Epc proposal 3x660 mw with cost analysis

CONTENTS

1. INTRODUCTION

2. PROJECT MANAGEMENT PROCEDURES

3. PLANT DESIGN BASIS

4. SCOPE OF WORK, TERMINAL POINTS AND EXCLUSIONS

4.1 SCOPE OF WORK

4.2 TERMINAL POINTS

4.3 EXCLUSIONS

5 TECHNICAL WRITE UP

5.1 MAIN PLANT (STEAM GENERATOR & STEAM TURBINE

GENERATOR AND AUXILIARIES)

5.2 BALANCE OF PLANT- MECHANICAL

5.3 BALANCE OF PLANT – ELECTRICAL

5.4 BALANCE OF PLANT CONTROL AND INSTRUMENTATION

5.5 CIVIL, STRUCTURAL AND ARCHITECTURAL WORKS

6 BASIS OF OFFER

7 TECHNICAL DATA SHEETS AS PER TENDER SPECIFICATIONS

8 DRAWINGS AND DIAGRAMS

STANDARD

PROPOSAL

MODULE FOR 3x660

MW COAL BASED

THERMAL POWER

PLANT BASED ON SUPERCRITICAL TECHNOLOGY

PIYUSH KUMAR SINHA MBA Power Management

[email protected]

2008

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Standard Proposal Module for 3x660 MW Coal based Thermal Power Project

Power Crisis has been a long clamor in India and this seems to persist for the

coming decade or so. Beyond optimistic illusions, ground realities are too

fierce to be accepted.

Seeds of improvement are however being planted at all possible arenas

broadly Indicating: -

The Project Idea springs from one of the reforms Viz. generation of Power.

To cater the accelerated need of the country Ultra Mega Power Plants

(UMPPs) have been proposed. These are giant power plants of 4000 MW at

one place. In addition to these, a number of Mega Power Projects (More than

1000 MW) are also being promoted. The unit size of power plants has also

experienced a supercritical shift in technology. Thus focus is on more efficient

supercritical units of 660 MW and 800 MW. However considering imported

coals as the main fuel, unit size can go up to 1000 MW. As the domestic coal

POWER SECTOR REFORMS

EXECUTIVE SUMMARY

FIGURE – 1

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available for power sector is having very high (40 to 45%) ash content

feasibility of higher size units are yet to be examined. Meanwhile after

500MW / 600 MW (subcritical) the next suitable supercritical size was

decided 660 MW or 800 MW for coal based thermal power plants.

This Project has been based on study and formulation of EPC proposal of

3x660 MW coal based thermal power plant (Super Critical Technology). It

also includes plant design basis, scopes of work different packages &

technical write up of main plant as well as Balance of Plants.

Cost estimation and percentage cost breakup of the Thermal power plant

spells out the brief overview of the EPC project cost.

The study shall form the basis for the standard proposal module for the 660

MW project. As the gear of technology is experiencing a critical shift in

power sector, India is keen to welcome the Supercritical technology. The first

stage of capacity shift is seen to be 660 MW which is being adopted by NTPC

and other private sector players for several upcoming projects.

The assignment covers supply of complete main plant with BOP package on

Engineering, Procurement and Construction (EPC) basis and making standard

proposal module of this. EPC work can exclude civil works, coal handling

system, ash handling system, external raw water system and water intake

system depending upon the projects.

The power plant configuration considered for the project shall be having 3

identical units to generate gross power 1980 MW.

2.0 INTRODUCTION

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Things to be included in the EPC Proposal

1. INRODUCTION

2. PROJECT MANAGEMENT PROCEDURES

3. DESIGN BASIS

4. SCOPE OF WORK, TERMINAL POINTS & EXCLUSIONS

5. BASIS OF OFFER

6. TECHNICAL DATA SHEETS

7. DRAWINGS & DIAGRAMS

8. SCHEDULE OF PRICES

9. TIME SCHEDULE

10. PERFORMANCE GUARANTEE SCHEDULE

11. COMMERCIAL BID

Brief Descriptions of these are as follows:-

1. INTRODUCTION

MAJOR EQUIPMENTS:-

3 units of steam generator, 3 units of steam turbine generator and other associated systems in line

with specific tender document taken as reference and as per the scope of work.

Besides this, FUEL DETAILS, WATER ARRANGEMENTS, LAYOUT, POLLUTION STANDARDS, LOGISTICS

PLANNING, POWER EVACUATION ARRANGEMENTS, WATER REQUIREMENTS, PLANT LAYOUT, POLLUTION,

LOGISTICS ARRANGEMENT, LAND REQUIREMENTS(1.4 MW/Acre for indigenous coal and 0.53 for imported

coal including MGR & cooling tower) are given in introduction.

2. PROJECT MANAGEMENT & PROCEDURES

MANAGEMENT APPROACH

Define sequence of work and establish project organization.

Staff the organization, required communications & equipments.

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PROJECT COORDINATION

It is very important at all levels Viz. Engineering, Procurement, Construction, and Start Up.

Some Other Important aspects of project management are as follows:-

3. PLANT DESCRIPTION & DESIGN BASIS

This is mainly detailed description of all important equipments(Steam generator, Steam

turbine & generator, Water system, Fire protection system, Compressed air system, Fuel oil

handling system, Air condition & ventilation system etc) their technical specifications and

manufacturing parameters. Please go through main project report for more details.

PLANNING & SCHEDULING MANAGEMENT INFORMATION SYSTEM

DOCUMENT CONTROL & DESIGN

SUBMISSIONS

PROCUREMENT & FIELD CONTRACTING

PRODUCTION CONTROL & MANUFACTURE INSPECTION & TESTING

MATERIAL CONTROL QUALITY ASSURANCE

CONSTRUCTION MANAGEMENT COMMISSIONING & TESTING

START UP DOCUMENTATION SITE MANAGEMENT & INSURANCE

Project organization Structure - Office

FIGURE – 2

Table – 1

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4. SCOPE OF WORK, TERMINAL POINTS & EXCLUSIONS

SCOPE OF STEAM GENERATOR : - Followings equipments come under the scope of steam

generator. Boiler pressure parts (Economiser, Super Heater, Reheater), Boiler structure

Flues , Ducts, Fuel feeding system, Oil system, Combustion equipments( Pf Burners, Igniters,

Oil Burners), Boiler auxiliaries( FD , ID, PA – Fans, BCP, Air heaters), Cabling, control &

monitoring system, Electrical ( HT & LT Motors, Insulation, Refractory), ESP, Milling plant (

Coal Pulverizer)

SCOPE OF WORK : – MECHANICAL

Water system, CHP & AHP, Effluent treatment plant, Fire protection system, Air

conditioning & Ventilation system, Cranes & hoists, Turbine auxiliaries, Compressed air

system, Power cycle piping, Fuel oil systems, Chemical laboratory & equipment, Pumps,

Auxiliary boiler

SCOPE OF WORK : – ELECTRICAL

Evacuation & distribution system, Main generation system, Emergency power, Transformers

Switchyard, Isolators & circuit breakers, Cabling & illumination, Earthing & lightning

protection, Control protection & metering system, Plant communication system

SCOPE OF WORK : – CONTROL & INSTRUMENTATION

Distributed control system, Programming logic controllers, Control & instrumentation for

STG & auxiliaries, Steam water & analysis system, Continuous emission monitoring system,

Centralized vibration monitoring system, Plant security & surveillance system, Plant LAN

work, Testing & calibration system, Air & weather monitoring system.

TERMINAL POINTS: - This is the point of deliveries under mutual agreements between

contractor and owner. E.g. - Raw water, Coal, CW piping, Fuel oil, Civil works, Electrical

evacuation, Construction system, Construction power, Roads.

EXCLUSIONS: - This is mainly distinction of responsibilities, clarification of scope of works,

obligations, schedule of works.

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5. BASIS OF OFFER

This is mainly distinction of responsibilities, clarification of scope of works, obligations,

schedule of works, vendor list and quality manuals wish can be categorized under following

heads:

• Clarification to tender documents………………..……………..Doubts are made crystal clear

• Customer obligation………………………………………… Expectations from customer/ Owner

• Project schedule…………Detail anticipated project completion schedule are submitted

• Vendor list……………………………………………………………….………….Equipments Suppliers list

• Quality manual………………………………………..…..This shall be provided by the Contractor

6. TECHNICAL DATA SHEETS

These are all technical data of all equipments supplied and installed with their capacities.

Please go through main project for detailed technical specifications.

7. DRAWINGS & DIAGRAMS

All drawings are supplied wherever required. Namely … Plot Plan, PIDs (Process N

Instrumentation Diagrams), Turbine Cycle Scheme, Water & Steam System Scheme, Coal

Handling System Flow Diagram, Fly Ash Handling System, Bottom Ash Handling and Slurry

System etc.

8. SCHEDULE OF PRICES

Price Schedule (FOB/CIF plus duties & Taxes) is submitted which has details of followings:-

OFF SHORE SUPPLY CONTRACT: - Cost components of foreign & Indian rupees with

marine freight & Insurance, Custom Duty, other taxes & duties.

ON SHORE SUPPLY CONTRACT:- Includes Ex-works price of equipments including

design and engineering, packing and forwarding, Excise Duty, Central and State Sales Tax,

Transportation, entry tax & others.

ON SHORE SERVICES CONTRACT:- Includes Scope of services, mentioning design and

detail engineering, project management services, erection, testing and commissioning ,

clearing, forwarding of Offshore supply of goods at Indian port, transportation and transit

insurance, performance Guarantee tests, training and service tax & other duties.

9. TIME SCHEDULE

Time schedule are given for design, manufacture, delivery at site (FOB portion and Ex-Works

portion), equipment erection, commissioning, performance guarantee tests Start and finish.

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10. PERFORMANCE GUARATEE SCHEDULE

This has to be given for all units of power plant and auxiliaries in respect of all items based

on specified design and parameters mainly specifying the followings:-

PERFORMANCE GUARANTEE UNDER LIQUIDATE DAMAGE: - Value inclusive design,

manufacture & other tolerances with required clarifications. (Gross STG Power Output,

Total Auxiliary Power Consumption, Gross unit heat rate, Station Heat rate, SGMCR etc.)

PERFORMANCE GUARANTEE UNDER CORRECTION:- This contains Value inclusive

design, manufacturing and other tolerances including measurement uncertainty with

required clarifications(BMCR & TMCR Ratings, Noise Level, Vibration level, other

systems as per tender specifications)

11. COMMERCIAL BID

Letter of Submission, Company profile, Bid security, Power of Attorney/Letter of Authority,

Information forms, Application for bidding, Statement of bidders, Experiences & references,

Financial data, Schedules, Un-price, Clarification / Deviation schedule to general conditions

of contract & Letter of submission have to be specified in this.

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COST ESTIMATION & CLEARANCES FOR 3x660 MW TPP

Sr.

NoPreliminary cost Estimate for 3x 660 MW TPP

COST

( Crore )% Cost

100 Preliminary investigation & survey 2.5 0.04%

200 Civil Works 800.0 11.40%

300 Mechanical Works 5367.4 76.46%

401 Main Plant 3900.0 55.56%

401 Steam generator with associated auxiliaries 2500.0 35.61%

401 Turbo generator with associated auxiliaries 1400.0 19.94%

402 Coal handling Plant 480.0 6.84%

403 Ash Handling Plant 260.0 3.70%

404 Water System 540.0 7.69%

404 Sea Water Intake including intake piping and outfall 200.0 2.85%

404 Water treatment plant( Desalination & DM) 180.0 2.56%

404 Cooling tower including pumps 160.0 2.28%

405 LP & CW piping including valves, specialities and fittings 65.0 0.93%

406 Air conditioning system and ventilation system 20.0 0.28%

407 Fire protection system 60.0 0.85%

408 Cranes/ Hoisting Equipments 10.0 0.14%

409 Compressed air System 13.0 0.19%

410 Miscellaneous Equipments, tanks, Piping, Insulation etc 19.4 0.28%

411 Sub Total 5367.4 76.46%

GRAND TOTAL MECHANICAL 5367.4 76.46%

500 Electrical Works 350.0 4.99%

501 Electrical cost AS PER ROW 300.0 4.27%

505

Cost of transmission line & plant instrument & control

Lumpsum 200.0 2.85%

600 Total works Cost ( Prelims+ civil + mech+ elec+ C& I) 7019.9 100.00%

700 EPC Project Cost 7019.9 100.00%

COST BREAK UP COST

( Crore) % Total cost

(9023 Crores)

Supply Of Main Plant Equipment System 3900.0 43%

Supercritical Boiler Including Auxiliaries 2500.0

Supercritical STG & Auxiliaries 1400.0

Supply of BOP Equipment System 2317.4 26%

Other mechanical Equipment System 1467.4

Electrical Equipment System and C&I 850.0

Engineering & Project management 351.0 4%

Erection & commissioning 352 4%

Civil Works 800 9%

Total 7720.5 86%

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There were some limitations with respect to the analysis and data that may

affect the accuracy of the results:

EPC Proposal depends largely on Bid Requirements so may be some

sections may not be as applicable.

This is only a rough cost estimate and may differ from prevailing market

conditions.

As EPC has three models BTG+BOP, Total EPC, STG+BOP, hence

scope of work and cost estimation can vary from project to project.

Some costs components like Land, Transportation etc. can vary

depending on site location.

LIMITATIONS

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Growing economies always need a proportional need for power. Country like

India has a required growth in power sector close to 15 %. In order to match

the accelerated need of country, there is urgent need is to take the challenge to

squeeze the time and cost required to complete a coal based power project. If

some more R&Ds could fetch some reductions in total EPC costs and could

increase operating efficiencies, it would be a great relief to fund hungry power

projects.

We should go for large size projects which are more efficient and less

polluting than several smaller units. One more field which needs to be

prioritized is Risk management and project management that play a very

crucial role in carrying out such big projects.

www.cea.nic.in , Report on land Requirement

http://powermin.nic.in/, Report on Generation

www.ntpc.co.in , Generation & Plants

http://www.worldenergy.org/ ,

www.bhel.com

www.power.alstom.com

www.google.com

http://en.wikipedia.org/

BIBLIOGRAPHY

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Epc proposal 3x660 mw with cost analysis

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