KARNATAKA POWER CORPORATION LTD

EXPRESSION OF INTEREST (EoI)

for

Providing technology solutions to reduce

Suspended Particulate Matter (SPM)

in flue gas for210MW units-1 & 2

at Raichur Thermal Power Station.

JANUARY- 2017

Office of the Chief Engineer (Thermal Designs)

Karnataka Power Corporation Limited

No. 22/23, Sheshadri Road,

Bangalore 560 027

Telephone No: 080-22206223/22354346 Fax No: 080-22386517 Web site: www.karnatakapower.com email:kpclcetd@gmail.com/cetdeerm@gmail.com

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Technical Document forprovidingTechnology Solutions to reduceSuspended Particulate Matter(SPM) in flue gas for 2X210MW units 1 & 2 atRaichur Thermal Power Station.

Project: Raichur Thermal Power Station

Employer: Karnataka Power Corporation Limited

Issued on: 04.01.2017

Last Date for Submission of EOI :03.02.2017

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INDEX

Sl

No. Content Pag

No:

1 Introduction 4

2 Objective 4

3 Notice inviting EOI 5

4 Broad Scope of Work 5

5 Requirements for EOI 6

6 Terms and Conditions 6

Annexure-I Application Submission Form 7

Annexure-II Applicant Information Form 8

Annexure-III Technology Information Form 9

Table -1 Cost Estimation 10

Table -2 Boiler System Data 11

Table -3 Coal Analysis % Weight 11

Table-4 Precipitator Data (ESP Data) 12

Table-5 Voltage Current Data Of ESP Fields (Actual Readings) 13

Table-6 Ash Data 13

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Introduction

The Karnataka Power Corporation Limited, has been a prime mover and catalyst behind key

power sector reforms in the state for over four decades – measures that have spiralled steady

growth witnessed in both industrial and economic areas.

Right from the year of inception, in 1970, KPCL set its sights on “growth from within” meeting

growing industry needs and reaching out to touch the lives of the common man, in more ways

than one. From an industry vantage point, KPCL has raised the bar on the quality of deliverables

and is constantly working at lowering the cost per megawatt – a commendable cost-value

equation that has become a benchmark on the national grid. KPCL’s stock in trade is industry

proven – well-established infrastructure & modern, progressive management concepts and a

commitment to excel, helping it meet the challenges of the rising energy demands of Karnataka.

KPCL today has an installed capacity of 6498.91 MW of hydel, thermal, solar and wind energy,

with 9500 MW in the pipeline. The Raichur Thermal Power Station with an installed capacity of

1720MW (=7X210MW + 1X250MW) located in Raichur district is accredited with ISO 14001-2004

certification for its environment protection measures. To continue the efforts in meeting the latest

environmental norms KPCL is now exploring various solutions available in the market. A number

of technologies are found to have been developed to enhance the collection efficiency of

Electrostatic precipitator. In its efforts to reduce the particulate matter in flue gas, KPCL intends

adopt best suited solution by installing equipment for all the units on turnkey basis.

At the outset, KPCL intends to gain technical know-how of various proven technological solutions

available in the market, its feasibility at RTPS, carry out a techno-commercial comparative study

of options available in reduction of particulate matter and select the best option suited to RTPS.

Subsequent to selection of a proven technology, KPCL intends to adopt and implement the

chosen technology for units 1&2 at RTPS by calling tender with two cover system.The current

proposal is for 210MW each of RTPS units 1 & 2 only and KPCL has plans to extend the same to

other units on a later date.

1. Objective:Ministry of Environment and Forest(MoEF), vide notification No. 2620 dated 07.12.2015 has

stipulated that all thermal power stations shall reduce the particulate matter in flue gas within two

years from the date of issue of said order. Karnataka Power Corporation Limited (KPCL)proposes

to adopt cost effective proven technology for reduction of opacity in flue gas emission at our

Raichur thermal power plant to meet the environmental norms within the stipulated period.

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2. Notice Inviting EoIKPCL Invites Expression of Interest (EOI) from reputed, experienced, technically and financially

sound companies, firms engaged in the business of design, manufacture, installation, testing and

commissioning of equipment to reduce the Particulate Matter in flue gas through open

advertisement in Newspapers and KPCL website for providing technical solutions to meet

environmental norms, reduction of Suspended particulate matter in flue gas from the present

value of about 150mg/Nm3 to less than 50 mg/Nm3for coal based thermal power plant.

3. Broad Scope of Work:Technology solution provider shall aim at providing solutions for SPM

reduction to 50mg/Nm3 from an ESP designed for SPM of 150mg/Nm3. The parameters of Coal &

Ash necessary for design of their solution are furnished in tables 2 to 6.

a) The agencies shall submit an executive summary covering the following:

Working principle of the offered technology.

Extent of SPM achievable with proposed technology considering the present Coal and flue

gas parameters as mentioned in tables -2 to 4.

Brief note on how the same can be achieved, with supporting calculations, if any.

Scalability as add-on facility to achieve better opacity if norms are further reduced/made

more stringent.

No modification is proposed in the existing ESP structure. However, any minor modification

to be carried out in the existing infrastructure to accommodate new equipment shall be

elaborated.

Requirement of consumables on routine basis for running of equipment offered. Probable

running expenses per annum.

Modalities of executing the project and requirement of shut down of existing equipment and

the period of shut down and total project completion period.

Approximate cost of supply, installation, commissioning works.A budgetary offer in Indian

Rupees shall be furnished. This is merely for cost comparison of various technologies.

Technical specifications of the equipment.The bidder shall submit general technical

specification of the equipment relevant with the technology. The proposed

technology/system must be in regular operation in any coal based thermal power plant of

210MW and above units.

Details of Infrastructural requirements to be provided by KPCL for installation of the

proposed equipment.

Any other applicable details.

b) The agencies shall make a technical presentation before the Committee.

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4. Requirements of EOIThe interested bidders shall be required to submit along with the EoI document the following:

a. Application submission form, Application Information form, Technology Information form as

per Annexures-I, II and III enclosed.

b. The Technology solution provider shall submit completion certificate and performance

certificate of at least one work given by client.

c. Documents like Product literature, brochure, specification sheet, etc. clearly describing

various features and technical specifications for each of items used in the proposed solution

including all its components.

d. Details of similar projects executed in past with Client references for the projects done.

5. Terms and Conditions:a. By responding to this EoI request, the bidder should understand that at this stage the

Department is only exploring the different viable options.

b. KPCL reserves the right to accept /modify or reject any or all EoI offers any time, without

incurring any liability.

c. Costs to be Borne by Bidder: All costs and expenses (whether in terms of time or money)

incurred by the bidder in any way associated with the development, preparation and

submission of the EoI Offer, including but not limited to attendance at meetings,

discussions, demonstrations, etc. and providing any additional information required by

KPCL, will be borne entirely and exclusively by the bidder.

CHIEF ENGINEER(THERMAL DESIGNS)

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Annexure-I

Application Submission FormDate: [insert day, month, and year]

Tender Notification No. and title: [insert number and title]

To: [insert full name of Employer]

We, the undersigned, apply to be prequalified for the referenced TENDER NOTIFICATION and declare that:

(a) We have examined and have no reservations to the Prequalification Document, including Addendum(s) No(s)., issued if any.

(b) We meet the eligibility requirements, we have not been suspended by the Employer based on execution of a Bid Securing Declaration.

(d) We declare that “No commissions or gratuities have been or are to be paid by us to agents or any third party relating to this Application”.

(e) We understand that you may cancel the prequalification process at any time and that you are neither bound to accept any Application that you may receive nor to invite the prequalified Applicants to bid for the contract subject of this prequalification process, without incurring any liability to the Applicants.

(f) All information, statements and description contained in the Application are in all respect true, correct and complete to the best of our knowledge and belief.

Signed [insert signature(s) of an authorized representative(s) of the Applicant]

Name [insert full name of person signing the Application]

In the capacity of

Duly authorized to sign the Application for and on behalf of: Applicant’s Name

Address

Dated

Annexure-II

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Applicant Information FormDate:

TENDER NOTIFICATION No. and title:

Applicant's name

[insert full name]

Applicant's Category: Original Manufacturer / Original Manufacturer in technical collaboration / [Select One]Authorized Dealer

Applicant's country of registration:

[indicate country of Constitution]

Applicant's year of incorporation:

[indicate year of Constitution]

Applicant's legal address [in country of registration]:

[insert street/ number/ town or city/ country]

Applicant's authorized representative information

Name: [insert full name]

Address: [insert street/ number/ town or city/ country]

Telephone/Fax numbers: [insert telephone/fax numbers, including country and city codes]

E-mail address:

Annexure-III

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Technology Information FormDate:

TENDER NOTIFICATION No. and title:

Technology Title:

[insert full name]

Working Principle in about 1000 words :

[Add as separate annexure, if necessary]

Opacity achievable with use of offeredtechnology and scope:

[ KPCL requirement is maximum 50mg/Nm3]

Extent of Scalability:

[applicable if partial retrofitting of existing equipment is proposed]

Scope of Work:

[brief note on whether partial or total retrofitting of existing equipment or providing a new additional system]

Area of Land required for the proposed technology for installation of Equipments:

Project Completion time required:

[From date of Letter of Award to Commissioning]

Required Shut Down time of BTG:

Probable cost of supply installation [ Budgetary offer]:

Annual Cost of Consumables:

Annualized cost of spares:

Energy Consumption in kWh:

Requirement of manpower for day to day maintenanceand monitoring:

Statutory requirements for adopting/usage the technology, if any:

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Table1. Cost Estimation Evaluation Currency: Indian Rupee

Bidder Budgetary offer

Annual cost of consumables and other running expenditure if any.

Cost of spares required annually

Shut down of units

Auxiliary Consumption in

KWh per annum

Total Price

(a) (b) (c) (d) (e) (f) (g) = (b) + (c) + (d) + (e)+(f)

Note: The above is a sample loading pattern for cost estimation.

Table2.BOILER SYSTEM DATA

BOILERManufacturer M/s BHEL Rating (MCR)

Type Natural Circulation, Radiant ReheatHeat Input 509.6X10^6 Kcal/hrSteam 620 T/hrsPressure 155 kg/cm²Combustion Air 862T/hrExcess Air 3.5%Burner Type Coal / Tilting Tangential

Air HeaterType Rotary Regenerative 27VIMT 2000Arrangement Regenerative Tri-sectorNumber / Boiler TwoGas Temperature Inlet 346°C / Outlet137° CAir Temperature 35°CFlue Gas Static Pressure (at A.H. Outlet ) -170 MMWC

FansInduced Draft Forced Draft

Make BHEL NDZV 31Sidor BHEL AP1-18/11Number / Boiler 2 2Capacity 226.1m3/sec 90.9m3/secStatic Pressure 42.2mbar 48.8mbarMotor Capacity 1500kw 600kw

Table3. COAL ANALYSIS % WEIGHT:

%Carbon 35.42Hydrogen 2.64Oxygen 8.75Nitrogen 0.72Sulphur 0.5Moisture 16.82Ash 35.15GCV on fired basis 3440Volatile 21.93

Table4. PRECIPITATOR DATA (ESP DATA)

Process Electrostatic principle Suspended Material (gms/Nm3) 87.7 gms/Nm3

Fuel CoalElevation 6No of ESP per Boiler 2No of Chambers/Cells parallel to Gas Flow FourNo of fields in direction of Gas Flow 6No of Gas passages per Chamber/Field TwoNo of Total / collection plates per ESP 7296Length of Collecting Plates (meters) 9mSpacing between Collection Plates (meters) 300mmHeight of Collecting Plates per ESP (meters) 400mm widthTotal No of Discharge Electrodes per ESP 28416Type of Transformer Rectifier Control Thyristor base

single phase rectifier transformer

mA Rating of Transformer Rectifiers 800 MaxKV Rating of Transformer Rectifiers 70 KVNo of Transformer Rectifier / Field OneAspect Ratio (plate ht / precipitator length) 2.133Stack (Chimney) Height (meters/feet) 130mTreatment Time (sec) 22.1secESP Average Velocity (m/sec) 0.87 m/secBoiler Gas Volume 347.2 m³/sec

DESIGN CONDITIONS ACTUAL OPERATING CONDITIONS

Gas Pressure (mmWC) : -177Gas Flow Rate (m3/sec) : 347.2 408Gas Flow Temp (oC ) : 140 150Inlet Dust Conc (gms/Nm3 32.2 52.0ODB (mg/Nm3) : 130 143Moisture (%) : 8.7 16.82Efficiency (%) : 99.37 99.37SCA (m2/m3/sec): 147 145Gas Velocity (m/sec): 0.87m/sec 0.85

Table5. VOLTAGE CURRENT DATA OF ESP FIELDS(ACTUAL READINGS)

Field kV m A Spark Rate Nos. per min

A1 25 50 10A2 28 100 10A3 33 150 10A4 36 200 10A5 39 250 10B1 25 50 10

B2 28 100 10 B3 33 150 10 B4 36 200 10 B5 39 250 10 C1 25 50 10 C2 28 100 10 C3 33 150 10 C4 36 200 10 C5 39 250 10 D1 25 50 10 D2 28 100 10 D3 33 150 10 D4 36 200 10 D5 39 250 10

Table6. Ash Data:

Component % in Fly AshSiO2 50.16Al2O3 27.92CaO 3.57MgO 0.86MnO 0.01TiO2 1.33Na2O 0.01K2O 0.6Fe2O3 13.55P2O5 0.84SO3 1.15