FOR 1X 660MW (P -III) E U 5 SAGARDIGHI T P S T D . M W.B. · westbengal...

WEST BENGAL

POWER DEVELOPMENT CORPORATION LTD.

FEASIBILITY REPORTFEASIBILITY REPORTFOR 1 X 660 MW (PHASE-III) EXTENSION UNIT 5

SAGARDIGHI THERMAL POWER STATION

AT SAGARDIGHI, DIST. MURSHIDABAD, W.B.

March 2016March– 2016

DEVELOPMENT CONSULTANTS PRIVATE LIMITEDDEVELOPMENT CONSULTANTS PRIVATE LIMITEDCONSULTING ENGINEERS

24 PARK STREET : KOLKATA-700016 : INDIA

Feasibility Report for 1X660 MW Phase-III Extension Unit- 5

Sagardighi TPS, W.B.

1

FOR 1 x 660 MW PHASE-III EXTENSION UNIT-5

SAGARDIGHI THERMAL POWER STATION

AT SAGARDIGHI, DISTRICT MURSHIDABAD

IN WEST BENGAL

ν INTRODUCTION AND STUDY AT A GLANCE 1.1 Foreword

1.2 Project Proposal

1.3 Study at a Glance

NEED FOR THE PROJECT 2.1 Power Scenario of Eastern Region & West Bengal

2.2 Justification of the Project

BASIC INPUT REQUIREMENTS 3.1 Introduction

3.2 Plot Availability for Main Plant

3.3 Water Requirement & Availability

3.4 Coal Requirement & Availability

3.5 Ash Disposal

3.6 Power Evacuation



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3.7 Infrastructural Facilities

TECHNICAL FEATURES

4.1 General

4.2 Main Plant & Equipment

4.3 Auxiliary Systems & Accessories

4.4 Electricals System

4.5 Civil Engineering Aspects

4.6 Environmental Aspects

PROJECT IMPLMENTATION AND RECOMMENDATION

5.1 Project Implementation

5.2 Recommendation & Follow-up Actions

SECTION – 5 Annexure – 5.1 - Design Raw Water Analysis

Annexure – 5.2 - Estimation of Consumptive Water Requirement

Annexure – 5.3 - Analysis of Coal & Ash SECTION – 6 Drawing No.K8A07-DWG-M-002 - Plot Plan Drawing No.K8A07-DWG-M-WBD-001 - Water Balance Diagram



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SECTION – 1

I N T R O D U C T I O N

AND STUDY AT A GLANCE

1.1 Foreword M/s. The West Bengal Power Development Corporation Limited

(WBPDCL) proposes to extend their on-going Phase-II extension

project of 2x500 MW at Sagardighi by adding one more unit of 660

MW as Phase-III extension unit. Sagardighi TPS is located in the village

Manigram in Murshidabad district of West Bengal, India.

Presently, WBPDCL have 365 Ha of land under possession for

Phases I, II & III of the plant proper and another 184 Ha for ash

disposal.

1.2 Project Proposal The new unit (proposed as 1 x 660 MW) under Phase- III

located on the north of Phase-II on-going 2 x 500 MW station,

was earlier proposed as 1X500 MW station, in continuation to

the Phase-II units.

It is considered that coal would be received from the same

source as the plant under Phase-I station with similar

characteristics and a new mine at Pachwara (north) in

Jharkhand being developed by WBPDCL through Bengal EMTA.

For coal unloading, crushing and storage facility it is proposed



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to utilise coal handling plant of Phase-II station with suitable

extension from the end of Transfer Point.

Available allocation of raw water for Phase-II station is 60

Cusec. However, it is presently estimated that about 50.2

Cusec of water would be consumed for Phase-II & III.

The adequacy of landmass in the identified plot for Phase-III

extension was reviewed considering the new set size and space

for auxiliary equipment required viz. the cooling tower,

switchyard etc.

With the above in view, WBPDCL have entrusted M/s.

Development Consultants Private Limited (DCPL) to study

and prepare the Feasibility Report (FR) for installation of the

5th unit extension of Sagardighi Thermal Power Station by 1x660

MW station in the identified plot and address other relevant

features for implementation.

1.3 Study at a Glance General : Project Authority : The West Bengal Power

Development Corporation Limited (WBPDCL).

Project : Phase-III extension of Sagardighi

Thermal Power Station (SGTPP) by adding 1X660 MW to the northern side of on-going 2x500 MW Phase-II station.

Selected Location : Sagardighi in Murshidabad District,

West Bengal.



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Latitude – 24° 22’ 13.7” N Longitude – 88° 6’ 15.8” E Nearest Major Towns : Ajimganj,Jangipur, Raghunathganj. Seismic Zone : Zone-III as per IS 1893-1984. Access by Road : From National Highway (NH-34).

Access by Rail : Manigram R.S. on Bandel-Barhawara branch line.

Access by Sea : Nearest port is Kolkata. Access by Air : Netaji Subhas Chandra Bose

International Airport at Dum Dum in Kolkata.

Preliminary Project Particulars:

Main Fuel : Coal from allocated block to WBPDCL at Pachwara north in Jharkhand.

Fuel Transportation : By rail in rake loads of BOBR/’N’-

BOX wagons. Water : From river Bhagirathi (5 km)

through the proposed intake pump house under implementation for Phase-II station.

Land : Vacant land adjacent to the units in

Phase-II identified for setting up the extension unit.

Layout Features : One 660 MW unit to be

accommodated within the available space alongside the battery of two 500 MW units under Phase-II powerhouse.

Land Development : The main power plant would be

built at an elevation of 34.5 m above mean sea level (MSL). The



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plot is well above highest flood level (HFL) of the area.

Technical Features :

Power Generating Units : One unit of standard 660 MW turbine generator sets fed by steam from independent coal fired P.F. boilers operating at super-critical range.

Cooling System : Semi-open recirculating condenser

cooling system with wet-type natural draft cooling tower.

Coal Handling System : It will be shared with the CHP of

ongoing Phase-II station. Suitable extension from the end of Transfer Point (TP-19) to be done.

Ash Disposal System : Dry extraction and disposal with

provision for wet lean slurry disposal for bottom ash and fly ash (during exigency) is considered. Ash water recirculation system to be provided.

Power Evacuation : At 400 kV level. Environmental Aspects : A 275 m high single-flue stack as

per MoE&F guidelines and an adequately designed electrostatic precipitator with more than 99.96% efficiency are envisaged. Waste water quality to be maintained as per MoE&F notification. Flue Gas Desulphurization (FGD) & Selective Catalytic Reducer (SCR) have to be installed to meet revised MoEF norms dated 07.12.15.

Rehabilitation Requirement : Nil



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Project Implementation : Mode of Implementation : To be suitably decided.

Project Time Frame : Forty four (44) months from zero date i.e. the date of ‘Letter of Award’ to the Main Plant Contractor for commercial operation of the unit.



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SECTION – 2

NEED FOR THE PROJECT

2.1 Power Scenario of Eastern Region & West

Bengal For the purpose of power planning and operation of regional grid

the Eastern Region consists of the following states/UT/Command

area:

• West Bengal • Bihar • Jharkhand • Odisha • Sikkim • Andaman-Nicobar (UT) • DVC

All three sectors namely Central, State & Private contribute to

the power generation capability in the region. The power

generating capability in the region is predominantly thermal. The total installed capacity including allocated shares in joint &

central sector utilities in eastern region as on 31.01.2016 is

34551.53 MW. Energy deficit to the tune of (-) 758 MU and

peak demand deficit of (-) 104 MW had been recorded during

the period of April 2015 to December 2015 in the Eastern Region

(Source : CEA Data). As per 18th EPS, electrical energy requirement for eastern region

would be 163,294 GWh by the end of 12th Plan and 231,646



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GWh by the end of 13th Plan period. Average peak electrical load

for eastern region is forecast to be 15,396 MW and 24020 MW

by the end of 11th and 12th Plan respectively. Thus a capacity

addition requirement of 12320 MW has been estimated

considering plant availability factor @ 0.7 in 12th plan period

starting from April 2012. Projected value may be higher

considering the cascading effect due to the slippage of required

capacity addition during the 11th Plan period (2007-2012).

The State of West Bengal covers an area of 88000 km2 with a

population density of 1000 persons/km2. Per capita

consumption in the state during the year 2011-12 was 564 kWh

which is below to the national average of 884 kWh (Source:

Annual Report 2013-14 by Planning Commission, Govt. of

India). Total installed capacity of West Bengal as on 31.01.16 is

10063.84 MW. Detailed break up is tabulated below.

Sector

Thermal Nuc. Hydro RES Total

Coal Gas Diesel Total State 5720 100 0 5820 0 977 91.95 6888.95

Private 1941.38 0 0 1941.38 0 0 39.76 1981.14

Central 922.45 0 0 922.45 0 271.3 0 1193.75

Total 8583.83 100 0 8683.83 0 1248.3 131.71 10063.84

(Source: CEA, Fig in MW)

2.2 Justification of the Project Based on above discussions it can be inferred that sustainability

of economic growth of a country has a direct relationship with

electricity consumed both industrial and domestic. In the

budget for the year 2014-15 current government has made a



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commitment to provide 24 x 7 uninterrupted power supply to all

homes under ‘Deendayal Upadhyaya Gram Jyoti Yojana’.

Per capita consumption of electricity of India is low compared to

world average which is above 3000 unit/year. Following are per

capita consumption of electricity of BRICS countries except India

as recorded in 2011 :-

Brazil - 2438 kWh/year

Russia - 6486 kWh/year

China - 3298 kWh/year

South Africa - 4604 kWh/year

Whereas India has a dismal figure of just 957 kWh/year as

published by CEA for the year 2013-14. To leap forward

towards the world standard of per-capita consumption of

electricity in the near future, huge capacity addition every year

basis is required. 12th Plan has set a target for capacity addition

to a tune of 18000 MW per annum. As India is connected via

National Grid capacity addition in one region can contribute to

the countries overall target, no matter if that particular region is

power surplus.

In this scenario, the proposed 1x660 MW coal based extension

power station by M/s. The West Bengal Power Development

Corporation Limited (WBPDCL) at Sagardighi TPS, West Bengal

fits well in country’s aspiration for sustained growth.

The major reasons for setting up proposed 1 x 660 MW

Sagardighi Extension Unit #5 are:



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• Land availability within the acquisition limit of project

authority.

• Availability of water. Allotment of 60 cusecs of water from river Bhagirathi by WRD, Govt. of W. B. would be sufficient for ongoing Units #3 & #4 and Extension unit #5.

• Availability of coal from captive mines.

• Extensive infrastructure developed during execution of Phase-

I & Phase-II.

• Auxiliary facilities viz. raw water reservoir, intake pump house, LDO & HFO System, railway siding, CHP area etc. can be shared.

• 400 kV sub-station would require marginal extension for Unit

#5.

• An attractive timeframe for commissioning the unit can be attained.

With the above in view, it is expected that the energy cost would

be reasonable.

Thus new capacity addition will be a welcome move.



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SECTION – 3

B A S I C INPUT REQUIREMENTS

3.1 Introduction Feasibility study is to be carried out for installation of 1X660 MW

supercritical unit in Phase-III within the available space at

Sagardighi TPS along with all necessary auxiliaries including FGD

and SCR for meeting latest MoEF notification and all related BOP

packages. This was earlier conceived of 1X500 MW capacity. The

basic requirements for setting up and operating the proposed

Phase-III extension unit using coal as main fuel are:-

• Availability of adequate land within the existing plot. • Availability of sufficient water of appropriate quality on year-

round basis.

• Ensured supply of adequate fuel. • Power evacuation possibility to the grid at desired voltage

level(s). • Possibility of extensive utilisation of the existing

infrastructure viz. utilisation of existing road network during construction and operation, accessibility of power and water during construction, optimum utilisation of manpower deployed.

• Adequacy of ash disposal in existing ash dyke.



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3.2 Plot Availability for Main Plant

The area earmarked for the plant site considering the ultimate

stage is approximately 365 hectares (900 Acres), excluding the

ash dump area, township etc. The layout in Phase-I (2x300

MW) and Phase-II (2x500 MW) was developed on the basis of

ground survey and soil investigation conducted earlier keeping

adequate space provision for extension of one more unit of 500

MW set (earlier conceived) and giving due consideration of the

natural slope, drainage canal, nearness to existing railhead,

ease of evacuation of power etc.

With the available land contour, the newly proposed Phase-III

station of 1x660 MW would be laid at the same ground level

(GL). This plot would be able to accommodate the main plant

with cooling towers, transformer yard, switchyard and all other

auxiliaries. Coal Handling System proposed for Phase-II units

would be gainfully utilised for Phase-III unit. Raw water

reservoir planned to be constructed for Phase-II would cater the

water requirement for Phase-III extension unit also.

The township proposed under Phase-I & II would be augmented

to accommodate additional housing required for the staff of the

extension unit.

Thus no land acquisition for Phase-III extension unit would be

involved.



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3.3 Water Requirement & Availability The station has an allocation of 60 Cusec of raw water for

Phase-II. The raw water analysis as received to meet the

cooling and consumptive water requirement is given in

Annexure-3.1. The estimated raw water requirement for

Phase-II & Phase-III station together works out around 5119

m3/hr (50.2 cusec). As stated above, raw water availability from

the Bhagirathi River is assured and it may be summarized thus

the water for the Phase-II & III units would be available from

the present allocation.

The break-up of the estimates is shown in Annexure-3.2 of the

report. The above estimate considers semi-open recirculating

cooling water system with cycle of concentration (COC) as 5

and lean slurry disposal of ash with provision of recovery and

recirculation of ash water for both Phase-II & Phase-III. The

consumptive water requirement for the units installed in Phase-

II & Phase-III is shown in water balance diagram attached

herewith.

No separate pump house is envisaged for the extension unit #5.

It is planned to feed raw water requirement for the Phase-III

station through two (2) working & one (1) stand by river water

intake pumps designed under Phase-II stage. Water would

come to the in-plant reservoir through 1 no. 1200 NB pipe.



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The capacity of raw water reservoir developed inside the plant

premises is of capacity 16,00,000 m3 , which can cater raw

water requirement of both Phase-II & III units for about 13

days.

However, some modification/augmentation to be carried out in

DM water circuit in Condensate Storage Tank (CST) and

Condensate transfer pump house as detailed in section-5.

3.4 Coal Requirement & Availability Sagardighi Thermal Power Station is linked to the mines of ECL.

Coal is planned to be transported in rake loads through the

existing Pakur-Tildanga-Dhulian-Monigram broad gauge line or

through Pakur-Nalhati (proposed)–Takipara-Gosaingram-

Poradanga-Monigram broad gauge line. The coal would be

carried in rake loads of BOBR/BOX-N wagons.

Depending on source, the range of different parameters of

proximate and ultimate analysis of coal and ash to be received

by the station is given in Annexure-3.3 enclosed. Coal would

be received in sizes of (-) 300 mm and would have volatile

matter in the range of 20%.

One(1) track hopper was constructed for Phase-I station. For

Phase-II station one additional track hopper of 225 m length and

one(1) wagon tippler are under installation. These are considered

adequate for Phase-III extension station also. Further two(2)

nos. stacker-cum-reclaimers have been proposed for Phase-II &

III units. Two conveyor streams having guaranteed/rated

capacity of 2000 TPH with facility for crushing and stock



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piling/reclaiming have been proposed for supplying coal required

for the station.

Coal consumption for 2X500 MW (Phase-II) and 1X660 MW

(Phase-III) is estimated to be around 1140 TPH in TMCR

condition and 1230 TPH in BMCR running condition.

Hence, it can be concluded that with the present selected

guaranteed capacity of 2000 TPH for coal conveyor stream, coal

requirement of Phase-II & III units can be met.

Presently installed coal stock-pile of capacity 3,00,000 m3, is

sufficient for 10 days’ consumption of units of Phase-II & III at

85% PLF.

Coal Requirement for Phase-III station is tabulated below:

Particulars Unit Value

Station Heat Rate Kcal/ kWh 2151.2

GCV of Coal kCal/ kg 3300

PLF % 85

Hourly Coal

Consumption

TPH 430.2

Daily Coal

Consumption

TPD 10325.6

Annual Coal

Consumption

MTPA 3.2

Fuel oil (HFO/LDO) would be normally transported by railway oil

tankers from the nearest oil depot. The existing two (2) nos. of



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LDO tanks of 2000 m3 each and two (2) nos. of HFO tanks of

2000 m3 each for the Phase-I and additional two(2) nos. of HFO

tanks of 2000 m3 each being constructed under Phase-II project,

will cater for storage of LDO and HFO required for start-up and

coal firing support purpose of the Phase-II & III units also. It is

also found that HFO forwarding pumps, with provision for future

extension, shall cater the requirement of Phase-II & III units.

Similarly, installed LOD forwarding pumps of Phase-II can also

cater requirement of Phase-III unit.

3.5 Ash Disposal Ash handling plant was earlier conceived as lean slurry disposal

both for bottom ash (BA) and Fly ash (FA) for 3X500 MW i.e. for

Phase-II & Phase-III combined. Accordingly ash handling plant

has been designed for Phase-II station, which can also cater the

requirement of newly proposed 1X660 MW station under Phase-

III. However, with the latest MoEF notification for water

consumption limitation, it has been decided to consider ash

water recovery system under operation from the beginning for

Phase-II & III units.

Total ash evacuation for both BA & FA for Phase-II & III units

shall be completed within seven (7) hrs (apprx.) per shift. The

capacity of ash water sump & ash slurry sump is found to be

sufficient for operation of Phase-II & III units. However, the ash

water/slurry pumping arrangement to be suitably augmented as

detailed in section-5 of the report.



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3.6 Power Evacuation Mode Power generated from 660 MW extension U#5 would be

evacuated at 400 kV level through existing/new lines, as detailed

in the Plot plan.

For this existing 400 KV switchyard of Phase-II will be extended

to accommodate following bays:

a. 1 No. Generator Transformer

b. 2 Nos. Station Transformer

c. 2 Nos. future Lines/bays 3.7 Infrastructural Facilities The existing facilities planned in the area for Phase-I & II and

with the available local infrastructure, the proposed extension

unit would enjoy the much needed initial support during project

implementation stage. Moreover, the major habitation centres

in the area namely, Jangipur, Manigram, Sagardighi etc. are in

a position to provide the necessary infrastructural assistances in

the form of housing, education, market, healthcare, skilled and

unskilled manpower, SSI units etc.



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SECTION – 4

TECHNICAL FEATURES

4.1 Introduction West Bengal Power Development Corporation Limited (WBPDCL)

intends to build a coal based 660 MW capacity power project

under Phase-III with coal from Panchwara (N) field of Rajmahal

in Jharkhand. The project would be an extension of the existing

Phase-II units under construction near Sagardighi in West

Bengal. The proposal is mooted to deploy the state-of-the-art

technology and accordingly one unit of 660 MW is being

considered. Water would be available from intake on the River

Bhagirathi and conveyed through pipeline to the intake pump

house covering an approximate route distance of nearly 5 km.

The basic plant design would consider unitised concept as far as

possible. Judicious provisions would be considered for

reasonable spare capacities in various systems and system

components and inter-changeability of equipment/system.

State-of-the-art technology has been considered for design of

the proposed station.



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Basic design parameters for equipment and systems are as

follows : - • Ambient temperature, Extreme High : 46.1 °C Low : 3.9 °C • Seismic zone as per IS:1893 : III • Maximum wind velocity : 47 m/sec • Cooling water inlet temperature : 33 °C (max.) • Instrument air/plant air : Dry oil-free. • Power supply to drives (3 Ph, 50 Hz): Upto 200 kW rating

at 415 V. Above 200 kW and upto 1500 kW at 3.3 kV.

Above 1500 kW at 11 kV. • Control voltage for electrical : At 220 V D.C.

(unearthed) equipment • Power supply for control and : At 24 V D.C. Instrumentation 4.2 Main Plant & Equipment

Turbine Generator & Auxiliaries Type : Single reheat multi cylinder

tandem compound, Condensing steam turbine directly driving a 3000 rpm, 2-pole, 50 Hz, synchronous generator.

Nominal Capacity : 660,000 KW at 306 K (33 °C)

condenser cooling water temperature.



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Normal Operating Frequency Range : 47.5 to 51.5 Hz Inlet Steam Parameters: - Main Steam Hot Reheat

Pressure, Kg/cm2 (abs.) : 247 50.3

Temperature, °C : 565 593

Steam flow at MCR T/hr. (approx.) : 1942 1610 Exhaust Pressure : 76 mm of Hg (abs.) Steam Extractions : CRH + 5 to 7 Nos. stages from

HP, IP and LP turbines for condensate/feed water heating (depends on manufacturer).

Type of governing : Electro-hydraulic governing with

fire resistant fluid. Turbine HP-LP bypass system : Capacity- 60% of TMCR. Condensing Equipment : Shell and tube type, surface

condenser of single flow design, operating on re-circulating cooling water with evapora-tive cooling towers.

Regenerative feed heating Arrangement : Three/four stages of LP heaters

(U-tube design). One spray-cum-tray type deaerator, two parallel chains of HP heaters.

Boiler feed water pumps : 2 x 50% capacity steam

turbine-driven BFP with booster pump & 1x50 % electric motor driven, horizontal, centrifugal BFP.

Condensate extraction pumps : 3 x 50% capacity vertical,

centrifugal CAN type



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construction, 3.3 kV motor driven.

Generator : 776,000 KVA output at 0.85

power factor (lagging) 3 pH, 50 Hz and 20-24 kV voltage.

Steam Generator & Auxiliaries Type : Pulverized fuel, once through,

two-pass/tower type, semi-outdoor, dry bottom, coal-fired unit with tangential firing and with associated auxiliaries suitable for sliding mode operation.

Nominal Capacity : 2100 Tones/Hr

Nominal Outlet Steam Parameters at BMCR :-

Main Steam Hot Reheat Pressure (Kg/cm2) : 256 55.3

Temperature, °C : 568 593

Steam flow, T/hr. (approx.) : 2100 1675 Steam temp. Control range : 40-100% BMCR or better. Super heater/Re-heater : Attemperation spray and tilting

burner control. Temperature control Nominal Air Heaters Capacity : 2 x 60% of BMCR. Draft Fans : • 2 x 60% capacity axial flow

forced draft (FD) fans with blade pitch control.

• 2 x 60% capacity axial

induced draft (ID) blade pitch control fans.



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• 2 x 60% capacity P.A. Fans. Pulverizing Mills : Slow speed large bowl or ball

and race type in **N+2 configuration.

Coal Firing System : Direct suspended firing with

state-of-the-art low NOX burners giving stable fire between 40-100% MCR or better.

Start-up/auxiliary fuel : Light Diesel Oil for cold start

and for support (capacity up to 10% BMCR).

Heavy Fuel Oil (HFO) for flame

support up to 40 % of BMCR. / Ash removal : Bottom Ash: Extraction in

semi-wet form and disposal to ash pond in slurry mode.

Fly Ash : In dry condition

through vacuum and by pressurized air conveying for ultimate disposal from silos by truck for possible utilization or disposal in Lean Slurry mode to the ash disposal area during emergency.

Note : ** N-denotes the number of mills required to reach boiler

MCR with design coal and 85% mill loading.

Note : * Vendor to specify.



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4.3 Auxiliary Systems & Accessories

Plant Water System/Booster Pumps : (For Phase-II & III units together) Intake Raw Water Pumps : Source : From Bhagirathi River.

Type : Vertical wet pit mixed flow multi-

stage.

Fluid Handled : River water

Capacity : 3700 m3/hr each

Number : Three (3) [2 working + 1 operational

standby].

Drive : Electric motor, 3.3KV/415 V, 3 Ph.,

50 Hz.

Raw Water Reservoir : Type : Clay lined.

Number : Three (3) Capacity : 1601182 m3 Raw water Pumps : 4 (3W+1 S) – capacity 1600 m3/hr

Clariflocculator : Type : High Rate Solid Contact Clarifier Capacity : 2000 m3/hr.

Number : Three(3)

Construction : RCC for conventional clariflocculator.



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Clarified Water Storage Tank :

Type : RCC (Partly underground) Twin

chamber

Capacity : 63,000 m3

DM Plant :

Type : Combination of RO, MB system. Control Room : Indoor Capacity : Three (3) streams of 100 m3/hr,

each stream consisting of ultra-filtration, RO units activated carbon filters, cation exchanger, anion exchanger and mixed bed exchanger. A common atmospheric degasser is also provided. The system would also include acid and alkali handling and storage facilities for exchanger regeneration.

Operation : PLC based from control room.

DM Water Storage Tanks :

Type : Vertical cylindrical steel tank with inside rubber lining.

Capacity : 2000 m3

Numbers : Two(2) Condensate Storage Tank :

Type : Vertical steel tank with inside rubber lining.

Capacity : 750 m3

Numbers : Three (3)



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Cooling Water Circuit : (For Phase-III unit) Cooling Tower :-

Type : Natural Draft

Nos. : One(1)

Cooling Water Quality : Clarified water

Total circulating water flow : 80,000 m3/hr.

Design cooling range : 43 °C to 33 °C i.e. 10 °C

Approach : 5 °C

Cooling Tower make-up Pumps :-

Type : Vertical, centrifugal

Fluid Handled : Clarified water

Capacity : 1300 m3/hr. each

Head : 30.5MWC Number : One(1) Circulating Cooling Water Pumps :-

Type : Vertical Wet Pit

Fluid Handled : Clarified water

Capacity : 40,000 m3/hr. each

Number : 2 W+ 1 S Auxiliary Cooling Water Pumps :-

Type : Vertical wet pit installation.

Flow : 4000 m3/hr.

Fluid : Clarified water

Number : Two(2) [1 working + 1 standby]



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2. Coal Handling Plant (For Phase-II & III units together) Conveying System : Type : Twin stream conveying system,

hydraulic motor driven. Capacity : 2000 Tons/hr. Crushers :- Type : Ring granulator Number : Four(4) (2 working + 2 standby) Capacity : 1000 TPH each Input coal size : (-)300 mm Output coal size : (-)20 mm Vibrating Screen :- Type : Roller screen type. Number : Four(4) (2 working + 2 standby) Capacity : 1000 TPH Stacker-cum-Reclaimer :- Type : Hydraulic motor-driven rail-mounted

unidirectional having slewing and adequate lifting arrangement.

Stacking Capacity : 2000 TPH

Reclaiming Cap : 2000 TPH

Number : Two(2)

Coal size : (-)20 mm



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3. Solid Waste Handling System Equipment (For Phase-III unit) Ash Handling System : / Basic Design Parameters : Max. Bottom Ash generation 46.8 Tons per hour. Eco Ash- 11.7 TPH Max. Fly Ash generation–234

Tons/hr. / Type : Water impounded/extraction and wet

disposal for Bottom Ash and dry extraction and dry/MCS disposal of fly ash. MCS during exigency only.

/ Bottom Ash cleaning : Intermittent (2 hrs. of operation per

shift including flushing) / Fly Ash cleaning : Auto-sequential operation with 5

hours of operation per shift.

Fly Ash Handling System :

Intermediate Surge Hopper :- Type : MS construction Number : Two(2) Capacity : 250 T each Outlet : Five (5) [4W + 1S] for

Pneumatic conveying to terminal silos.



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Fly Ash Terminal Silo:-

Type : RCC construction Number : One (1)

Capacity : Ten (10) hours’ storage capacity each unit considering fly ash generation for the station at rated load with worst coal – 2400 MT.

Outlet : Two(2) for closed truck disposal. One(1) for open truck disposal. Two(2) spares

4. Main and Start-up Fuel Oil System (For Phase-III unit)

LDO Storage Tanks :

/ Capacity :

/ Number :

LDO Unloading/Transfer Pump : Common for Phase-II & III units

/ Type :

/ Number :

HFO Storage Tanks :

/ Capacity : Common for Phase-II & III

/ Number :



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HFO Unloading/Transfer Pump :

/ Type : Positive displacement.

/ Number : Existing HFO storage-Tanks : / Type : Vertical cylindrical M.S. construction

with bed coil and suction heater for HFO tank.

/ Number : Two(2) / HFO Pressurizing Pump : Four(4) 5. Auxiliary Equipment Turbine Hall EOT Crane : Capacity :- / Main Hook : 110 T

/ Auxiliary Hook : 25 T

/ Number : One (1) Fire Protection System : Fire Hydrant System :- Type : Common for Phase-II & III units Hydrant Pumps :

Air Compressor : (For Phase-III unit) / Type : Screw type – oil-free, dry type.

/ Number : 2 (1 IA + 1 SA)

/ Free air capacity at normal : 55 Nm3/min. each pressure and temperature



4 - 13

/ Rated discharge pressure : 8.0 kg/cm2) (g)

/ Location : Indoor

/ Assumed inlet air temp. : 45 °C (max.)

/ Air Receiver : One(1) per compressor.

/ Air Drying Plant : One stream of capacity 55 Nm3/min. fully automatic type.

Hydrogen Generation Plant : (For Phase-II & Phase-III units) / Type : Bipolar Electrolytic module or

equivalent.

/ Electrolyte : KOH

/ Capacity : 2 units of 10 m3/hr.

/ Accessories : Bottling arrangement of H2 & O2 in cylinders.



4 - 14

4.4 Electrical System 1. Generator : - Type : Two-pole cylindrical rotor,

rotating field with static/brushless exciter.

- Capacity : 660 MW, at 0.85 p.f. (lag)

- Generating Voltage : 24 kV

- Speed : 3000 rpm - Cooling : Generator – totally hydrogen

cooled.

- Insulation : Class-F with temperature rise limited to Class-B.

2. Generator Neutral Grounding Equipment : - Type : Metal-enclosed cubicle

- Components : Disconnecting link, grounding trans-former and resistor.

- Type of N.G. Transformer : Dry, AN type - Resistor element : Cast-iron 3. Generator Busduct : - Type : Isolated phase, conductor and

enclosure-aluminium, insulators-porcelain.

- Voltage : 24 kV

- Current rating : 25,000 A main run, 1600 A tap-

off run

- BIL : 125 kVp



4 - 15

4. Transformers : • Generator Transformer - Capacity : 3 – 1 Ph - 275 MVA

- Voltage ratio : 24 kV/420 kV √3 - Cooling : OFAF

- Tap changer : Off Load : range ± 5% @ 2.5%

- Neutral Grounding : Effectively earthed • Unit Transformer - Capacity : 40 MVA each

- Voltage ratio : 24/11.5 kV

- Cooling : ONAN/ONAF

- Tap changer : OLTC. : Range +7.5% to -12.5% @ 1.25%

- Neutral Grounding : Low resistance grounded. • Station Transformer :- - Capacity : 90/45/45 MVA

- Voltage ratio : 400/11.5 kV

- Cooling : ONAN/ONAF

- Tap changer : OLTC : Range +10% to -12.5%

@ 1.25%

- Neutral Grounding : Low resistance grounded.



4 - 16

• MV Transformer - Type : Oil filled with outdoor service. - Capacity : 20 MVA for UAT 20 MVA for SAT - Voltage ratio : 11 kV/3.5 V - Cooling : ONAN - Tap changer : Off-circuit : Range ± 2 x ± 2.5% • LT Auxiliary Transformers - Type : Dry type. - Rating : Not exceeding 2000 kVA - Voltage ratio : 11 kV/433 V - Cooling : AN (Dry) - Tap changer : Off-circuit : Range 2 x ± 2.5% 5. 11 & 3.3 kV Switchgear : - Type : Vacuum circuit breaker. - Enclosure : Metal enclosed indoor drawout

type. - Rated voltage : 11 kV & 3.3 kV - BIL : 75 kVp



4 - 17

6. 415 V Equipment : • 415 V Switchgear :- - Type : Air break/Molded Case - Enclosure : Metal-enclosed indoor drawout

type. • MCC & DB (AC & DC):- - Type : Metal-enclosed indoor draw-out

type with Air circuit breakers/Molded Case and motor starter units.

- Components : MCCBs, contactors, control fuses,

thermal overload relays, SPPS. - Voltage : 415 V for ACDB, 220 V for DCDB. 7. DC System : • Battery :- - Type : Lead-acid-Plante’ Positive - Cell voltage : 2.0 Volts (Lead-acid) - Emergency load duration : 1 hour • Charger :- - Type : Air-cooled, solid-state - Service : Float and boost charge



4 - 18

8. Electric Motors : - Type AC : Three/single phase,

squirrel cage induction. DC : Shunt/compound wound

with resistance starter. - Voltage AC : i) 11000 V & 3300 V, 3

phase for motors of rating above 200 KW.

ii) 415 V, 3 phase for

motors of rating up to 200 KW.

DC : 220 V 9. Diesel Generator : - Type : 4-stroke, water-cooled, direct-

injection, turbo-charged with after-cooler.

- Speed : 1500 rpm

- Capacity : 1600 kVA

- Voltage : 415 V, 3 pH, 50 Hz

- System : 3 phase, 3 wire ungrounded

- Insulation : Class-F limited to Class-B

- Exciter : Brushless



4 - 19

10. Switchyard : • System Particulars (400 kV) :- - Nominal System Voltage : 400 kV

- Highest System Voltage : 420 kV

- Frequency : 50 Hz +3% (51.5 Hz) and –5% (47.5 Hz). - Phase : 3

- System neutral earthing : Effectively earthed

- BIL (Lightning/switching/PF) : 1425/1050/630 kVp (rms) - Bus Bar Arrangement : One and half breaker system.

- System fault level : 40 kA (Sym.)

- Short time withstand : 40 kA (Sym.) current (1 sec) • Circuit Breaker :- - Type : SF-6, 3 Pole

- Installation : Outdoor

- Rated Voltage : 400 kV

- Rated Normal current : 1250 Amp - Rated short circuit : 40 kA for 1 sec. breaking current - Rated short circuit making : 100 kA current - Rated duty cycle : 0-0.3 sec – CO – 3 min - Control : Transformer feeder and bus-

coupler breaker shall be 3-pole gang operated, line feeder and bus tie breaker shall be single-pole type.



4 - 20

• Isolators :- - Rated Voltage : 400 kV - Type of disconnecting : Horizontal break, centre rotating

type and pantograph. - Installation : Outdoor - Rating : 1250 Amp - Short time withstand : 40 kA for 1 sec. Current - Rated dynamic short circuit : 100 kA (peak) withstand current - Control : Motor operating mechanism type. • Current Transformers :-

- No. of cores : As required. Separate core will be provided for metering.

- Rated System Voltage : 400 kV

- Secondary current : 1 A

- Rated short time thermal : 40 kA current for 1 sec. - Rated dynamic current : 100 kA - Accuracy Class :- Protection : 5P20/PS Metering : 0.5 - Installation : Outdoor



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• Lightning Arrester :-

- Type : Heavy duty station class, gapless

- Voltage Rating : 360 kV

- Nominal Discharge Current : 10 kA (Heavy Duty) • Voltage Transformer :-

- Rated System Voltage : 400 kV

- Type : CVT - Ratio : 400 kV/110 V/110 V √3 √3 - VA : 800

- Accuracy class :- Protection : 3P Metering : 0.5 - Installation : Outdoor

4.5 Civil Engineering Aspect

Detail soil investigation shall be undertaken in the project area at

an appropriate stage of project implementation. Based on the

sample soil report pile foundation is planned for the plant and

equipment. The area under consideration comes under Zone-III

as per the demarcation of IS 1893 (latest edition) of Indian Code

of Practice. For wind pressure IS 875 – 1987 shall be adopted.

Earthwork in filling and leveling shall be carried out considering

high flood level and area drainage.

Plot plan depicting Phase-III station is given in the Drawing

No.K8A07-DWG-M-002.



4 - 22

4.6 Environmental Aspect As per latest MoEF notification, dated 07.12.15, the TPPS to be

installed from 01.01.17 shall meet the limits as detailed below.

SPM- 30 mg/ Nm3

SOx- 100 mg/ Nm3

NOx- 100 mg/ Nm3

Hg- 0.03 mg/ Nm3

Specific water consumption- 2.5 m3 / MWh (Max) and achieve

Zero Discharge.



5 - 1

SECTION – 5

PROJECT IMPLEMENTATION AND Recommendation

5.1 Project Implementation

Successful implementation of a project calls for joint

participation of the Owner, the Consultant, the Vendors and the

Contractors. The Owner plays the most important role in

spelling out the objectives, setting out the priorities and time

schedules and ensures timely flow of funds. In line with the

recent trend, WBPDCL would implement the proposed project in

a limited number of Turnkey packages. The scope of each

turnkey package contractor would include Engineering,

Procurement and Construction for the package.

This approach for implementation would ensure:

• Engagement of limited number of agencies and thus improve co-ordination among themselves.

• To maintain the timeframe normally desired by the lenders

• To satisfy the commercial requirement of funding agency

• To minimise the delay normally faced in multi-agency deployment

The principal objective of the project execution team to be

formed by the Project Authority are to overview the design,

procurement, construction and commissioning of the power

station within the scheduled time and cost, ensuring high



5 - 2

availability of the Plant and Machineries. These are broadly

classified as under.

Guarantees will be given for maximum continuous output and

heat rate performance for the unit. Scope of the contract will be

defined in the project specification. The project timescale is 44

months for the completion of the extension Unit-5 station from

zero date. Contractors under technical supervision by turnkey

executor and their equipment supplier will carry out the

construction of the power station. Responsibility for the

management of turnkey contract will be with turnkey executor.

Pragmatic clause on liquidated damages will be incorporated to

safeguard against time over run.



5 - 3

5.2 Recommendation & Follow-up Actions

BTG plant for 660 MW unit can be accommodated within the

allocated space, but it appears to be in a tight condition due to

present MOEF and CC requirement of FGD/ SCR installation and

lime stone, ammonia, gypsum handling facility to be developed

near the chimney area as shown in the plot plan as per the latest

MoEF and CC notification.

However, road layout around the proposed BTG unit may have to

be suitably modified to cater the final requirement of main plant

layout with FGD/ SCR units along with their handling

arrangement.

Existing raw water intake and its transportation system, raw

water clarifier system along its piping arrangement appears to

be adequate to meet the system load of Phase-II & Phase-III.

The capacity of plant water with its distribution system,

firefighting system, DM plant with its feed system appears to be

adequate for Phase-II & Phase-III in combine. Two (2) nos DM

water storage tanks of capacity 2000 m3 each can cater the

requirement of units of Phase-II & III.

However, One (1) no Condensate Storage Tank (CST) of suitable

size may have to be installed for Phase-III unit. One(1) no.

Boiler fill pump, One(1) no. condenser cycle make-up pump &

two(2) nos. CPU regeneration pump of suitable capacity to be



5 - 4

installed in the space kept in Condensate transfer pump house

for the Phase-III unit.

Water allocated for Phase-II unit would meet the consumptive

water requirement for all the units installed under Phase-II &

Phase-III.

CW & ACW system for phase III unit would operate

independently with its make-up/ blow down arrangement to be

operated in combination with Phase-II unit. However, the make-

up water requirement for FGD/SCR units for Phase-III unit, can

be met by 2 nos (1W+1S) make-up pumps to be installed in the

CW-ACW pump house for Phase-III unit.

CT make up pumps (3W+1S) and raw water transfer pumps

(3W+1S) installed under Phase-II units would cater consumptive

water requirement both for Phase-II & Phase-III units. However,

its pumping arrangement has to operate at about 3% overload

condition.

DM plant feed pump (2W+1S), service water pumps (2W+1S),

DM water transfer pumps (3W+1S) and Potable water pumps

(1W+1S) presently installed under Phase-II would cater the

requirement for Phase-III unit also.

Requirement of coal for Phase- II & III unit would be catered by

operation of the presently selected coal handling plant for

approx. 16-18 hours per day. Coal conveyor system and wagon

trippler needs special attention for operation and preventive



5 - 5

maintenance, so that their availability in guaranteed operating

condition should be ensured all the time, being in critical path

operation.

Fuel oil unloading/ storage system can be operated in

combination for Phase-II & Phase-III unit. HFO pressurising

system for Phase-III unit can operate parallel in combination

with that of Phase-II units, by installation of one additional HFO

pressurising pump of suitable capacity. LDO pressurising system

for Phase-II consists of two pumps (1W+1S), each of adequate

capacity to cater requirement of two units of 500 MW. For the

increased oil requirement of 660 MW unit, each LDO pressurising

pump will operate for the future 660MW unit, considering firing

of Phase-III unit only at a time. However, during that period of

pump operation, LDO can also be fed to one 500MW unit at

reduced rate (slightly less than the required rated capacity).

Compressed air system (IA & SA) for phase-III unit can operate

parallel in combination with Phase-II unit compressed air

system, by installation of one IA & one SA compressor of similar

capacity, whose foundations are already constructed at site .

In ash water pump house one (1) higher capacity LP water pump

suitable for 660 MW unit and two (2) nos. of similar capacity HP

water pumps are to be installed for Phase-III, working in parallel

to that of Phase-II unit pumps. In ash slurry pump house, one

(1) no. slurry pump chain to be installed for Phase-III units in

addition to the existing four (4) (2W+2S) chains presently

installed for Phase-II units. In recovery water pump house

located near ash dyke area, one (1) recovery water pump of



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higher capacity suitable for 660 MW to be installed, working in

parallel to pumps of Phase-II units. One (1) recovery water

clarifier with two (2) (1W+1S) recycle water pumps may have to

be additionally installed inside the plant premises to avoid

continuous overloading of existing clarifier system for Phase-II &

III. One (1) no. additional instrument air compressor may have

to be installed in addition to for four (4) nos. of conveying

compressors for Phase-III unit. One (1) no Fly ash silo of suitable

capacity may have to be installed for Phase-III unit.

Mill reject system for Phase-III unit would require one mill reject

conveying compressor to be installed, which would work parallel

to the pneumatic conveying compressors installed for mill reject

system of Phase-II unit.

Fire protection & hydrant system for Phase-III unit would be

developed by suitably extending the system installed for Phase-II

unit.

Three (3) numbers DG set of 1500 kVA capacity each presently

being installed under Phase-II station and space for one unit of

DG set of same capacity has been kept. This would meet the

requirement of the Phase-II & Phase-III units together.

Existing 400 KV switchyard of Phase-II will be required to be

extended to accommodate following bays:

a. 1 No. Generator Transformer

b. 2 Nos. Station Transformers

c. 2 Nos. future lines/bays



5 - 7

Electrical facilities of all drives/equipments to be suitably

augmented in respective areas for Phase-III units.

Feasibility Report for 1 x 660 MW Phase-III Extension. Unit-5

Sagardighi TPS, WB

Annexure – 5.1

1. Calcium (Ca++) as CaCO3 86 2. Magnesium (Mg++) as CaCO3 52 3. Sodium & Potassium (Na+ & K+) as CaCO3 138 Total Cations 276

4. Bicarbonates (HCO3) as CaCO3 200 5. Carbonates (CO3) as CaCO3 - 6. Hydroxyde (OH) as CaCO3 - 7. Sulphate (SO4) as CaCO3 35 8. Chloride (Cl) as CaCO3 41 9. Nitrate (NO3) as CaCO3 - 10. Phosphate (PO4) as CaCO3 -

Total Anions 276 11. Total Hardness (as CaCO3) 138 12. Permanent Hardness (as CaCO3) - 13. Temporary Hardness (as CaCO3) 138 14. Methyl Orange Alkalinity (as CaCO3) 200 15. Phenolphthalein Alkalinity (as CaCO3) - 16. Iron (Original) (as Fe) - 17. Iron (in solution) (as Fe) 1.0 18. Manganese (as Mn) - 19. Ammonia, free (as NH3) - 20. Carbon Dioxide free (as CO2) - 21. Silica (in solution (as SiO2) 20.0 22. Dissolved Oxygen (O2) - 23. Suspended Solids - 24. Dissolved Solids 438 25. pH at 25 °C 7.5 – 8.0 26. Organic Matter (in terms of Oxygen absorbed

from acid permanganate solution in 4 hours) 2.0

27. Appearance Turbid 28. Odour Nil 29. Turbidity 500 NTU

Source : WBPDCL


Sagardighi TPS, WB

Annexure – 5.2

ESTIMATION OF CONSUMPTIVE WATER REQUIREMENT For 2 x 500 MW + 1X660 MW Coal Based Extension Units 3, 4 & 5 at Sagardighi, Dist. Murshidabad in West Bengal

(m3/hr)

(m3/hr)

(m3/hr)

(m3/hr)

1. a. Heat Cycle Make-up b. Chemical Feed System c. Make-up Reqmt. for Closed Circuit Cooling System d. CPU Regeneration e. H2 Generation Plant f. Reject Water from DMRO System g. Regeneration Waste from MB Exchanger

110 6 6

15 10 26

2

Sub-Total : 175 175 2. a. Potable Water for plant

b. AC Plant Make-up c. Chemical Cleaning Waste (Intermittent) d. (UF+ Filtration) Backwash

17 10

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Return to clariflocculation plant

Sub-Total (1 + 2) : 281 281 3. a. Cooling Tower Make-up Requirement

b. Ventilation System c. Service Water d. Ash Handling System- Sealing e. Coal Handling - Sealing f. DG Set g. Fire fighting h. FGD + SCR (For Unit # 5)

4043 115 270

50 20 10

- 120

CTBD - 798, COC- 5 Add: 558 m3/hr from CTBD-Ash Water Make-up Add: 150 m3/hr from CTBD- DE/DS Add: 90 m3/hr from CTBD- Plantation

Sub-Total (1 + 2 + 3) : 4909 4. a. Desludging (To Ash Slurry Sump) 146 30 m3/hr return to clariflocculation plant from ash sump

Sub-Total (1 + 2 + 3 + 4) : 5055 5055 5. a. Evaporation loss in reservoir

b. Reuse of water from ash sump & filtration plant 173

(-) 109

GRAND TOTAL : 5119 50.2 Cusec


Sagardighi TPS, WB

Annexure – 5.3

PROXIMATE ANALYSIS OF COAL (As received Basis) Sl. No. Description Symbol Design

Coal Worst Coal

Best Coal

Range of Adequacy Coal

1. Total Moisture TM% 15.00 18.00 12.00 12 - 18 2. Ash A% 40.00 46.00 36.00 33 - 46 3. Volatile Matter VM% 19.00 18.00 22.00 23 – 18 4. Fixed Carbon FC% 26.00 18.00 30.00 31 - 18 ULTIMATE ANALYSIS (As Received Basis) 1. Carbon C% 29.73 23.08 37.32 40.60-23.08 2. Hydrogen H2% 3.70 3.54 3.92 4.02-3.54 3. Nitrogen N2% 1.80 1.45 1.60 1.40-1.45 4. Oxygen (by difference) O2% 8.66 6.70 8.32 8.12-6.70 5. Sulphur S% 0.50 0.60 0.40 0.40-0.60 6. Carbonates CO3% 0.58 0.60 0.40 0.03-0.04 7. Phosphorous P2% 0.03 0.03 0.04 0.03-0.04 8. Total Moisture TM% 15 18 12 12-18 9. Ash A% 40 46 36 33-46 10. Total % 100 100 100 11. Gross Calorific Value (as

received basis) GCV

kCal/kg 3300 2800 4000 4300-2800

12. Hard Grove Index HGI 55 50 60 50-65 13. YGP Index mg/kg 95 110 80 ASH ANALYAIS 1. Silica (SiO2)% 59.79 61.30 56.70 62.00 – 56.00 2. Alumina (Al2O2)% 25.36 26.00 23.00 28.00 – 23.00 3. Iron Oxide (Fe2O2)% 7.20 6.00 1000 6.00 – 10.00 4. Titanium (TiO2)% 1.20 1.00 1.50 1.00 – 1.70 5. Phosphoric Anhydride (P2O5)% 2.60 1.50 3.00 1.00 – 3.00 6. Lime (CaO)% 0.88 0.50 1.50 0.50 – 1.70 7. Magnesium (MgO)% 0.55 0.40 1.00 0.40 – 1.10 8. Sulphuric Anhydride (SO2)% 1.20 0.50 1.40 0.50 – 1.70 9. Alkalis (by difference) (Na2O+K2O)% 1.22 0.80 1.40 0.60 – 1.80

ASH FUSION RANGE (Under reducing atmosphere) 1. Initial Deformation Temp. IDT °C 1100 1100 1100 1100-1150

2. Hemispherical Temp. HT °C 1300 1250 1350 1250-1400 3. Flow Temperature FT °C 1400 1400 1400 1400-1450

Source : WBPDCL

FOR 1X 660MW (P -III) E U 5 SAGARDIGHI T P S T D . M W.B. · westbengal...

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