1 SALIENT FEATURES OF 2x660MW ENNORE SEZ STPP PROJECT NAME OF THE PROJECT Ennore SEZ project of 2x660MW coal

l based super critical thermal power project at ash dyke of North Chennai Thermal Power Station (Kattupalli) The identified site is located about 35 Kms northern side from Chennai city and located near the Ennore Multi Product Special Economic Zone proposed by TIDCO in Vayalur Village in Thiruvallur District. The site is located between latitude, 13 degrees 17 to 13 degrees 18 North and Longitude 80 degrees 18 to 80 degrees 19 East. 500 acres under the possession of TNEB Application submitted to Ministry of Coal. Firm Linkage not yet obtained. Hence MoU has already been signed with MMTC for the supply of import coal (4.50 Million Ton per annum) Yet to be obtained. Chennai at a site(approx.) distance of 60km from

LOCATION

LAND AVAILABILITY COAL LINKAGE

MOEF & AVIATION CLEARANCES Nearest Airport Nearest railway station Nearest sea port Chimney Project schedule UNIT 1 & UNIT II Zero date of the Project Commissioning of Unit TECHNICAL DATAS:

Athipattu Pudunagar on Chennai-Howrah route 5km from site Ennore Port (5kms) 275 m high, twin flue RCC Chimney

Date of issue of LOA to the EPC Contract 4 months for arranging finance Plus 36 months for Commissioning i.e 40 months from zero date.

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SCOPE AND BRIEF DESCRIPTION OF WORK The scope of Contractor shall include complete design, manufacture, packing, assembling, testing at manufacturers work, supply for site, storage at site, erection, testing and commissioning of all electrical equipments required for the main plant (BTG) and Balance of plant (BoP) auxiliaries complete with all materials and accessories for efficient and trouble free operation of Two (2) units of 660 MW including external coal handling system upto JTB-3 (ECHS) and sea water intake system (SWIS). 1.0 MECHANICAL

Steam Generator(s) (SG) Package: Type shall include all equipment required for two (2) numbers of once through, single/double pass (tower type/two pass type either spiral wall (inclined) or vertical plain/Riffled type water wall tubing). The SG design shall be direct pulverized coal fired, top supported, single reheat, radiant furnace, dry bottom, balanced draft furnace and shall be suitable for outdoor installation. The evaporator shall be suitable for variable pressure operation from sub critical to supercritical pressure range. RATING OF STEAM GENERATOR(S) (BMCR PARAMETERS): 1. 2. 3. 4. 5. 6. Steam flow at superheater outlet Pressure at HP Turbine inlet (at inlet to mainsteam strainer) Pressure at superheater outlet header Steam temperature at superheater outlet Steam temperature at reheater outlet Feed water temperature at economiser inlet 2100 TPH with following parameters Atleast 247 kg/cm2(a) At least 256 kg/cm2(a) At least 568C At least 596C Not less than 296C (To be optimized by bidder)

Note : BMCR flow will atler with increase in steam parameters, Bidder will furnish the value according to steam parameters selected.

STEAM SEPERATOR(S)

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a) b) c)

Design Code Design Temperature Design Pressure

IBR Max. fluid temperature plus 40C (Min.) 1.05 times the max. operation pressure or highest set pressure of the spring loaded safety valve for full discharge whichever is higher

Steam Separator construction shall have: a) Materials as specified at clause no 1.19 of this section to suit maximum design pressure / temperature. b) Fusion welded construction with welded hemispherical dished ends. c) Nozzles for Steam/Water connections and tappings for instrumentation, sampling and other mountings/fitting etc d) Nozzles/tapping to comply with heat treatment, weld and other requirements as per ASME Section I/BS 5500 e) Hand hole with forged steel cap. f) Minimum load with separator dry shall be 30-40 % TMCR (As per Manufacturers proven practice). BOILER STARTUP RECIRCULATION AND DRAIN WATER SYSTEM Boiler start-up recirculation & drain system shall be provided with start-up drain re-circulation pump and alternate drains to Atmospheric flash tank. 3x50% condensate pumps shall be provided for pumping the flash tank condensate to turbine condenser. SUPER HEATERS & REHEATERS Superheater(s) and Reheater(s) shall be designed, suitably sectionalized and positioned to comply with the following, for the specified load(s), coal(s) and for normal, upset, most adverse and other operating conditions. 1. Maximum average flue gas 12 m/sec. (The maximum velocity with 25% excess air at localized velocities across the economizer outlet cross- section shall not exceed

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4 13m/ sec.) Maximum allowable tube metal skin temperature : 40 degree Celsius below oxidation limit for the tube metal\ Means of Temperature Control a) SUPER HEATERS: Spray Water attemperation, (utilizing water tapped off from downstream side of HP heaters or intermediate banks of economizer or Economizer outlet). Tapping of spray water upstream of top HP heater is not allowed. b) REHEATERS * Tilting of burners/gas biasing/gas recirculation (gas to be tapped off after ID fans), spray water attemperation (utilizing water tapped off from interstage of BFP) * Note: In case gas recirculation system is offered for reheat tem.control, minimum 2x100% gas circulation fans with atleast 20% margin on flow and 44% margin on head over calculated maximum requirement of fan flow and head respectively shall be provided for each steam generator. ECONOMIZERS Non-steaming type with parallel cross flow or counter flow arrangement. RAW COAL FEEDERS : Gravimetric, belt type with minimum size of 36" COAL PULVERIZERS:: Classification Vertical Spindle No. of Mills Type Bowl Mill Adequate to achieve 100% TMCR for all specified coal(s) and all operating conditions but not less than Eight (8) mills.

2.

3.

FD FANS /ID FANS/ PA FANS: Two (2) nos. of axial type, constant speed FD fans, fans rotational speed 1500 rpm max. Two (2) nos. ID fans (Axial type, constant speed or Radial type with variable speed) fans rotational speed 600 rpm max.

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5 Two (2) numbers of two stage, constant speed, variable pitch, axial/radial type with variable speed. PA fans type of blades for each steam generator with stream lined/Aerofoil bladed type, designed to withstand high bending and axial load. COAL BURNERS Low Nox type Coal Burners (total Nox emission fuel as well as thermal Nox shall not exceed 260 gms/giga joule of heat input of the boiler) REGENERATIVE AIR PRE-HEATER (RAPH) (TRISECTOR) Two (2) numbers Trisector air preheater for primary and secondary air system PROVISION FOR FUTURE INSTALLATION OF FGD SYSTEM A flue gas desulphurization (FGD) system may be installed by the Employer in future to meet the requirements of pollution control. Following provisions need to be kept by the Contractor for this purpose: a) Suitability of duct between ID fan and chimney for future interconnection of FGD system with minimum modification b) The ducting and supporting structure to be designed to take care of future Guillotine damper to be installed between the two tap offs before chimney. 2.00 ELECTRICAL GENERATORS TYPE Three phase, horizontal mounted indoor installed, two-pole, class F winding insulation, Stator water/Hydrogen cooled, cylindrical hydrogen cooled rotor type, machine with brushless excitation. Directly driven by steam turbine at rated speed conforming to IEC 60034-1, 60034-3 or other equivalent standard. GENERATOR RATING Generator and its excitation system shall have a capability at least matching the declared maximum continuous rated output of the associated steam turbine (for the secondary cooling water inlet temperature of 39 deg C) at all power factors between 0.85 lagging and 0.95 leading with +3% to -5% frequency variation, terminal voltage variation of +/- 5% and combined voltage & frequency

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6 variation of 5% (absolute sum). It shall be ensured that when the Generator is working at this capability and cooling water inlet temperature is 39 deg C, no part of the Generator shall attain a temperature in excess of the temperature limits specified for class B insulation as per IEC-60034. EXCITATION SYSTEM: Brushless excitation system GENERAL TECHNICAL PARTICULARS FOR GENERATOR Sl. No. 1. 2 3 4 5 6 7 8 9

Parameters Capacity (MVA) Power Factor Terminal voltage, KV (depending on manufacturers std) Frequency Speed Short circuit ratio (With zero negative tolerance). Efficiency Insulation class of winding Temperature rise limit class

Rating 776.47 (minimum) 0.85 (lagging) 18~27 kV 50 Hz 3000 rpm > 0.48 > 98.5 % Class F Class B

Basic insulation levels Nominal Voltage (kV) 400 kV 11 kV 3.3 kV Symmetrical short circuit ratings

BIL kV (peak) 1425 75 40

The three phase symmetrical short circuit ratings of the switchgear at different voltage levels shall be as indicated in the Table below: Voltage level 400 kV 11 kV Symmetrical Breaking Capacity 63 kA for 1 sec 50 kA for 3 sec Making Capacity 163 kA 125 kA

2.

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7 1. 2. 3. 4. 3.3 kV 415 V 220 V DC 48 V DC 40 50 25 10 kA kA kA kA for for for for 3 1 1 1 sec sec sec sec 100 kA 125 kA -

TRANSFORMERS: Description QTY GENERATOR TRANSFORMER A bank of three nos. single phase of 275 MVA each, having a voltage ratio of 420/3KV STATION TRANSFORMER Qty* , 3 phase, *MVA, having a voltage ratio of 400/11.5KV (Bidder to indicate the qty & MVA) UNIT TRANSFORMER Qty * , 3 phase, .MVA having a voltage ratio of generated voltage/11.5KV (Bidder to indicate the qty &MVA) UAT Qty * , 3 phase, MVA having a voltage ratio of generated 11/3.6KV (Bidder to indicate the qty &MVA)

SERVICE TRANSFORMERS Cast Resin, Dry type, three (3) phase, transformers with all fittings and accessories for suitable rating to be decided by the contractor, with voltage ratios 11/0.433 kV or 3.3/0.433 kV,

400 kV Gas Insulated Substation (GIS) is proposed The scope covers design, manufacture, assembly, testing at manufacturer's works before despatch, packing, marking, shipping, erection, testing and SF6 GIS, Gas Bus Ducts and ancillary equipments as specified here under. commissioning of factory assembled, metal-enclosed, Insulated

The GIS shall have one and a half bus configuration and will comprise following bays/ circuits. a) Two (2) Generator Transformer bays

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8 b) One (1) Station transformer bay c) Four (4) Line bays d) One (1) Bus Coupler bay e) Two (2) Bus VTs f) One (1) Bus Reactor bay g) One (1) equipped bay for future GT h) Two (2) equipped bays for future lines. The switchgear shall be capable of future extension on both sides, without requiring a complete shutdown. SUBSTATION AUTOMATION SYSTEM (SAS) FOR 400 KV GIS SWITCHYARD The SAS shall be a computer-based system that shall integrate independently operating subsystems, such as Bay Control Units, Bay Protection Units, Metering, and alarm annunciation, into a unified data acquisition, monitoring, protection and control system in the substation. This consists of Human Machine Interface with process data base. 220 V DC POWER SUPPLY SYSTEM is required for supplying power to essential unit auxiliaries, control, protection, interlock and annunciation. As such the following shall be provided. a) 2 X 100% set of 220V Ni-Cd battery with associated float cum boost charger for main plant and station loads. b) 2 X 100% set of 220V Ni-Cd battery with associated float cum boost charger for Coal Handling plant. c) 2 X 100% set of 220V Ni-Cd battery with associated float cum boost charger for Ash handling plant.
d) 2 X 100% set of 220V Ni-Cd battery with associated float cum

boost charger for sea water intake pump house. DIESEL GENERATORS 2 x 100 % capacity DG sets (1750 KVA capacity) shall be provided for catering to the emergency supply requirements of the main plant as well as auxiliaries of
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9 each unit ALL MOTORS above 10KW with S1 duty with ENERGY EFFICIENT LEVEL IE 2 as per IS 12615:2011 3.0 CONTROL AND INSTRUMENTATION

The Control & Instrumentation shall be furnished, erected and commissioned and all other services shall be performed by the bidder as covered under this specification and this work shall be fully in compliance with the requirements stated herein in the tender specification for following equipments/systems/subsystems and shall not be limited to the following:a) Boiler & its Auxiliaries 1. 2. 3. 4. 5. 6. 7. 8. 9. b) c) Boiler integral controls Burner Management System/ FSSS SADC System Soot Blowing System Auxiliary P.R.D.S. System etc. Mills Control H.P. Bypass System BFP Controls & TSI Other controls as required.

Electrostatic Precipitator (Requirement of controls have been defined in ESP specifications elsewhere). Turbine and Generator set & its auxiliaries. 1. TG set integral control 2. Automatic Turbine Run Up Control System 3. Turbine Stress Evaluator control system 4. Turbine Governing System (DEHC) & TSI 5. Automatic Turbine Tester 6. L.P.Bypass System 7. Other controls as required.

d) e) f) g) h)

HP/LP Heater & Deaerator. Power Cycle pumps. Turbine Driven & Motorised BFP Power cycle piping and valves Circulating Water Pumps

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10 i) j) k) l) m) n) o) p) q) r) s) t) Auxiliary Cooling Water, DMCW System & DM Makeup system Condensate Polishing Unit Chemical dozing system On line condenser cleaning System. Control valves and dampers with actuators Venturi pipes / Flow elements Field instrumentation for Compete plant. Complete Instrumentation & Control cables including all data cables, special cable, fiber optical cables required for power plant & cable trays, raceway. Plant wide area Network including complete MIS system, PC, hardware & Software and ERP system. Complete control panels & instruments in Central & Local control room. Complete C&I for off-site packages including PLC/Relay based controlsystem, UPS, 24 V DC system, Field instruments, Cables, cable trays etc. All type of Electrical System as mentioned below (All details, SOE, status shall be in DDCMIS, Requirement of controls & operation have been defined in specifications elsewhere). i. Generator Transformer, Station Transformer and Unit Auxiliary Transformer ii. 6.6 KV Switchgear & Bus duct, LT switchgear, LT Transformer. iii Generator Bus duct iv. Bus Transfer Scheme v. Protection System for Generator, Generator Transformer, Unit Auxiliary Transformer, Station, Transformers and motors and Generator synchronizing scheme. vi. Any other electrical system as per requirements. Providing Engineering Drawings, documents, licensed copy of Softwares and development tools, data, instructions, operation and maintenance manual etc for Owners review/approval/record. Arranging for Owners Inspection and testing of manufactured as well as bought out items at the respective works. Packing and Transportation of Instruments, equipments, accessories and erection hardwares, tools from the Manufacturers works to the site, including transit insurance.

u)

v) w)

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11 x) y) z) aa) bb) cc) dd) ee) ff) Receipt, storage, preservation and conservation of instruments, equipments and erection hardware at the site. Fabrication of Site-Constructed Items. Pre-assembly (if any), erection, testing and commissioning of all the equipments and instruments in totality (including erection hardware, accessories/devices etc.). Performing availability tests and Performance and Guarantee tests on the completion of Commissioning. Furnishing of spares, tools and tackles, test and Laboratory Instruments. Fulfilling post commission liabilities. Arranging training of Owners personnel of different categories at Equipments manufacturer works. Other Activities detailed in the subsequent sections of the technical specification. Prepare and submit all approved and as built drawings both in hard and soft copies.

4.00 SALIENT FEATURES OF BOP : 1. SEA WATER INTAKE SYSTEM

Source of Water : Bay of Bengal Number of Pumps : 4 x 33% (3W + 1S) Type of pumps : Vertical Turbine Pumps. Provision : installation of additional pumps for future unit. Pumps to be housed in Sea Water Intake pumphouse.

2. SEA WATER TREATMENT PLANT

Pretreatment Plant - comprising of cascade aerator, stilling chamber, clarifier and chemical dosing system. Clarified Water Reservoir Capacity 5000 cum housing 2 x 100% RO stage I supply pumps. RO Stage I comprising of 5 Nos (4W +1S) RO Stage I Permeate Tank Capacity .. cum or 12 hrs storage whichever is higher housing Two (1W+1S) RO Stage II Supply pumps. RO Stage II 2 x 60% RO Modules and .. cum RO Stage II Permeate Tank.

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DM Plant - Three (2W+1S) RO Stage II Permeate water Pumps, Three (2W+1S) capacity streams of MB Units, Two DMWST, each of . cum capacity.

3. ELECTROCHLORINATION

CW System - 2 x 100% sea water booster pumps, 2 x 100% capacity automatic self cleaning filters, 2 x 100% Transformer rectifiers for providing DC current and 2 x 100% Sodium hypochlorite Generators, Two(2) Nos Sodium hypochlorite Storage tanks each of capacity 15 m3(min) and 2x100% Sodium hypochlorite dosing pumps. Sea Water Intake System - 2 x 100% capacity sea water booster pumps, self cleaning filters, hypochlorite dosing pumps and Two(2) Nos Sodium hypochlorite storage tanks, each of capacity 15 m3(min)

4. CONDENSATE POLISHING SYSTEM

4 x 33% Full flow Condensate Polishing for each unit (Total eight vessels).

5. CIRCULATING WATER SYSTEM (with NDCT and 1.3 Cycle of Con-

centration)

Six (6 W + 2S) CW Pumps with drive motors, base frame & foundation bolts etc. Three (2W +1S) vertical Blowdown pumps with drive motors, base frame & foundation bolts etc. Associated piping & Valves. CW Pipe shall be RCC Duct.

6. ACW & DMCW SYSTEM 2 (1W+1S) per unit Total 4 Nos ACW Pumps. 3 (2W + 1 S) DMCW Pumps for each unit Total 6 nos for TG & BOP Auxiliaries. 2 (1W + 1 S) DMCW Pumps Total 4 nos for SG auxiliaries. 3 x 50% PHE for TG & BOP auxiliaries of each 800 MW unit . Total no. of PHEs is six (6).

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13 2 x 100% PHE for SG auxiliaries of each 800 MW unit . Total no. of PHEs is six (4).

7. NATURAL DRAFT COOLING TOWER

Two (2) RCC NDCT Cap : CT Capacity m3/hr Cooling Range : 10 deg C 20% Wet Bulb Temperature : 27 8.50 C

8. FIRE PROTECTION DETECTION & ALARM SYSTEM

9.

Hydrant System for all areas HVWS System for Transformers, MOT, Boiler Burner Front, Turbine Oil tanks, DG Set, Boiler feed pump oil tanks, etc. MVWS for all coal conveyors, cable vaults, HDO/ LDO storageTanks, ESP TR sets etc Foam Protection System for HFO/ LDO Tanks Inert gas Flooding system for Control Room Portable Fire Extinguishers Fire Detection System Fire Water Pumphouse & Tanks 3 Motor driven pumps & 3 engine driven pumps for hydrant & spray service. Two Jockey pumps One RCC fire water storage tank Booster pumps for boiler COAL HANDLING SYSTEM As detailed in the Standing committee note.

10.FUEL OIL HANDLING SYSTEM 5 ( 4W+1S) HFO and 2 (1W+1S) LDO Unloading pumps HFO/ LDO unloading manifold One 2000 KL HFO Tank One 1000 KL LDO Tank Oil Water Separator Drain oil tank & pumps

11.ASH HANDLING SYSTEM

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Dry disposal of fly ash & conventional wet bottom ash disposal

12.CRANES & HOISTS EOT Cranes in turbine hall, CW Pumphouse, Sea Water Intake Pumphouse, Ash Compressor House, Ash Water Pumphouse, Ash Slurry Pumphouse, Ash Compressor House, ash Water Recovery pumphouse, clarified Water Pumphouse, RO Stage I Permeate Pumphouse, Filter water Pump house, Air compressor room, DG Room, Workshop, Boiler Feed Pump house, Workshop building and stores Hoists in other areas

13.COMPRESSED AIR SYSTEM Three (2W+1S) oil free multistage rotary screw compressors for IA System for each 800 MW unit Three (2W +1S) Air Drying plants for each 800 MW unit Three (2W+1S) oil free multistage rotary screw compressors for SA System Four (4) vertical Air Receivers for IS system and & Four (4) vertical Air Receivers for SA sytem

14.AIR CONDITIONING SYSTEM Centralized chilled water system for central control room comprising of 2 x 100% chilling units, 2 x 100% condensing units, 2 x 100% condenser water pumps, 2 x 100% chilled water pumps, 2 x 100% FRP cooling towers 2 x 100% DX type AC plant for Air handling units (per AHU room). 2 x 100% package air conditioners for all other control rooms. 2 x 100% Ductable split units for admin & service building. 2 x 100% split units for weigh bridge control room, ETP control room, Fire station bldg control room & office areas & meeting room of workshop building. 2x50% fresh air fan unit per AHU room

15.VENTILATION SYSTEM Evaporative Ventilation for TG Building

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15 Unitary Air filtration for ESP building General Ventilation for other areas, 2 x 100% or 3x50% Air washers 2 x 100% Unitary Air Filtration Units.

16.ELEVATORS

One (1) Rack & Pinion Elevator of 400 Kgs for Chimney One (1) Rack & Pinion Elevator of 2000 Kgs for TT 5 One (1) Rack & Pinion Elevator of 2000 Kgs for Crusher House One (1) Rack & Pinion Elevator of 2000 Kgs for JTB-5 Four (4) Conventional Passenger Cum Goods Elevator of 3000 Kgs for Steam Generator and auxiliaries. Two (2) Conventional Passenger Elevator of 1088 Kgs for Steam Generator. Two (2) Conventional Passenger Elevator of 680 Kgs for TG Building. Two (2) Conventional Passenger Elevators, each of 680 Kgs for Service Building. One (1) Conventional Passenger Elevator of 680 Kgs for admin building. One (1) Conventional Passenger Elevator of 680 Kgs for ESP Control building. One (1) Rack & Pinion Passenger Cum Goods Elevator of 1000 Kgs for Flyash Silos. *****

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