125 kV/75 kV
peak

75 kV/40 kV
peak

75 kV peak

40 kV peak

9.

Power frequency
withstand HV/LV

50 kV/28 kV
rms

28 kV/10 kV
rms

28 kV/3 kV
rms

10 kV/3 kV rms

10.

Applicable
Standards

IS 2026

11000 V SWITCHGEAR
20 The 11 kV systems will be medium resistance earthed. The switchgear will be
rated for symmetrical fault current of 40 kA. The 11kV switchgear will
comprise draw-out type Vacuum / SF6 circuit breakers housed in indoor,
metal-enclosed cubicles and will cater to all 11kV motors and 11kV/433V
transformers. The switchgear will be equipped with control, protection,
interlock and metering features as required. Motor feeders of coal handling
switchgear will be provided with fuses and vacuum contactors. All other motor
feeders will be provided with circuit breakers. Fast auto changeover feature
will be provided between the unit and station supplies in the unit switchgears.
Technical parameters of 11kV switchgear are given in Table-XIII.6.

Table-XIII.6
11 kV and 3.3 kV Switch Gear
SN

Particulars

1.0

Switch gear

1.1

Nominal system voltage

11 kV Switchgear

11kV, 3 Ph., 50 Hz

3.3 kV Switchgear

3.3kV, 3 Ph., 50 Hz

1.2

System Neutral Earthing

Medium resistance
earthed

Medium resistance
earthed

1.3

Power frequency withstand

/impulse withstand voltage

28 kV rms/75kV peak

10 kV rms/40kV peak

1.4

Short time rating (1 sec.)

40kA rms/100kA peak

40kA rms/100kA peak

1.5

Applicable standards

IS 3427

IS 3427

2.0

Circuit breaker

2.1

Type

Vacuum/SF6, drawout

Vacuum/SF6, drawout

2.2

Operating duty

03min-CO-3min-CO

03min-CO-3min-CO

2.3

Rated current

As required

As required

2.4

Rated breaking/making current

40kA rms/100kA peak

40kA rms/100kA peak

2.5

Short time rating

40 kA for 1.0 sec.

40 kA for 1.0 sec.

2.6

Mechanism

Motor charged spring

closing

Motor charged spring

closing

3.0

Contactors

3.1

Type

Vacuum

3.2

Application

Motors in CH system

4.0

HRC Fuses

4.1

Type

Current limiting HRC fuses

4.2

Application

Short-circuit protection of
3.3 kV motor feeders with
vacuum contactors

4.3

Symmetrical Breaking capacity

40 kA rms

4.4

Applicable standards

IS 9224

3300 V SWITCHGEAR
21 The 3.3 kV systems will be medium resistance earthed. The switchgear will be
rated for a symmetrical fault current of 40 kA. The 3.3 kV switchgear will
comprise draw-out type Vacuum / SF6 circuit breakers housed in indoor,
metal-enclosed cubicles and will cater to all 3.3 kV motors and 3.3kV/433V
transformers. The switchgear will be equipped with control, protection,
interlock and metering features as required. Separate 3.3 kV switchgear will
be provided for the coal handling system.
Motor feeders for all plant
including for CHP would be provided with fuses and vacuum contactors.
Technical parameters of 3.3 kV switchgear are given in Table-XIII.6.
415 V SYSTEM
22.

The 415V, 3 phase, 3 wire power for the 415V auxiliaries will be obtained from
11kV/433V transformers. The system will be a solidly earthed system. For
maximum reliability, duplicate power supplies with auto changeover facility will

be provided for the essential power and motor control centres. The 415V
switchgear will be of metal enclosed design with a symmetrical short circuit
rating of 50 kA for 1 sec.
23.

All power and motor control centres will be compartmentalised and will be of
double front execution. They will be of fully draw-out design with all circuit
components mounted on a withdrawable sheet metal chassis. The circuit
breakers will be of air break type. Motor starting will be direct-on-line. All LT
motors will be controlled by air break, electro-magnetic type contactors
provided with ambient temperature compensated, time lagged, hand reset
type thermal overload relays, having adjustable setting with built-in single
phase preventor backed up by HRC fuses for protection against short circuits.

24.

The technical particulars of 415V switchgear are as given in TableXIII.7.

Table-XIII.7
415 V Switchgear
Sl.
No.

Particulars

Rating

1.0

Switch gear & Bus bar rating

1.1

Rated voltage/No. of phases/frequency

415V / 3 Ph / 50 Hz

1,2

System neutral earthing

Solidly earthed

1.3

One minute power frequency withstand

voltage
(a)

Power circuit

2500 V

(b)

Control circuit

1500 V

(c)

Aux. Circuits connected to CTs

2000 V

1.4

Maximum allowable Temperature of Bus

bars

900C

1.5

Short circuit withstand of Bus bars

50 KA for 1 sec.

1.6

Dynamic rating of busbars

100 KA peak

Table-XIII.7 (Contd)
Sl.
No.

Particulars

Rating

2.0

Circuit breakers

2.1

Type

Air break, motor charged

spring closing mechanism

2.2

Operating duty

0 3 min CO-3 min CO

2.3

Rated breaking current / Making current

50 KA at 415V AC & 0.25 pf /

100KA

Sl.
No.

Particulars

Rating

2.4

Short circuit withstand current

50 KA for 1 sec.

3.0

Starters

3.1

Type

DOL

3.2

Contactor rated duty as per IS 2959 & IS

8544

Continuous & Intermittent

3.3

Utilisation categories as per IS 2959

AC 3 & AC 4

4.0

Applicable standards

IS 2516

DC SYSTEM
Each unit will be provided with a 1x100% capacity 220 V battery bank with
associated 1x100% capacity chargers with separate float and boost units,
which will feed unit DC switchboards. The incoming and outgoing feeder
circuits in DC switchboard will be provided with switch-fuse units, which will
have suitable supervisory devices against fuse failure.
For catering to station D.C. loads, 1x100% capacity 220 V battery of suitable
capacity with 1x100% float and boost chargers and DC distribution board
would be provided. The unit and station DC system will act as standby to
each other. The station battery and the unit batteries will be rated to cater for
unit load as well as station loads. An additional common stand-by battery
charger will be provided which will act as a common standby charger to either
station or unit chargers.
In the switchyard control room, 2x100% rated 220 V batteries of suitable
capacity with 2x100% capacity float-cum-boost chargers will be provided to
cater to 400 kV and 220 kV switchyard loads. Coal handling plant will be
provided with 2x100% rated batteries with 2x100% capacity float-cum-boost
chargers. 2x100% rated 24 V battery sets of suitable capacity with 2x100%
rated float-cum-boost chargers will be provided to cater to the D.C. supply for
the control and instrumentation system of each unit.
The batteries will be of stationary lead acid type complete with battery racks,
porcelain insulators, inter-cell and inter-tier connectors. The chargers will be
of silicon rectifier type with automatic voltage control and load limiting
features. Separate 48V battery and chargers will be provided in the
switchyard control building to cater to the PLCC loads.

EMERGENCY POWER SUPPLY

To enable safe unit shutdown during complete A.C supply failure in the
station, certain important plant auxiliaries will be provided with a reliable A.C
power supply through a separate source. For this purpose, one (1) 415V
quick starting diesel generator set with automatic mains failure (AMF) feature
will be provided for each unit. The rating of the DG set will be about 1250
kVA.

28.

The diesel generator will feed an emergency 415V switch gear, to which all the
essential loads such as the A.C emergency bearing lube oil and seal oil
pumps, turning gear motor, battery chargers, emergency lights, and essential
instrument power supply feeders will be connected. When the station A.C
supply is healthy, the emergency switchgear will be fed from the unit service
switchgear.

29.

When the station A.C supply fails, the DG set will start automatically and will
feed the loads connected to the emergency switchgear. When the normal A.C
supply is restored, these essential loads will be manually changed over to the
normal power supply. Each DG set considered will cater to the emergency
loads of one unit only. However, interconnection will be provided between the
emergency switchgears of the two units.
UN-INTERRUPTIBLE POWER SUPPLY SYSTEM
For panel-mounted instruments, CRTs, printers, analysers, recorder, etc., 110
V, single phase A.C un-interruptible power supply will be made available.
This power supply will be derived from parallel redundant with static bypass
un-interruptible power supply system having two (2) sets of converters and
inverters with two sets of back up batteries. Also a standby regulated AC
supply will be provided as a back up to the inverters which will be switched on
through static switch in case of inverter failure.
GENERATOR AND SWITCHYARD PROTECTION & CONTROL

27.

The details of the protections that will be provided for the various electrical
equipment viz., generators, generator transformers (GT), station transformers
(ST), unit transformer (UT), service transformers, 400kV switching equipment,
400kV lines, motors, switchgear, etc., are indicated below.

28.

The selection of the protective scheme will be based mainly on reliability,

sensitivity, selectivity and technical merits. All main protections will be of fast
acting type in order to isolate the faulty system from the healthy system in the
shortest possible time, to minimise damage to the equipment and ensure
continuity of power supply, if possible.
Generator Protections

29

One generator relay panel (GRP) will be provided for each unit. This panel
will be located in the unit control room. The following protection schemes will
be provided in the GRP and the protections will be divided into two groups;
each group being 100% redundant and on separate DC supply, so that even if
one group of protections is not available or under maintenance, the generator
is protected by the other group.
(a)

Generator differential protection (87G)

(b)

Generator stator 0 95% earth fault protection (64 GI)

(c)

Generator stator earth fault (95 100%) protection (64G2)

(d)

Generator back-up stator earth fault (0-95%) protection (64G3)

(e)

Rotor earth fault protection (2 stage) (64F1 & 64F2)

(f)

Generator negative phase sequence protection (46GI & 46G2)

(g)

Generator reverse/low forward power protection (32G1 & 32G2)

(h)

Generator loss of excitation protection (40G1 & 40G2)

(i)

Generator pole slipping protection (78G)

(j)

Generator under frequency protection (81G & 81G2)

(k)

Generator over-voltage protection (59G1 & 59G2)

(l)

Generator backup impedance protection (21G)

(m)

Generator stator overload protection (50GS)

(n)

Generator VT fuse failure protection (60G)

(o)

Dead machine protection (61B)

(p)

Generator field over-voltage protection (as part of excitation system)

(59F)

(q)

Generator, Generator Transformer and Unit Transformers over-fluxing

protection (99G)

(r)

In case of static excitation, excitation transformer protection will be a

part of the excitation system.

Generator Transformer Protections

30.

The following protections will be provided for the Generator Transformer:

(a)

Generator transformer HV winding restricted earth fault protection

(64GT)

(b)

Generator, generator transformer and unit transformers overall

differential protection (87OA)

(c)

Generator transformer differential protection (87GT)

(d)

Generator transformer over-current protection (51GT)

(e)

Generator transformer neutral over-current protection (51NGT)

(f)

Buchholz (63), winding temperature (49WT) and oil temperature

(490T) protections, OLTC Buchholz.

(g)

Generator transformer pressure relief protection (63PTX)

(h)

Generator transformer fire protection trip, oil level low, cooler trouble
alarms.

Unit Transformer / Unit Auxiliary Transformer / Station Transformer /

Station Auxiliary Transformer Protections
31.

The following protections will be provided for the unit & station
transformers/unit auxiliary & station auxiliary transformers:
(a)

Differential protection (87UT) and short circuit protection on HV side

(50UT)

(b)

Back-up over current protection on HV and LV sides (51)

(c)

Back-up earth fault protection on LV side (51N)

(d)

Buchholz (63), winding temperature (49WT) and oil temperature

(490T) protection

(e)

Pressure relief protection (63PTX)

(f)

Fire protection and trip (63 RTX)

11000 V / 433 V Service Transformer Protections

32.

The following protections will be provided for service transformers:

(a)

Over current protection on HV and LV sides (51) and short circuit

protection (50) on HV side

(b)

Earth fault protection on HV and LV sides (50N & 51N)

(c)

Buchholz (63), winding temperature (49WT) and oil temperature

(490T) protections

400 kV Lines Protection

33.

The 400 kV lines will have the following protections:

(a)

Distance protection (21-1)

(b)

Distance protection (21-2) and Directional inverse time phase over

current with high set unit (67 / 50)

(c)

Fuse fail relay (FFR) for each secondary of CVT

(d)

Directional inverse time earth fault protection (67N)

(e)

Under voltage relays for live line / dead bus and dead line / live
bus closing and safe grid establishment (27-1, 27-2, 27S)

(f)

Fault locator (FL)

(g)

Fault recorder (FR).

(h)

Neutral impedance replica of distance relay (21NTR)

(i)

No voltage protection.

400 kV Bus Bar Protection

34.

Tuned high-impedance high-speed bus fault relay is proposed for detecting

the fault on 400 kV buses. The bus bar protection scheme will have detecting
elements for each of the main bus and one check zone element. The main
and check zone elements will be connected two different secondaries of CTs
and tripping will be initiated only when respective bus element and check
zone elements operate. Bus wire supervision relays to guard against faults in
the CT secondary wiring and bus wire shorting relay to short CT secondary
bus wires on fault are also proposed. The scheme shall be expandable to
accommodate future lines.
Local Breaker Back-up (50 LBB)

35.

All 400 kV circuit breakers including generator transformer breaker will be

provided with local breaker back-up protection. For generator transformer
breaker, an additional relay will be provided to detect breaker failure for

ground and phase fault in the generator circuit and other low magnitude faults
also.
36

The local breaker back-up protection relay will be a triple pole over-current
relay with high drop-off to pick-up ratio with fast acting feature. This will
provide protection against stuck breaker condition for the 400 kV system.
This protection will be initiated by primary fault detecting relays and time
delayed to permit the breaker to trip.
Circuit Breaker Protection

37.

All the trip coils of the circuit breakers will be supervised.

protections will also be included :
(ii)

Pole discrepancy protection

(iii)

Trip coil supervision relay for each trip coil (98L1 to L6).

(iv)

Anti pumping device for breaker closing (94).

The following

Protection of 11 kV and 3.3kV Motors

38.

All 11 kV and 3.3kV motors will be provided with the following protections :
(a)

Thermal overload protection

(b)

Overload alarm protection

(c)

Instantaneous over current protection

(d)

Locked rotor protection

(e)

Negative sequence protection

(f)

Differential protection (For motor ratings of 1000 kW and above)

(g)

Earth fault

(h)

Bus under voltage

(i)

Bearing temperature monitor

(j)

Water flow monitor for CACW motors

(k)

Lube oil pressure monitor

(l)

Winding temperature monitor

Protection of 415 V Motors

39.

Motors rated below 100 kW will have bi-metallic relays for thermal overload
protection and HRC fuses for short circuit protection. Motors rated 100kW to
200kW will be provided with locked rotor protection in addition to above.
Power Supply and Lighting Circuits

40.

The power supply feeders will have properly rated HRC fuses for short-circuit
protection. Lighting circuits will be protected by miniature circuit breakers.

400 kV SWITCHYARD CONTROL

41.

All breakers and isolators will be controlled from switchyard control panels
(SCP) located in main control room. Relay panels pertaining to switchyard
will be located in the switchyard relay room, which will be kept locked.

42.

All control operations like closing and opening of circuit breakers and isolators
will be performed from the respective control panels. Discrepancy type
control switches will be provided on the control panel. In addition to the
control switches, the control panels shall consists of the following:
(a)
Mimic of bay layout
(b)
Metering
(c)
Facia annunciation
(d)
Indicating and monitoring lamps
(e)
Synchronizing facilities, etc..
CABLING SYSTEM

43.

Power
(a)
(b)
(c)
(d)
(e)

44.

The following types of cables will be used:

(a)

cables would be selected based on the following criteria :

Continuous circuit current rating
De-rating factors for ambient temperature and grouping
Short circuit rating of the circuit
Voltage dip
Standardization of cable sizes to reduce inventory

For 11 kV system
11kV unearthed grade, stranded aluminium conductor, cross linked
polyethylene (XLPE) insulated, extruded black PVC inner sheathed,
galvanized steel wire armoured for three core or aluminium wire
armoured for single core and overall FRLS extruded black PVC
sheathed cables conforming to IS : 7098.

(b)

For 3.3 kV system

3.3kV unearthed grade, stranded aluminium conductor, cross linked
polyethylene (XLPE) insulated, extruded black PVC inner sheathed,
galvanized steel wire armoured for three core or aluminium wire
armoured for single core and overall FRLS extruded black PVC
sheathed cables conforming to IS : 7098.

(c)

For medium and low voltage system

Power cables of 1100V grade, stranded aluminium conductor, cross
linked polyethylene (XLPE) insulated, extruded black PVC inner
sheathed galvanized steel wire armoured for three cores or Aluminum
wire armoured for single core and overall FRLS extruded black PVC
sheathed cables conforming to IS : 7098.

(d)

For control applications

1100 V grade annealed high conductivity stranded copper conductor,
PVC insulated, PVC inner sheathed armoured and FRLS extruded
black PVC outer sheathed cables conforming to IS : 1554. Conductor

cross section will generally be 1.5 sq.mm. CT, PT and switchyard

control circuits will use 2.5 or 4 sq.mm copper conductor cables.
(e)

For instrumentation applications

Stranded high conductivity annealed tinned copper conductor,
multicore, PVC insulated, flexible, twisted pair / triplets, individually
and overall shielded (for low level analog signals) and only overall
shielded for digital signals, PVC inner sheathed, steel wire armoured
and overall FRLS PVC sheathed cables. Conductor cross section will
be 0.5 sq.mm.
Individual / pair shielded and overall shielded twisted pair copper
cables would be used for analog signals and overall shielded cables
would be used for digital signals. All these cables are armoured.
Overall sheath would be FRLS quality. The size of the wire would be
0.5 sq.mm FRLS, 1.5 sq.mm copper control cable would be used for
cabling between MCC and Control system. Compensating cables will
be provided for connecting the thermocouple inputs to the control
system.

45.

Cables would be laid in fabricated steel ladder type or perforated type cable
trays in the station and other auxiliary buildings and upper elevations of the
steam generator area. Between buildings, the cables would be laid in built-up
trenches. Cables to other plant areas located far off from the station building
would be directly buried in soil or carried on overhead racks.
LIGHTING SYSTEM

46.

Suitable illumination necessary to facilitate normal operation and maintenance

activities and to ensure safety of working personnel would be provided. This
would be achieved by artificial lighting.

47.

For yard illumination, flood lights would be installed at suitable locations to

provide the requisite level of illumination. Pole-mounted high-pressure
sodium vapour fixtures would be used for approach roads.

48.

Generally, fluorescent fixtures would be used for indoor illumination. A

combination of high-pressure sodium vapour and fluorescent fixtures would
be used for the turbine building. For steam generator area and pump houses,
high-pressure sodium vapour lamp fixture will be provided.

49.

The illumination levels at different places would be maintained as per

accepted norms. The lighting system would be designed to ensure uniform
illumination.

50.

Power distribution from the lighting transformers would be through 415V, 3

phase, 4 wire distribution boards. A suitable number of lighting panels would
be located in each area. Power to the lighting panels would be supplied from
the 240V, 1 phase, 2 wire distribution.

51.

About 80% of the total light fittings would be connected to the normal 240 V
AC lighting supply and the balance 20% to the station emergency bus fed
from the DG set in the station building and steam generator areas.

52.

DC emergency lights are envisaged at strategic points in the power station

viz., near entrances, staircases, control rooms, etc. These would be fed from

220 V DC system, which would be normally off when AC power is available.

These would be automatically switched on when the normal / emergency AC
supply fails. Offsite buildings will be provided with emergency lights with selfcontained batteries connected to the mains and will switch on automatically
when the supply fails.
SAFETY EARTHING AND LIGHTNING PROTECTION
53.

A safety earthing system comprising buried steel conductor earthing grid

would be provided for the switchyard and other outlying areas. This would be
connected to the earth grids in various buildings. The buried earth grids
would be further connected to earthing electrodes. The selection of earth
conductor sizes would be based on the applicable fault levels.

54.

Lightning protection system comprising roof conductors, vertical air

termination and down-comers would be provided for all structures whose
calculated risk index requires protection as per applicable standards.
COMMUNICATION SYSTEM

55.

For effective communication in the plant, public address system, private

automatic branch exchange system (EPABX), radio paging system and P&T
telephone system with the features described below will be provided:
Public Address System
(a)

This system will have paging and party channels comprising handset
stations with amplifiers, transmitters, receivers, and loud speakers.
This system will facilitate paging, communication and also private
conversation as in conventional telephone.
EPABX System

(b)

This system will have adequate number of push button type handset
stations, central automatic telephone exchange, etc. The handsets in
the control room would be provided with priority service facility to
enable them to have immediate access to any handset even if it is
already engaged. Interface between the EPABX, PA, walkie-talkie and
radio paging systems will be provided to enable communication
between these systems.
P&T Telephones

(c)

Necessary number of P&T telephone sets would be provided at

strategic locations.
Radio Paging and walkie-talkie Systems

(d)

Radio paging and walkie-talkie systems will be provided for mobile

communications. These systems will be of particular use during
commissioning stage as well as subsequently for convenience during
maintenance.

FIRE DETECTION / ALARM AND FIRE PROOF SEALING SYSTEM

56.

A fire alarm system would be provided to facilitate visual and audible fire
detection at the incipient stage of fire in the power station. This system will
comprise manual call points located at strategic locations in areas which are
normally manned and automatic fire detectors such as smoke detectors / rate
of rise of temperature detectors located in plant areas, such as control room,
switch gear room, cable vaults, battery rooms, etc., to detect fire at an early
stage. Linear heat detectors will be provided for the cable gallery and
conveyors. Infrared type ember detector will be provided for the conveyor
gallery. All fire detection systems will be of the addressable type. Fire proof
sealing will be provided for all cable penetrations through walls and floors to
prevent spreading of fire from one area / floor to another. A central fire alarm
panel with zone indication facility will be provided and will be located in the
Unit control room.
ELEVATORS

57.

One freight-cum-passenger elevator of capacity 1360 kg and speed of 0.75

m/sec will be provided in each of the steam generator areas to serve major
platforms of the steam generators. A separate 8 passenger, 1m/sec elevator
will be provided for catering to the station building. This elevator will have
access to different floors of the station building.
CATHODIC PROTECTION

58.

Impressed current cathodic protection is proposed for the underwater

structures in CWPH like trashrack, travelling water screen, etc. and water
boxes of condenser, heat exchangers, water boxes of coolers.
CLOCK SYSTEM

59.

A clock system with one Master clock and 16 clocks located at various
strategic locations of the power plant will be provided. The master clock
pulses will also be used for synchronizing of reference time based apparatus
like Sequence of Events Recorder (SOE), Disturbance Recorders and Tariff
metering equipment. Synchronizing or Master clock with INSAT reference
time using suitable antenna and receiver is envisaged.

CHAPTER XIV
ENVIRONMENTAL PROTECTION AND WASTE MANAGEMENT
1.

This chapter details out the following environmental impact aspects :

Air pollution

Water pollution

Thermal pollution

Noise pollution

Sewage disposal

AIR POLLUTION
2.

The air polluting emittants from the power plant are as follows :

Dust particulates from fly ash in flue gas

Sulphur dioxide (SO2) in flue gas

Nitrogen oxides (NOx) in flue gas

Coal dust particles due to handling of coal

Fly ash dust particles from ash silos and ash disposal area

Regulations for Limiting Air Pollution

Indian Standards
3.

As per notification by Ministry of Environment and Forests dated

1993, the emission limits are as follows :
(i)

Suspended particulate matter (SPM) emission

(dust particulate from fly ash)

19 May

< 150 mg/Nm3

(ii) Sulphur di-oxide *

(iii) Nitrogen oxides

Not specified

(iv) Coal dust particles during

storage/handling of coal

Not specified

(v) Dust in the ash disposal area

Not specified

Note : *

Sulphur di-oxide emission would be controlled by specifying minimum stack

height limit which is as follows:

Generating Capacity

Minimum Stack Height

500 MW and more

200 MW and above to less than 500 MW
4.

275 m
220 m

As per notification by Central Pollution Control Board dated 11 April 1994, for
the ambient air quality, the permitted limits of ground level concentrations
of pollutants considering Industrial, Residential, Sensitive areas is furnished in
Table- XIV.1 below :
Table XIV.1
National Ambient Air Quality Standards
Pollutant

Sulphur
Dioxide
(SO2)
Oxides of
Nitrogen as
NO2
Suspended
Particulate
Matter
(SPM)
Respirable
Particulate
matter)
(RPM) (size
less than
10um)
*
**

Time
Weighted
Average

Concentration in Ambient Air

Industrial
Area

Residential,
Rural &
Other areas

Sensitiv
e Area

Annual
Average*

80g/m3

60 g/m3

15g/m3

24 hrs**

120g/m3

80g/m3

30g/m3

Annual
Average*

80g/m3

60g/m3

15g/m3

24 hrs**

120g/m3

80g/m3

30g/m3

Annual
Average*
24 hrs**

360g/m3
500g/m3

140g/m3
200g/m3

70g/m3
100g/m

Annual
Average*

120g/m3
150g/m3

60g/m3
100g/m3

50g/m3
75g/m3

24 hrs**

Annual arithmetic mean of minimum 104 measurements in a year

taken twice a week 24 hours at uniform interval.
24 hourly / 8 hourly values should be met 98% of the time in a year.
However, 2% of the time, it may exceed but not on the consecutive
days.

Notes:
1.

National Ambient Air Quality Standard : The levels of air quality

necessary with an adequate margin of safety to protective
public health, vegetation and property.

2.

Whenever and wherever two consecutive values exceeds the

limit specified above for the respective category, it would be
considered adequate reason to institute regular / continuous
monitoring and further investigations.

Dust Particulates from Fly Ash in Flue Gas

5.

Even though as per the above norms, the standard for particulate emission
applicable is 150 mg / N cu.m, it is proposed to consider a more stringent
norm of 100 mg / N cu.m as being insisted upon by the authorities since
recent past. The electrostatic precipitators (ESP) proposed to be installed in
this project would be designed to limit the emission level of the particulate
matter to this limit.
Sulphur Dioxide (SO2) in Flue Gas

6.

As per the above norms, one common stack (chimney) for two units of height
275 M, with two flues for effective dispersal of SO2 is proposed to be
constructed. Thus, there would be 2 chimneys for the four units. Space
provision is also made for future installation of flue gas desulphurisation
(FGD) plant.
Nitrogen Oxides (NOx) in Flue Gas

7.

To reduce NOx emissions, over-fire air system equipment with air ports would
be installed for the furnace. Further, the steam generators would be fitted with
advanced low NOx burners. The NOx emissions would be checked for ground
level concentrations (GLC) as per the above indicated Indian Emission
Regulations.
Coal Dust Particles due to Handling of Coal

8.

Coal dust would be generated generally at the conveyor transfer points, coal
unloading area and coal stockpile area. Hence, wagon tipplers, coal transfer
points and coal stock yard would be provided with dust suppression / dust
extraction facilities as described in the respective system chapters. Further, in
order to arrest the coal dust generation, all conveyors would be provided with
enclosed galleries. The bottom portion of all the conveyor galleries would be
provided with seal plates with in the power plant area and at road crossing.

9.

Dust collection system would also be provided in coal bunkers to evacuate

dust and hazardous gases like Methane from the coal bunkers. Collected dust
would be returned to either the associated belt conveyor or to the coal bunker.
The dust collector outlet emission would be restricted to 100 mg / Nm.

Fly Ash Dust Particles from Ash Silos and Ash Disposal Area

10.

Two fly ash storage silos, one for each unit are proposed to be provided. Fly
ash evacuated from the ESP collecting hoppers would be transported in
closed pipe lines by pneumatic means. At the time of unloading fly ash in to
the silos, some ash laden air would get vented out. In order to restrict the fly
ash dust particles to the limits of 100 mg / N cu.m, a vent filter would be
installed on top of each of the fly ash silos at the vents.

11.

The following pollution control measures would be installed for ash disposal :
(a)

To reduce the dust nuisance while loading the ash into the trucks from
fly ash silos, the fly ash would be conditioned with water spray.

(b)

It is proposed to cover the ash in the open trucks with tarpaulin to

prevent flying of fine ash during transportation.

(c)

Water sprinkling system would be provided in the ash disposal area to

restrain flying of fine ash due to wind.

(d)

The ash disposal area would be lined with impervious lining to prevent
seepage of rain water from the disposal area in to the ground and
pollute ground water.

WATER POLLUTION
12.

The water pollutants are :

Cooling tower blow down water

Boiler blow down water

Water treatment plant effluent

Effluent from Bottom ash handling system

Air pre-heater wash water effluent

Plant wash down water

Floor and Equipment drainage effluent

Rain water drainage

Sewage from various buildings in the plant.

Regulations for Limiting Water Pollution : Indian Standards

13.

Environmental (Protection) Rules 1986 issued by Ministry of Environment

and Forests - Schedule-I stipulate the following limits for effluent disposal :
(a)

Ash pond effluent :

- pH

: 6.5 to 8.5

- Suspended solids

: < 100 mg/l

- Oil and grease

: < 20 mg/l

(b)

Effluent from WT plant

: Not Specified

(c)

Steam generator blow down :

-

Suspended solids

: < 100 mg / l

Oil and grease

: < 20 mg / l

- Copper (total)

: < 1.0 mg / l

Iron (total)

: < 1.0 mg / l

(d)

Cooling tower blow down :

-

14.

Free available chlorine

: < 0.5 mg/l

Zinc

: < 1.0 mg/l

Chromium (total)

: < 0.2 mg/l

Phosphate

: < 5.0 mg/l

As per the notification issued by the Ministry of Environment and Forests

dated 19 May 1993, the Schedule-VI specifies the quality of effluent permitted
to be discharged. The quality of effluents have been specified under the
following categories :
-

Inland surface water

Public sewage

Land for irrigation

Marine coastal areas.

15.

For the proposed power plant, the category to be considered would be under
inland surface waters. The major effluent limits under category are :
-

Suspended solids

100 mg / l (max).

pH

5.5 to 9.0

Temperature

Shall not exceed 7oC

above the receiving water temp.

Oil and grease

20 mg / l

16.

It is generally reckoned that the concerned State Govt. Pollution Control

norms would also be within the MoEF norms.

17.

Following paras describe the blow down waters and their proposed re-use :
Cooling Tower Blow Down

18.

The cooling tower blow down water would be used for ash handling purpose
and for coal dust suppression purpose.

19.

The cooling tower blow down does not require treatment but relies on
minimising the level of pollutants by operating at reduced cycles of
concentration to prevent the build up of contaminants and through the proper
selection of treatment chemicals which do not introduce additional pollutants
such as Zinc and Chromium.
Boiler Blow Down Water

20.

The boiler blow down does not require treatment to achieve the limits but
relies on operating at sufficient blow down levels to prevent the build up of
contaminants. Also, by operating with proper chemistry in the condensate and
feed water systems, copper and iron are not present in significant quantities
in the blow down stream. The boiler blow down is also directed to the guard
pond.
Water Treatment Plant Effluent

21.

The effluent from the regeneration of the cation resin units in the water
treatment plant (DM Plant) are generally acidic in nature and from the anion
resin units are alkaline in nature. The combined waste water from the DM
plant would be neutralised in a neutralising pit. The neutralised effluent is
expected to have suspended solids less than 5 ppm and pH in the range of
6.5 to 8.5. This would also be led to the guard pond.

22.

Thus, the low and high conductivity discharges from demineraliser

regeneration would be sent to the regeneration waste neutralising pit, where
they are permitted to self-neutralise. If self-neutralisation is not accomplished,
the pH would be adjusted to between 6.5 to 8.5 by addition of acidic or
caustic before discharge to the guard pond. Mixing in the neutralisation pit
would be accomplished by means of air agitator and pump discharge
recirculation. Further, the waste discharges from filter back washing are also
sent to neutralising pit.
Effluent from Bottom Ash Handling System

23.

The drain and overflow water from the bottom ash handling system would be
collected at the bottom ash sump where the ash would be settled and clarified
ash water overflows to clear well section of the basin. This clear water would
be sent to guard pond.
Air Pre-heater Wash Water Effluent

24.

Frequently, the air pre heaters of the boilers need to be washed. The washed
water would be led to the respective settling basins located near the boilers.
From the settling basins, dust laden water would be pumped at suitable
intervals, to the guard pond.
Plant Wash Down Water

25.

In the power plant, some specific locations require washing to maintain good
plant house keeping and prevent build up of dirt and waste material. The
waste water would be led to the guard pond.
Floor and Equipment Drainage System Effluent

26.

The function of this system is to provide a means for collecting and draining
water from floors in process areas of the plant and collecting and disposing of
water and other liquids from process equipment, discharged fire protection
water and oil storage tanks.

27.

In the turbine building, the ground floor slabs would be sloped to drain out
floor drains. The equipment drains are piped directly to the drain system.
Drains are collected and directed to sumps outside the buildings from where it
would be pumped to the guard pond.
Rain (Storm) Water Drainage

28.

The rain (storm) water removed from the building roofs and yard area grade
level surfaces would be directed through the open ditches and culverts to the
storm drainage piping. All ditches would be concrete lined and located along
the roads. All drainage ditches would be located to provide the shortest
practical drainage path while providing efficient drainage for the yard. Grade
level would be contoured such that storm water run off is directed on the
ground by sheet flow, to well defined drainage paths leading to the ditches.

Sewage from Various Buildings in the Plant

29.

Sewage from various buildings in the power plant area would be conveyed
through separate drains to septic tanks. The effluent from septic tanks would
be disposed off in the soil by providing dispersion trenches. There would be
no ground pollution because of leaching. Sludge shall have to be removed
and disposed off as land fill.
Monitoring of Ground water

30.

Four bore-wells have been identified inside / outside the plant premises to
monitor the ground water quality as per IS : 10500 (1991).
THERMAL POLLUTION

31.

The cooling tower blow down detailed out in the previous paras would be
passed ultimately to the guard pond to keep temperature before re-use. The
excess treated effluent water would be seen that it has lesser temperature
than the stipulated one before discharge in to the river and hence thermal
pollution is not applicable.
NOISE POLLUTION
Source of Noise Pollution

32.

The source of noise in a power plant are :

-

Steam turbine generator

Other rotating equipment

Combustion induced noises

Flow induced noises

Steam safety valves

Regulations for Limiting Noise Pollution : Indian Standards

33.

As per the Environmental (Protection) Rules 1986, the limits in the noise
levels are :
Industrial area

75 dB (A) in day time

(6 AM to 9 PM)

70 dB (A) in night time

(9 PM to 6 AM)

34.

The Occupational Safety and Health Administration Standards (OSHA),

USA indicate the following permissible noise levels :
---------------------------------------------------------------Duration per Day (Hours)
Sound Level (dBA)
---------------------------------------------------------------8
90
6
92
4
95
3
97
2
100
1.5
102
1
105
0.5
110
0.25
115
---------------------------------------------------------------

35.

All the equipment in the power plant would be designed / operated to have
the noise level not exceeding 85 - 90 db(A) measured at a distance of 1.5 m
from the equipment. Also, all the measures would be taken to limit the noise
levels at the plant boundary with in the stipulated limits.
POLLUTION MONITORING AND SURVEILLANCE SYSTEMS

36.

The emission and gas monitoring systems installed in this Project consist of
the following :
(a)

Flue Gas O2 and CO Monitoring : These would be measured at the

economiser outlet. In addition, O2 would be monitored at the air pre
heater outlet. For this purpose, CO and O2 monitor probes and
analysers would be installed separately.

(b)

Stack emissions : Flue gas exiting into the atmosphere would be

monitored for CO2, NOx, SO2 and Opacity. Stack emission readings
would be sent to the DCS for monitoring. For this purpose, dilution
probes, associated gas analysers and support equipment, sample lines
and Opacity sensor / transmitters would be installed. The Opacity
sensors would be equipped with a blower to protect the optics from
coating by flue gas particles.
The system operation would be continuous. Stack gas analysis for So2,
Co2 and NOx would be performed by extracting a gas sample from the
flowing stream in the stack, filtering to remove particulate droplets,
diluting with scrubbed instrument air and conveying the sample to the
analysers.
One sampling system per unit would be provided.

Air Monitoring
37.

Air Monitoring Stations (AMS) would be set up to monitor the air quality in the
neighbouring villages. The parameters being monitored are suspended
particulate matter (SPM), respirable particulate matter (RPM), Sulphur dioxide (SO2), Nitrogen Oxide (NOx), Carbon monoxide (CO) and Hydro
carbons (HC). The air quality monitoring is being carried out continuously
including the times during which power plant boiler firing with 100% coal as
test firing is done.
Meteorological Data

38.

Meteorological station, which was set up already at the nearby Sidhi town, to
monitor the wind velocity / direction, temperature, rain fall, relative humidity
and barometric pressure would be used for the proposed expansion plant
also.
GREEN BELT

39.

In the proposed power plant, for raising plantation adequate saplings would
be planted covering about 30% of the total acquired area in side the power
plant.
ENVIRONMENTAL IMPACT ASSESSMENT / MANAGEMENT STUDIES

40.

These studies have been carried out.

IMPACT OF POLLUTION/ENVIRONMENTAL DISTURBANCE

41.

Since all necessary pollution control measures to maintain the emission levels
of dust particles, Sulphur dioxide and nitrogen oxides within the permissible
limits would be taken and necessary treatment of effluents would be carried
out, there would be no adverse impact on either air or water quality in and
around the power station site on account of installation of the proposed plant.
ENVIRONMENTAL CLEARANCE

42.

Appendix - 2 gives the environmental appraisal for the proposed power plant
in the format required by the National Committee on Environmental Planning
and Co-ordination.

CHAPTER XV
PROJECT SCHEDULE AND IMPLEMENTATION
PROJECT SCHEDULE
1.

The project milestone schedule is presented in Exhibit-12. It is envisaged to

synchronise the first 600 MW unit in 36 months, reckoned from the date of
financial closure. The synchronization of unit would be two (2) months ahead
of their commercial operation date (COD). The second unit would be
synchronised and commercially operated within 3 months from the respective
dates of first unit. Thus, the COD of the second unit (Unit # 2) would take
place in a period of 39 months reckoning from date of financial closure.
TRANSPORTATION/HANDLING OF EQUIPMENT

2.

The distance of proposed PH from Waidhan Town is 30 Km approximately in

south west direction. Reasonably motor able road is available up to
Rajmelan. The distance from Rajmelan to power project is about 10 Km.
Approximately 7 Km of road to be upgraded for heavy vehicle traffic and new
approach road has to be constructed for about 3 Km. nearer to power project.
TRANSPORATATION OF EQUIPMENT

3.

The list of heavy equipment that needs to be transported is furnished in TableXV.I below :
Table - XV. 1
Typical Weights of Heavy Components.
Sl. No.
1.
2.
3.
4.
5.
6.
7.
8.
9.

4.

Description
Boiler drum
Generator stator
Generator rotor
Generator transformer
L.P turbine outer casing lower half
L.P turbine outer casing - upper half
L.P turbine rotor
H.P Heater assembly
Boiler Feed Pump

Weight (Tonnes)
appx.
165
290
80
295
58
55
75
43
40

The following mode of handling at site is envisaged for heavy equipment at

the erection stage :
(a) The steam-generator drum would be jacked up from the transport carrier
and skidded to the point of erection. The drum would then be hoisted
into position using winches.

(b) The generator stator would be unloaded from the carriers by means of
hydraulic jacks or mobile cranes in the maintenance bay of the station
building. At the time of erection, the stator would be placed on the TG
Pedestal using the hydraulic jacks or mobile cranes.
(c) All equipment in the station building including the generator rotor would
be erected using the Station E.O.T.Cranes. The transport carriers would
be brought into the maintenance bay of the station building to facilitate
handling by the E.O.T. cranes.
(d) The generator transformer would be jacked up and unloaded on the
railway track provided for transformers close to the foundations and
moved to the position by means of the bi-directional rollers provided and
using winches, the smaller transformers would be skidded into position.
OPERATION AND MAINTENANCE
5.

The proposed organisation structure for operation and maintenance (O&M) of

the (2 x 600 MW) power station expansion is presented in Exhibit-13. In order
to ensure adequate technical competence in operation and maintenance of
the power station, the following measures are proposed to be taken:
(a) EPMPL personnel identified for O&M functions would comprise a cadre
of engineers having the required background and experience in
commissioning, operation and plant maintenance functions for a coal
fired thermal power plant of similar capacity.
(b) These O&M personnel would be recruited at an early stage of the
project and would be given adequate training at the manufacturer's
works, at site, and / or in training simulators so as to familiarise them with
the necessary O&M functions relating to plant and equipment specific to
this project.
(c) The O&M management after commissioning of the 2 x 600 MW unit
would be carried out by EPMPL.
PRELIMINARY AND OTHER WORKS

6.

To ensure timely project execution, within the cost envisaged, a great deal of
preparatory work would have to be done before the date of financial closure.
However, apart from obtaining necessary approvals and clearances, some of
the important site-related works such as site enabling works viz. temporary
site office, storage sheds, construction water and power supply would be
taken up and completed early.

CHAPTER XVI
PROJECT COST ESTIMATES AND TARIFF
1.

The cost estimate is based on the identified location of the proposed power
station in Sidhi district of Madhya Pradesh as shown in the layout attached to
this report.
BASIS OF COST ESTIMATES

2.

The Project would be implemented through two or more no. of LSTK EPC
package basis. Same is considered for project cost estimate. The total project
cost estimate includes the cost of land, equipment/ systems cost of steam
turbine generators and auxiliaries, steam generators and auxiliaries, coal /
ash handling systems, water systems, control and instrumentation system,
electrical system and Balance of Plant required for the power plant,
overheads and pre-operative expenses, interest during construction and
financing costs. The main plant equipment (consisting of boiler and turbine
islands) cost is evaluated and considered from a very recent quotations of
BHEL for a similar plant. For all other systems / structures / equipment /
services, the costs are estimated from the data bank.
Cost of Land

3.

The cost of the land for the plant to be acquired from private owners and Govt
agencies has been estimated based on a rate of Rs. 2.8 lakhs per acre.
Civil Works

4.

The project cost includes the following :

(a) A station building without basement and all other plant structures
(b) The cost of ash disposal area development
(c) Non-plant buildings such as gatehouse, warehouse, and site offices and
other infrastructures required during the construction period
(d) Cost of site grading for areas like SG /TG area, switchyard, cooling tower
area, coal handling area and other non-service areas
(e) Boundary wall and anti climbing fencing for the area proposed to be
acquired for the power plant.

(f)

Basic issue rates of building materials are considered as follows:

Cement

Rs. 3,500 per tonne

Reinforcement steel

Rs.30,000 per tonne

Structural steel

Rs.35,000 per tonne

Mechanical and Electrical Works

5.

While all the mechanical and electrical equipment required for a complete
power plant are included, the following are to be noted :
(a) Raw water is proposed to be used from Govind Vallabh Pant Sagar.
(b) Cost of transmission system has not been included in the cost of
electrical works as it has been assumed that the entire transmission
between the switchyard and Power Grids substation would be installed
by Power Grid Corporation at its cost.
(c) Cost of spares for mechanical and electrical equipment at 3% of exworks cost is considered.
(d) Costs of erection, testing and commissioning for all the equipment has
been included.
(e) The cost estimates have been carried out with the assumption that the
project would be categorized under Mega Power Project and hence no
duties and levies have been considered.
(f)

No price escalation is considered during execution of the project.

INTEREST DURING CONSTRUCTION PERIOD

6.

Based on debt-equity ratio of 80 : 20 and weighted average interest rate

including financing charges of 11 % the interest on loan during construction
(IDC) has been calculated. Since IDC can be capitalised, the overall project
outlay includes this amount.

PROJECT COST

7.

The total project cost including IDC is estimated at Rs. 4860 Crores (about
Rs. 4.05 Crores / MW) for the stage I of 1200 MW capacity as indicated in
Appendix - 6.
TARIFF

8.

The cost per kWh works out to Rs. 2.16 for the first year of operation when
all the units are stabilised at a PLF of 80%. The levellised tariff works out to
Rs. 1.82 per Kwh for the stage I of 1200 MW capacity.
ASSUMPTIONS IN ARRIVING AT TARIFF

9.

The two-part tariff model as per the guidelines of Government of India has
been adopted to calculate the cost of generation :
Debt equity ratio

80 : 20

Cost of coal as received at site

Rs. 620 / tonne

Cost of fuel oil as received at site

Rs.23,000 / KL

Interest rate on primary debt

11% per annum payable quarterly

(Inclusive of tax)

Interest rate on subordinated debt

13% per annum

Return on equity

:
:

Depreciation

Depreciation at 7.84 % on project

cost.

Operation and maintenance

charges

2.5% of Project cost. (4% inflation

considered)

Gross heat rate

2,450 Kcal/ kWh

Gross calorific value of coal

3,800 k Cal / kg

Project completion period

Unit No.2 : 39 months

Repayment period for loans

Initial moratorium of 6 months

and then repayment in 40 equal
quarterly installments.

Details of working capital

20 %

(a)

Margin money

25 % of total working capital

(b)

Interest rate on balance of

working capital

11 % per annum

Auxiliary power consumption

9%

PHASING OF EXPENDITURE
10.

The year wise phasing of expenditure of the total project cost has been done
on the following basis:

1st year: 23%

2nd year: 30%

3rd year: 27%

4th year. 20%

It is proposed to utilise both debt and equity in the ration of 80 : 20 during

project execution period.
FIXED CHARGES
11.

The items of cost forming a part of the fixed charge component are :
(a)

Interest on loan becoming due during the year

(b)

Return on equity

(c)

Interest on balance of working capital

(d)

Repayment of loan

(e)

Operation and maintenance charges

(f)

Income Tax.

VARIABLE CHARGES

12.

The variable charge component of the tariff includes the cost of primary fuel
which is coal and secondary fuel which is fuel oil. Based on government of
India norms, the following are considered while computing the annual running
cost for periods beyond the initial stabilisation period:
(a)

Annual cost of fuel oil

(b)

Annual cost of coal.

APPENDIX 1
PROJECT SITE DETAILS
Sl.
Description
No
.
1. Project details

Details
2,000 MW thermal power station (coal fired) in
Madhya Pradesh state

2. Location Details
a. State / District / Village

Madhya Pradesh state, Sidhi district, near

Bandhaura, Khairahi, Karsualal & Nagwa

b. Longitude & Latitude etc.

Latitude and Longitude of North West corner

are 24 deg 0 min 0 sec and 82 deg 0 min 0 sec
respectively.

3. Details of Ecologically Sensitive AreasThere is no metropolitan city or eco-sensitive

like tropical forests, biosphere reserves,spots including national park, wildlife sanctuary,
national part, sanctuaries, importantbiosphere reserve, historical and cultural sites,
lakes, coastal areas rich in coraldefence installation, places of historical,
formations endangered species of florareligious and cultural importance present in the
and Fauna and distance from site etc.
vicinity of the proposed site as per MoEF
guidelines.
4. Approach to Site
a.

Railway line

Nearest Railway Station is Singrauli of West

Central Railway of Katni-Chopan Section which
is 35 Km from the proposed PH site.
Coal field of NCL are well connected with Rly.
Siding from Singrauli Railway Station and
NTPC Rly siding (MGR) for providing coal
transportation to Singrauli TPS, Vindhyachal
TPS and Rihand TPS (3,000 MW
Another Railway Station namely Shakti Nagar is
provided for public use at a distance of 35 Km
on Karala Shanktinagar section.

b.

Road : Existing Highway/roads distance The distance of proposed PH from Waidhan

from site
Town is 25 Km approximately in south west
direction. Reasonably motorable road is
available up to Rajmelan. The distance from
Rajmelan to power project is about 10 Km.
Approximately 7 Km of road to be upgraded for
heavy vehicle traffic and new approach road
has to be constructed for about 3 Km. nearer to
power project.

c. Distance from nearest airport

Varanasi Airport (280 Km)

5.

Land Availability

a.

Extent of land available for Plant,

Township, Ash Disposal etc

For power plant

: 427.8 Ha (1057 acres);
For ash disposal area : 267.6 Ha (661 acres);
For colony
: 30.2 Ha (75 acres)

b.

Land use pattern (agricultural, barren,

forest etc)

Agriculture / Revenue Partly Barren, Partly

poorly cultivated

c.

Incase of agricultural land, whether

Non Irrigated, one crop per year
irrigated/non-irrigated, number of crops
Land ownership (Govt. Pvt., tribal, non- Govt. & private
tribal etc).
Prevailing land cost details
Assumed Rs. 2.8 lakh per acre inclusive of all
costs of acquisition.

d.
e.
f.
8
a.

Estimation of population affected,

Yet to be collected
Homestead Oustees, Land Ownership
Details
Topography of the area
Ground profile and levels
Generally flat

b.

Permanent features

Coal field of NCL are well connected with Rly.

Siding from Singrauli Railway Station.

Soil Condition

Hard murrum, Yellow and sandy soil, hard soil

with Kanker

10
a.

Site Data
Whether the site is flood prone & HFL
of the site
Existence of mines and present &
future development activity / proposal

b.

The site is not flood-prone.

Nil

11
a.

Water
Source of Circulating / Consumptive
water

Govind Vallabh Pant Sagar Reservoir, which is

at about 37.0 km from the site.

b.

Location in relation to
River/Canal/Dam, water availability
and quality

The site is about 37 Km on west side of the

Govind Vallabh Pant Sagar. Water is available
to the required quantity of 80 cusecs.

c.

Lean season water availability and Need not required. Source is perennial.
allocation source in case main source
not perennial.

d.

Approved water allocation quota

Government of M.P has been approached for
(Drinking, Irrigation and Industrial use) confirming availability and allocation of water.
and surplus availability
Inter-State Issue, if any
Nil

e.

f.
g.

Requirement of construction of
Nil
Dam/barrage etc., if any
Feasible ways of bringing water to site Raw water pumphouse is proposed to be
indicating constraints if any.
constructed from where water is pumped to the
power plant site.

h.

Recommended type of cooling system

12
a.

Fuel
Source of coal/gas/lignite & distance

b.

Availability (probable mines, gas fields, Mahan coal block has reported reserves of 144
parameters, production programme,
million tones.
cost details)

c.

Transportation arrangement
contemplated
Fuel Transportation
The feasibility of availability of corridor
for the Conveyor system.

13
a.

Natural draught/Induced draught Cooling-tower

based cooling system.
Mahan coal block of Singrauli coal fields, about
4 Km from the proposed site.

By Conveyors
To be studied in detail at appropriate time

b.

If transportation contemplated through Not Applicable

railway network then surplus carrying
capacity available, future expansion
proposal including programme, gauge
conversion cost details etc. (for coastal
sites only)

c.

If Transportation contemplated through

sea route, existing port facilities and
future expansion/development
programme, cost details. (For coastal
sites only)
New facilities needed
At mine (s)
At power station
At port (s)/Jetty (If applicable)/
Railways.
Pipeline & others in case of gas.
Ash Disposal / Utilization
Proposed ash disposal arrangement

d.
I)
ii)
iii)
iv)
14
a.

b.

Details of existing & proposed cement

plants and quantity of ash, which could
be utilized in such cement plants.

c.

Various other feasible ways to utilize

Not applicable.

Conveyor loading system.

Conveyor un-loading system.
Not Applicable
Not applicable.
Ash generated is proposed to be used for
commercial purpose such as cement plants,
brick making and aggregate making. In the
event of excess ash, the same is proposed to
be dumped in a disposal through piping after
making ash slurry.
A separate study is required to be carried out in
this regard at appropriate time.
Ash generated is proposed to be used for

ash.

commercial purpose such as cement plants,

brick making and aggregate making.

d.

Plan for 100% ash utilization

It is proposed to use complete fly ash for

commercial purpose within a period of 10 years
of power plant operation.

15
a.

General
Source of construction water and
potable water
Source of construction power & start up
power
Source of availability of construction
material like sand, brick, stone chips,
borrow earth etc.

State Bodies/Local Enquiry

Govind Vallabh Pant Sagar Reservoir

Proximity to infrastructure facilities

available nearby

Nearby towns are Waidhan and Singrauli which

are fairly developed in regard to infrastructure
availability such as schools, hospitals and
residential accommodation.

b.
c.

16

132 KV St/stn. Waidhan

Adequate construction materials are reported
to be available locally in the vicinity of the
proposed power plant site.

APPENDIX - 2
BASIC INFORMATION FOR ENVIRONMENTAL APPRAISAL

GENERAL INFORMATION ABOUT THE PROJECT

Name /Title of the project
Name and address of the
project proponent

: Essar Power M.P Ltd. (EPMPL)

Mahan Superthermal Power Project
: Essar Power M.P Ltd. (EPMPL)
Mahalaxmi
Mumbai 400 034

Site where proposed plant

would be located ( Site map,
Land layout plan to include 25
km radius zone around the
site )

: In Singrauli Area near Mahan Coal blocks near

Bandhaura, Khairahi Karasualal & Nagwa
Villages. (Please refer Vicinity Map : Exhibit - 2)
about 37 Km (approximate) West of Govind
Vallabh pant sagar.

Capacity of the project under

consideration

: 2 x 600 MW in Phase I and Ultimate capacity of

2000 MW.

Whether alternative sites were

explored? If so, give details for
each site (Maps to be
enclosed)

: Alternative sites were identified by CMPDI in its

Report dated March 2004 as per the terms of
reference given by CEA as part of their mission to
develop 100,000 MW additional capacity
generation by 11th Five Year Plan. However,
EPMPL has selected this particular site.

Land use pattern of the land

: Waste upland with scrubs mixed with patches of

single crop land.
Land is free hold land and owned by Govt. and
Private parties.

Cost of land per acre.

: Rs. 2.8 lakh / acre for the land to be acquired for

the power plant.

Govt. Land / private land/

others

: Private land/ Govt. Land

Topographical features,
demographic profile and
physiography.

: Refer Chapter - IV of the Report

Nature of soil

: Hard murrum, Yellow and sandy soil, hard soil with

Kanker

Distance from the nearest

town/city/major human
settlement

: The distance of proposed PH from Waidhan Town

is 25 Km approximately in south - West direction.

Population to be displaced

: Yet to be collected

Distance from water source

: Govind Vallabh Pant Sagar Reservoir, which is at

about 37.0 Km from the site.

Area of forest land, if involved

No Forest Land is involved

Distance of forests from the site

: 5 Kms

Give basis for selection of

site

i)

This site is identified as a potential power

plant site.

ii)

Near by coal mines

iii) Availability of land

iv) Availability of water.
v)

Least habitation and displacement of

habitation.

Is this an extension? If so : No
indicate capacity of the existing
plant
What is the ultimate capacity ?
Name and address
consultant, if any.
73/1 St.Mark's Road

of

: 1,200 MW in Phase I and Ultimate capacity of

2000 MW..

the : TCE Consulting Engineers Ltd,

73/1, St Marks road
Bangalore-560 001

GENERAL ENVIRONMENTAL INFORMATION

Industries Nil
Power Plants :Vidhyachal STPS 28 Kms
Singrauli STPS 30.0 Kms
Rihand STPS 35.0 Kms
Quarries : North coal fields

Details of major industries,

thermal power plants, mines,
quarries etc. Existing within a
radius of 25 km of your plant

What is the total human

population of 25 km of the plant
site indicate the pattern of
population dispersal.

: Very thinly populated.

Give a broad description of

the site. Attach map showing
topographical features

Area of the land proposed to be

acquired (Attach layout plan)

Refer Exhibit - 2. The site is approachable from

Waidhan Mara Road.
For power plant
: 427.8 Ha (1057 acres);
For ash disposal area : 267.6 Ha (661 acres);
For colony
: 30.2 Ha (75 acres)
All the above have been identified in 3 pockets.
Refer Exhibit -2. for 1200 MW Phase I. Area
indicated is for ultimate 2000 MW

i)

Area required for plant

ii) Ash disposal

: Refer above.
: Refer above

iii) Colony (indicate separately : Separate colony proposed. The Operation and
for
departmental
staff,
maintenance staff are proposed to be
contractors (if any)
accommodated in the colony
iv) Transmission corridors and : By 400 kV Switch Yard
power evacuation system
v) Approach road, railway
bridges etc.

The distance of proposed PH from Waidhan Town

is 25 Km approximately in south-West direction.
Reasonably motorable road is available up to
Rajmelan. The distance from Rajmelan to power
project is about 10 km. Approximately 7 Km of
road to be upgraded for heavy vehicle traffic and
new approach road has to constructed for about 3
km nearer to power house.
Nearest Railway Station is Singrauli of West
Central Railway of Katni-Chopan Section which is
35 Km from the proposed PH site.
Coal field of NCL are well connected with Rly.
Siding from Singrauli Railway Station and NTPC
Rly siding (MGR) for providing coal transportation
to Singrauli TPS, Vindhyachal TPS and Rihand
TPS (3,000 MW)
Another Railway Station namely Shakti Nagar is
provided for public use at a distance of 35 Km on
Kerala Shanktinagar section.
:
Nil

vi) Others
Present use of land

Area proposed to be built-up or

developed

: Waste upland with scrubs mixed with patches of

single crop land.
Land is free hold land and owned by Govt. and
Private parties.
: For power plant : 300 Ha (740 acres);
For ash disposal area : 187 Ha (462 acres);
For colony : 30.2 Ha (75 acres)
All the above have been identified in 3 pockets.
Refer Exhibit -2. for 1200 MW Phase I. For
ultimate 2000 MW the total area required is
For power plant
: 427.8 Ha (1057 acres);
For ash disposal area : 267.6 Ha (661 acres);
For colony
: 30.2 Ha (75 acres)

Specify site characteristics

River basin/estuarine/
coastal/others

: Not applicable.

Is the site situated in the forest

area? Give following details:-

Area

: NA

Type of forests

NA

If site is situated nearer to the

forests? Give the distance from
the site
Give a description of the flora
within 10 km of your plant site
under the following heads:a) Crops
b) Forest
c) Grassland
d) Endangered species
e) Other (Specify)
Give a general description of
the fauna, especially wild-life,
endangered species, etc.,
within a radius of 25 km.
Give details of the following
features, if they exist, with-in a
radius of 25 km of the proposed
site?
i) Fisheries
ii) Sanctuary / natural park /
biosphere reserves
iii) Lakes / ponds / reservoir
iv) Stream / river
v) Estuary / sea
vi) Hill / mountains
vii) Historic / cultural /tourist /
archaeological/scenic
sites / defence installations
Human Settlement

Approx 5 Kms

:
Not applicable
Not applicable
Not applicable
Not applicable
Not applicable
: Not applicable

Details yet to be collected

Not applicable
Not applicable
Govind Vallabh Pant Sagar
Rihand River
Nil
Vindhyachal Hills
Nil

Total number of persons

proposed to be employed.
i ) During construction
ii) During operation

There is small patch of forest land.

Companys
Employees
25
150

Contractors
Employees
500
--

Total
525
150

Do you propose to build a : Separate housing colony for power plant staff is
township / housing quarters for
proposed.
your
employees/contractor's
workers?
Area required for above

: 40 hectares (100 acres)

Population to be
accommodated

: About 500

Distance and direction of

Within 15 km.

township from plant site

Service provided in township.
i)

Daily consumption of
water

ii)

Power system

iii)

Sewage treatment

iv)

Drainage

v)

Any other

: Yes
: Yes
: Yes
: Yes
:
Market, School, Bank, Post Office, Police station,
Telephone, Transport, Hospital & Recreation
Halls.

Number of persons to be
displaced along with details of
their occupation and income

: One settlement (to be established through R/R

studies)

Number of persons who do not

own property, but, derive their
sustenance from the land to be
acquired

: Not applicable

Details of rehabilitation plan for : To be established through R/R studies

the oustees
Site where
resettled

they

would

be

Compensation to be paid

:
: To be established through R/R studies

Authority responsible for their : Not applicable.

resettlement
Has
the
established?

linkage

been : Yes

Name of Mine/Block
Is it a working
yet to be opened?

: Mahan captive coal block of Singrauli coal fields,

about 4 Km from the proposed site.
mine

or :

Yet to be opened

Is the mine situated in the

forest area?

: Yes

Please furnish a fuel analysis

report from a recognised
laboratory(Details to include
percentage contents of C, H, N,
S and Oxygen(if any) and gross
calorific value)

: Refer Appendix - 4

Indicate the type of fuel firing to

be adopted

: Pulverised Coal firing

Air to fuel ratio to be Specified

: 5.7 : 1

WATER
Water use and liquid wastes : Refer Exhibit- 7.
(provide a detailed water
balance diagram)
What is the source of Water ? : Govind Vallabh Pant Sagar Reservoir, which is at
Would it be adequate for the
about 37.0 Km from the site.
future use? Do you propose
Water would be adequate for future use also.
any measures to augment the
The source being perennial, augmenting the water
water supply and how it affects
supply is not applicable.
other users
Lean season flow

: To be established after conducting hydrological

studies.

Give details of the receiving : To be established after conducting hydrological

water body.
studies.
Average daily quantity of Water
required for

For the stage I of 1200 MW capacity

i) Cooling tower makeup

(Total consumptive raw
water)
ii) Cooling Tower blow-down
iii) Process
iv) Others
v) Reuse of water
vi) Total

: 92,160 m3 / day
: Proposed to be re-used and hence not applicable
Included above
: : Complete water would be re-used
:
:

What type of cooling system is

proposed once through/closed

: Recirculation
NDCT/IDCT

i)

Give temperature
difference between inlet
and outlet.

ii) Annual temperature profile

of the receiving water
Quantity and expected
characteristics of the waste
water discharged per day from
the plant

type

cooling

system

with

:
Temperature rise across condenser is 10C
:
: Nominal amount of waste water is discharged out
of the plant. Hence not applicable.

i) Cooling

: Not applicable

ii ) Cooling Tower Blow-down

: Not applicable

iii) Process

: Not applicable

iv) Others

v) Total

: Not applicable

---

Type
of
waste
water : All effluents would be led to guard pond. The
treatment proposed to be
outlet water from the guard pond would be used
adopted for each stream
for coal dust suppression and ash dust
suppression.
Applicable standards
regulations for the Effluents

: Not applicable

Point of final discharge land / :

sewer / river / lake /bay /
estuary / sea

Rain water drain would be led to nearby drain.

Mode of final discharge Open : Not applicable

channel / pipeline / covered
drains
If the liquid effluents are finally
discharged to river/pond/lake,
the impact on the quality of
Water at the nearest human
settlement should be
mentioned

: Not applicable

Details of the reuse of waste : As indicated above

water
AIR EMISSIONS
Please
furnish
Location
Wind rose

for

your

: Refer Vicinity Plan and Plot Plan

: Indicated in Plot plan ( Exhibit 3)

Mean, maximum and minimum : January is the coldest month with the mean daily
temperature for every month of
maximum temperature at 24.3C and the mean
the year
daily minimum temperature at 8.1C. Mean lowest
temperature during January is reported as 3.3C.
May is the hottest month with the mean daily
maximum temperature at 42.0C and the mean
daily minimum temperature at 25.8C. Mean
lowest temperature during May is reported as
21.2C. Amongst the extremes of temperatures
recorded during 1951-1980, the highest value is
reported as 48.8C and the lowest as 1.0C.

Mean wind speed

: The months between October to December are

relatively much calm with wind speed of about
0.28 m/s than the other months. Winds are
generally light (0.28 to 2 m/s) during postmonsoon and winter months. They strengthen
during the summer and monsoon months.

Humidity, rainfall

: The annual average rain fall : 1132.7 mm. About

90% of rain is received during the monsoon
months. July is the month of maximum rain fall
accounting for about 30% of the annual rainfall.
The RH on an average : 66% during morning
hours and 49% during evening hours.
May is the driest month of the year with RH of
about 35% in the morning and 23% during the
evening.

Mean cloud cover

: Later

Percentage (frequency)
occurrence of inversions and
heights

: Later

Please specify the following:

Number of stacks

: 2

Number of flues in each stack

: 2

Inter-stack distance

: Not Applicable

Stack height

: 275m

Internal
diameter
each flue at the top

of : 6.5 m

Gas velocity

: 25 m / sec (at exit)

Flue gas characteristics

i) Volume(through each stack)

: 634 kg/ sec for 100% coal firing from each steam
generator.

ii) Temperature

: 140 C (coal)

iii) Density

: 0.86 kg / m

iv) Size distribution of

particulates

: Fines

v) Gas composition (by Vol.)

CO2
O2
SO2
N2
H2O

: 13.3 %
:
3.16 %
:
0.09 %
: 71.95 %
: 11.49 %

Heat emission rate of gases : 63 x 10 6 kcal / hr 100% coal firing

from each stack

Emission rate of SO2, NOx and : SO2 : 7.74 t / hr per stack (for 1200 MW) based
on sulphur content of 0.5%. Space provision for
particulates from each stack in
future installation of FGD has been provided.
micro gm/m3
Particulates 100 mg / Nm per boiler
Back ground pollution levels of : Detailed study being carried out for EIA / EMP
SO2, Nox and particulates kg/hr
report
a) What kind of stack emission
monitoring is proposed

: Flue Gas O2 & CO Monitoring: These are

measured at the economiser Outlet. For this
purpose, O2 & CO Monitor probes & analysers
are installed separately.
Stack emissions: Flue gas exiting into the
atmosphere is monitored for CO2, NOx, SO2 &
Opacity. Stack emission readings are sent to the
DCS for monitoring. For this purpose, dilution
probes, associated gas analysers & support
equipment, sample lines and opacity sensor/
transmitters are installed. The opacity sensors
equipped with a blower to protect the optics from
coating by flue gas particles. The system
operation is continuous. Stack Gas analysis for
SO2, CO2 and NOx is performed by extracting a
gas sample from the flowing stream in the stack,
filtering to remove particulate droplets, diluting
with scrubbed instrument air and conveying the
sample to the analysers.

b) What equipment is proposed : Same as above

to be acquired or used for
this purpose
Give details of the air pollution : High Efficiency electrostatic precipitator to limit
control equipment proposed to
particulate emission to 100 mg / Nm 3
be installed.
Give details of the organisation
set-up for maintenance of
pollution control equipment and
level of expertise and
authority of person in charge

: There would be an experienced and qualified chief

chemist in charge of analytical measurements and
pollution control

Emission rate of particulates

and sulphur dioxide to be
released when control
equipment is :

Functioning normally
SO2

: 7.74 t / hr (from stack for 1200MW capacity)

Particulates

100 mg / Nm3

Not functioning
SO2

: Not applicable as the plant would be shut down

Particulates

: -

What special procedure do you

propose to lay down for the air
pollution control during the
period when emission exceeds
prescribed limits for any reason
including malfunction of
pollution control equipment?

: Adequate design margins and standby capacity

are
provided
for
proposed
electrostatic
precipitators to forestall such problems

Other types of pollution

: Noise

Details of measures to control

noise

: All equipment would be designed / operated to

have a total noise level not exceeding 85 to 90
dB(A).

Details regarding
and control of
explosion hazards

prevention : All equipment vulnerable to explosion or fire would

fire and
be designed to relevant IS codes & statutory
regulations Suitable fire protection system
Comprising hydrants and spray systems are
provided for fire protection.

TRANSPORTATION OF FUEL:
Proposed mode of transport of
coal/ oil/ gas.

: Coal would be transported from the nearby Mahan

coal block in Singrauli coal fields by conveyors to
the proposed power plant. Coal movement within
the power plant is also by belt conveyors.

By sea & Rail

: Nil

By Road

: Fuel oil

By Pipe / Rope ways

: Nil

By Conveyors
: Coal
COAL AND ASH HANDLING:
What procedure would be : Coal with in the plant from stockyard would be
adopted for coal handling at the
transported to the bunkers through stacker- cumplant site?
reclaimer and series of belt conveyors.
Give details of dust
suppression / collection
equipment for reducing
pollution from coal fines and
other fugitive emissions from
coal handling (wagon tippling,
conveyor transfer points,
storage, crushing mills, Bunker
filling etc.)

: Dust extraction system at all coal transfer points,

bunker ventilation system for coal bunkers and
Ventilation system for tunnels are provided. Also
dust suppression system in the stock yard.

How do you propose to prevent

/treat the run-off from the coal
storage/ handling area?

: Refer Chapter X

What quantity of fly ash And : Fly ash : 6240 t / day, Bottom ash: 1560 t / day in
bottom ash would be produced
1st stage of 1200MW
per day?
(for 2 boilers at 100% coal firing with ash content
of 40 %)
Indicate
the
method
of : Fly ash : Fly ash collected in various hoppers
collection, transportation and
would be pneumatically (pressure) conveyed to
disposal of the ash.
the silos. From silo it would be either conveyed to
the disposal area in the form of slurry or collected
in dry form for commercial use.
Bottom ash : By drag chain scraper conveyors
and road trucks or to disposal area in slurry form.
What efforts have been made
or you wish to make towards
utilization of fly ash for Bricks
/cement/ road construction/land
fill/soil stabilization/ other forms
of disposal or use.

: Arrangements would be made with private

entrepreneurs for utilizing Fly ash for commercial
purposes

What precautions are proposed : Ash disposal pond would be completely- lined with
to be taken to prevent pollution
impervious liner to prevent ground water pollution
of water source and ground
water
from
solid
waste
disposal, especially with regard
to coal particles and ash slurry?
What land area is available for : 175 hectares (432 acres) for phase I this area is
ash disposal? Would it be
sufficient for storing about 50% of ash for power
sufficient for the expected life of
plant life for Phase I. and for both the phases 354
the plant?
hectares (875 acres)
CONSTRUCTION MATERIALS
Indicate source of supply of : Construction Materials would be available with in
stones and location of quarries
radius of 10 kms.
in the site map with the
alignment of the roads to the
projects site and its distance
from the site
Source of supply of sand and : Near by river bed.
its distance from the site
If new roads are built whether : No, In plant roads only planned
their alignment is through
agriculture land /forest/ grazing
land/human settlement/fallow
land
Mode of transportation of heavy : By road /rail route.
equipment, cement & steel i.e.
by road or rail or sea
Name of the nearest rail head : Singrauli, Shaktinagar Railway station.
where they would be off loaded
35 / 35 Km respectively
and its distance from the site

If a new road is to be built from

the rail head, the details of land
to be acquired should be given

: Not required

OCCUPATIONAL SAFETY AND HEALTH

Health status of workers : In coal handling and storage areas suitable dust
especially those engaged in the
control /collection equipment are provided to
coal handling, ash collection
ensure a clean and healthy environment. No
and ash disposal area
problems are envisaged in ash disposal area
where wetting of dry ash is envisaged.
Whether any adverse health
effect due to noise were
observed among the workers
engaged in the turbine,
compressor room, crushing
mills etc.

: Noise level would be limited to 85-90 dB(A) in

these areas and hence no adverse health
problems anticipated

If the plant is new, precau- : Elaborate safety measures are provided

tionary measures proposed to
be taken for safety and health
protection of workers may be
mentioned
ENVIRONMENTAL MANAGEMENT
Give details of organisational : Qualified chemist is in charge of the pollution
set-up you propose to have for
monitoring and control.
pollution
monitoring
and
control ?
What is the level of expertise of : Qualified engineers are in-charge of the job.
the person in charge of
pollution control ?
Briefly outline the proposed
environmental monitoring
programme, mention No. of
observation sites and frequency
of observations addressing to
the following parameters:

: Refer Chapter XIV

Air

Water

Ground water

Stack Monitoring

Have you been asked by the

: No
Central State Pollution Control
Boards To take any special
Environmental control Measures
and how do you Propose to
carry out these Obligations?

Raising of green belt(Area may : Green belt to be developed in the power plant
be indicated in a map)
area.
DETAILS OF EXISTING UNITS
If it is an extension, Please :
furnish the following details in
respect of the existing units:

Not applicable

Have there been public complaints

or questions
in the
Parliament or State assembly
regarding the Env. Problems posed
by the existing Units. If so, give
details.

No

Have there been any representation / :

protests from the Public/voluntary
organisations against the setting up
of the new units/plant at the
Proposed locations if so, give details

No

Economics of Pollution Control

What is the total project cost ?

Indicate costs of pollution control :

under the following heads

Rs. 4860 Crores (for the stage I of 1200 MW)

Capital cost for pollution control have been
included in the total project cost. Total capital cost
for pollution control : Rs. 240 Crores for the stage
I of 1200 MW capacity

Capital / Recurring (annual)

Air

Included above

Fly ash control

Included above

Sulphur dioxide control

Included above

Oxides of Nitrogen control

Included above

APPENDIX - 3
RAW WATER ANALYSIS

Raw Water From Govind Vallab Pant Sagar near Sasan village, Waidhan Sidhi
district in M.P
Sl.No.

Value (ppm)

Particulars

1.

Calcium

as CaCO3

34

2.

Magnesium

as CaCO3

15

3.

Sodium + Potassium

as CaCO3

19

4.

M-Alkalinity

as CaCO3

46

5.

Chloride

as CaCO3

12

6.

Sulphate

as SO4

10

7.

Silica

as SiO2

10

8.

Iron

as Fe

9.

pH

7.6-8.2

10.

Turbidity

NTU

60-500

APPENDIX - 4
ANALYSIS OF COAL
It is mentioned in earlier section for the annual coal requirement of 5 mtpa
based on GCV of 4100 Kcal/kg. However so as the plant and its auxiliary is
concerned, the design will be based on following values.
Following is the typical analysis of run-off-mine coal (un-washed) expected
out of Mahan coal block in singruali coal fields in the vicinity of Power
project, Sidhi District In Madhya Pradesh :
Description

Unit

Design Coal

worst Coal

Proximate Analysis

Fixed carbon

29.00

22.00

Volatile matter

24.00

20.00

Moisture

12.00

15.00

Ash

35.00

43.00

HGI

52.00

50.00

k Cal /
kg

3,800.00

3, 300

Carbon

37.48

Hydrogen

2.61

Sulphur

0.50

Nitrogen

0.75

Oxygen

8.67

Moisture

10.00

Ash

40.00

Grindability index
Higher heating value (HHV)
Ultimate Analysis

APPENDIX - 5
ANALYSIS OF FUEL OIL
Sl. No.

Particulars

1.
2.

Flash point
Viscosity @ 150C Maxi.

3.

Pour point

4.

Unit
Deg. C min.
Cst
0

Furnace
Grade MV2
(IS : 1593)
66
180

21

Ash content by weight

% max.

01

5.

Free Water content by volume

% max.

1.0

6.

Sediments by weight

% max.

0.25

7.

Total sulphur by weight

% max.

4.0

8.

Calcium

PPM

30.5

9.

Sodium

PPM

10

10.

Lead content

PPM

0.2

11.

Vanadium

PPM

40.50

12.

Carbon residence (Rams bottom)

% wt

7.74

14.

Approximate gross calorific value

Kcal/kg

15.0

SP gravity at 150C Max.

10,000
0.933

Oil

APPENDIX - 6
PROJECT COST ESTIMATE (For 1st stage of 1200 MW plant)

Sl.No

Description

Cost in INR
Million
USD

Land & Site Development

Steam Generator Island

Total cost
in INR
Million

INR
765

765

19296.39

400.34
Included in
2.0

Turbine Generator Island

BOP Mechanical

39.83

4115

6035

BOP Electrical

25.74

2114.5

3355

C & I Package

22.04

15.6

1078

Initial spares

2.63

187.35

314.04

Civil Works

4.15

4253

4470

494.73

10685.45

34548.43

Total hard cost excluding land & site

development cost
9

Contingency

1100

1100

10

Construction & Pre- Commissioning

Expenses

1395

1395

1661

1661

15606.45

39469.43

8368

8368

772

772

24746

48609

11

Overheads
Total cost excluding IDC and Margin
money

12

Interest During Construction (IDC)

13

Working capital margin

Total

494.73

494.73

APPENDIX - 7
ABSTRACT OF PROJECT COST

SL.NO.

ITEM

UNITS

REMARKS

Capacity of the Project (Phase I)

MW

1200

Net Units Generated (Gross Aux

consmpt)

MU

7652.736

Net Units Generated on which fixed

cost will be recovered

MU

7078.78

Specific coal consumption

Kg/kwh

Cost of coal consumed

Rs mil/pa

3335

Cost of fuel oil consumed

Rs mil/pa

387

Coal consumed per unit

Rs/kwh

Escalation factor for coal

Escalation cost of coal

Rs/kwh

0.440

Fuel oil consumed per unit

Rs/kwh

0.053

10

Total variable cost

Rs/kwh

0.493

11

Interest on primary loan

Rs mil pa

3582

12

Interest on subordinated loan

Rs mil pa

632

13

Interest on Working capital

Rs mil pa

255

14

Loan Repayment

Rs mil pa

3889

15

O&M expense

Rs mil pa

1264

16

Tax

Rs mil pa

256

17

Return on Equity

Rs mil pa

1944

18

Total fixed cost

Rs mil pa

11822

20

Fixed cost per unit (on recoverable

component)
Tariff per unit on 1st year

21

Levelised tariff

19

0.6447

0.436
1.01

Rs /kwh

1.67

Rs /kwh

2.16

Rs/kwh

1.82

80% PLF and 9%

Aux consmpt
7.5% will be supplied
at variable cost to
M.P
2450 PHR and 3800
Kcal/kg as GCV
Rs 620/Ton