WEST BENGAL POWER DEVELOPMENT CORPORATION LTD. FEASIBILITY REPORT FEASIBILITY REPORT FOR 1 X 660 MW (PHASE-III) EXTENSION UNIT 5 SAGARDIGHI THERMAL POWER STATION AT SAGARDIGHI, DIST. MURSHIDABAD, W.B. March 2016 March– 2016 DEVELOPMENT CONSULTANTS PRIVATE LIMITED DEVELOPMENT CONSULTANTS PRIVATE LIMITED CONSULTING ENGINEERS 24 PARK STREET : KOLKATA-700016 : INDIA
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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
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
2
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
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
1 - 2
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.
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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.
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
2 - 1
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
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
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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:
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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.
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
3 - 1
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.
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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.
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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.
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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
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.
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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.
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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.
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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.
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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.
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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.
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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.
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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)
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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]
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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.
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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• 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
Feasibility Report for 1X660 MW Phase-III Extension Unit- 5
Sagardighi TPS, W.B.
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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
Feasibility Report for 1 x 660 MW Phase-III Extension. Unit-5
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
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
Feasibility Report for 1 x 660 MW Phase-III Extension. Unit-5
Sagardighi TPS, WB
Annexure – 5.3
PROXIMATE ANALYSIS OF COAL (As received Basis) Sl. No. Description Symbol Design