SGTPS BIRSINGHPUR, UNIT NO. 1 & 2 (2X210 MW) · 2017-11-25 · SGTPS BIRSINGHPUR, UNIT NO. 1 & 2 (2X210 MW) Petition for Approval of R&M works at Unit No. 1&2, SGTPS, Birsinghpur

PETITION FOR APPROVAL OF

COMPREHENSIVE RENOVATION &

MORDERNIZATION WORKS

AT

SGTPS BIRSINGHPUR, UNIT NO. 1 & 2

(2X210 MW)

Petition for Approval of R&M works at Unit No. 1&2, SGTPS, Birsinghpur

April, 2017

M.P. Power Generating Co. Ltd Page 2

INDEX

S.No. PARTICULARS Page No.

1. PETITION 3 - 42

2. PRAYER 43

3. AFFIDAVIT 44 - 45

4. AUTHORISATION 46

5. MPERC Fee Details 47

6. LIST & ANNEXURES 48 - 68


April, 2017


BEFORE THE M.P. ELECTRICITY REGULATORY COMMISSION BHOPAL

Petition No of 2017

IN THE MATTER OF

Petition for approval of Renovation & Modernization Works at SGTPS

Birsinghpur, Unit 1&2 (2x210MW), under proviso 21 of MPERC (Terms

And Conditions For Determination of Generation Tariff) Regulations, 2015

{RG-26 (III) of 2015}

PETITIONER M.P. Power Generating Company Ltd, Jabalpur.

RESPONDENT

Vs

M.P. Power Management Company Ltd, Jabalpur.

The above named Petitioner, M.P. Power Generating Company Ltd

(MPPGCL) respectfully submits as under:-

1. The petitioner is wholly owned company of Government of M.P

engaged in generation of electricity in the State of Madhya Pradesh. It

is a successor entity of erstwhile Madhya Pradesh State Electricity

Board (MPSEB).

2. The Company has been incorporated as part of implementation of the

power sector reform in M.P., initiated by the Government of MP. The

Company has taken over the generation activities of MPSEB. The

company while operating and maintaining its existing Units and is also

constructing new power plants for increasing generating capacity in

the State of Madhya Pradesh. The Company is registered under

Companies Act 1956 and was incorporated on 22.11.2001. Its

registered office is at Shakti Bhawan, Rampur, Jabalpur.

3. The activities of Generation, Transmission and Distribution have been

looked after earlier in the State of M.P. by the integrated utility i.e.


April, 2017


MPSEB constituted under Section 5 of Electricity (Supply) Act 1948.

The Government of MP enacted M.P. Vidyut Sudhar Adhiniyam 2000

and in the spirit of said Act, the unbundling process of the MPSEB was

initiated by registering the following five Companies;

(i) Madhya Pradesh Power Generating Co. Ltd., Jabalpur

(MPPGCL) (GENCO).

(ii). Madhya Pradesh Power Transmission Co. Ltd., Jabalpur

(MPPTCL) (TRANSCO).

(iii). Madhya Pradesh Poorva Kshetra Vidyut Vitaran Company

Ltd. Jabalpur (MPPKVVCL) (EAST DISCOM).

(iv). Madhya Pradesh Madhya Kshetra Vidyut Vitaran Company

Ltd. Bhopal. (MPMKVVCL) (CENTRAL DISCOM).

(v). Madhya Pradesh Paschim Kshetra Vidyut Vitaran Company

Ltd. Indore (MPPKVVCL) (WEST DISCOM).

4. The above mentioned five companies which were registered in

November 2001 entered into Operation & Management Agreement

with MPSEB and they worked as agent of MPSEB from July 2002 to

May 2005. The companies started independent functioning w.e.f.

01.06.2005 under Cash flow mechanism as per order dated 31.05.2005

of State Government.

5. A sixth Company, namely MP Power Trading Company Ltd, was

incorporated as per the State Government’s Notification dated

03.06.2006 specifying the functions of TRADECO for purchase of

electricity in bulk from Generating companies /Traders, from within &

outside the State and to supply electricity in bulk to the Electricity

Distribution Companies in the State of Madhya Pradesh.

6. GoMP vide letter No. 6074/13/12/02 dated 29.03.2012 has changed the

name of M.P. Power Trading Co. Ltd. to M.P. Power Management

Company Limited. It has been made the holding company for all the

DISCOMS of M.P. Further, GoMP, vide its Notification dated

26.04.2012, has merged M.P. State Electricity Board with M.P. Power

Management Company Limited.


April, 2017


7. MPPMCL and the three DISCOMS of MP have entered into a

management and corporate functions agreement on 05.06.2012,

whereby the three DISCOMS have engaged MPPMCL to represent

them in all the proceedings relating to power procurement and tariff

petitions filed or to be defended before CERC, MPERC and other

regulatory authorities, Appellate Tribunals, High Courts, Supreme

Court and CEA etc.. Therefore the three DISCOMS have not been made

as respondents, separately.

8. GoMP vide its notification dated 03.06.2006 has provided that MP

Tradeco, now MP Power Management Company Ltd., shall purchase

entire power from the Genco (MPPGCL) at the tariff to be determined

by MPERC.

9. MPPGCL entered into Power Purchase Agreement (PPA) with MP

Tradeco (now M.P.P.M.C.L.) on 29.11.2006. The PPA provides that the

tariff payable by Tradeco to Genco and terms & conditions related

thereto shall be as determined by the State Commission. MPPGCL has

therefore raised the bills of energy sold to Tradeco since 1.6.2005 as per

the tariff determined by Hon’ble Commission from time to time.

10. MPPGCL is having various Thermal and Hydro power

stations/projects in the state of Madhya Pradesh. Sanjay Gandhi

Thermal Power Station (SGTPS) is one such power station of the

Petitioner located at Birsinghpur, Dist Umaria, Madhya Pradesh.

11. SGTPS, Birsinghpur is located 10 Km from Birsinghpur-Pali Railway

station situated on Bilaspur-Katni section under SECRLY. It has the

Thermal capacity of 1320MW detailed as under :-

Power House

Unit No.

Capacity in MW

CoD Age

in Years Make of TG Set

Make of Boiler

PH-1 1 210 26-Mar-93 24 BHEL ABL

2 210 27-Mar-94 23 BHEL ABL

PH-2 3 210 28-Feb-99 18 BHEL ABL

4 210 23-Nov-99 17 BHEL ABL

PH-3 5 500 28-Aug-08 08 BHEL BHEL

Total 1340


April, 2017


12. As evident from the above table, Unit No. 1 & 2 has almost completed

24 & 23 years of its useful life, respectively.

13. The operating parameter wise past performance of the units are

detailed as under:-

SGTPS Birsinghpur Unit # 1&2 (2 x 210 MW)

Financial Year

PLF %

PAF %

Aux. Cons %

Sp Oil Con ml/kWh

Heat Rate kCal/kWh

2006-07 68.27% 74.13% 10.95% 1.84 3098

2007-08 64.31% 59.13% 10.19% 1.14 3156

2008-09 60.75% 68.46% 10.06% 1.38 3247

2009-10 51.44% 58.44% 11.22% 1.79 3390

2010-11 51.94% 53.96% 11.45% 2.99 3101

2011-12 55.22% 64.17% 10.19% 2.50 2990

2012-13 70.72% 72.24% 9.88% 1.80 3052

2013-14 62.41% 74.86% 10.11% 1.37 3025

2014-15 48.37% 58.34% 10.82% 1.78 3043

2015-16 47.53% 72.30% 10.38% 0.93 2853

2016-17 42.71% 74.46% 10.08% 1.20 2856

14. As per clause 2.3 of Article 2,”Scope of the Agreement” of the Power

Purchase Agreement (PPA) (Annexure-1) with MPTRADECO now

MPPMCL, MPPGCL has to take steps to renovate, modernize,

refurbish, expand and augment capacity in the existing Generating

Stations and projects under construction subject to additional

capitalization approved by the State Commission, duly informed to MP

Tradeco and such additional capitalization shall be included in the

capital cost of the Generating Station.

15. The Energy Department, Government of MP, vide letter No.AF-3-

20/2014/13 Dated 28.01.2017 (Annexure-2) has extended the term

period of above Power Purchase Agreement upto Retirement / De-

Commissioning of Units. The MPPMCL has also intimated the same to

MPPGCL vide letter No 04-01/128 dated 01.02.2017(Annexure-3).


April, 2017


16. Brief Description of PH-1 & 2 SGTPS Birsinghpur.

M/s ABL and M/s BHEL are the Original Equipment Manufacturers

(OEMs) for the Boiler and Turbo-Generator of PH- 1 & 2 of SGTPS

Birsinghpur. The boiler is provided with front & rear firing system.

Condenser cooling system of the unit is designed on once through

cooling system. Power generated from the unit is being supplied to the

State grid. Power is being evacuated at 220KV. The primary fuel is

domestic coal sourced from South Eastern Coal Fields Limited. The

consumptive water for the power plant is being sourced from Johila

Dam. The other details are as under:-

S.No Feature Details

1 Location 10 K.M. from Birsinghpur Railway Station situated on Bilaspur Katni Section of S.E. Rly.

2 Capacity of Power Station PH-1 (2x210MW), PH-2 (2x210MW) & PH-3 (500MW)

3 Source of Water Johila Dam, Area- 1810 Hectare on Johila River

4 Dam Capacity 171 Million Cubic Meter

5 Fuel Primary Fuel:- Coal Secondary Fuel :- Furnace Oil/Light Diesel Oil

6 Coal Source South Eastern Coal Field Limited

7 Coal Area Korea- Rewa Area & Korba Area.

8 Mode of Transport Rail

9 Coal Linkage 63.60 LMT( Approx.) per annum(2007-08)

10 Power Evacuation 200 KV Line

Birsinghpur,Rewa,Satna Birsinghpur, Katni(2) Birsinghpur, Amarkantak(2)

19. EQUIPMENT DETAILS:

19.1. BOILER & AUXILIARIES

(a) BOILER - Manufacturer: ACC-BABCOCK Limited (ABL):-

Boiler Type: Opposed fired, Balanced Draft, Natural Circulation,

Radiant with two passes, Re heater type, Dry Bottom, Furnace

pulverized coal fired boiler.


April, 2017


The design parameters are as under:-

Description Units Design

Parameters

Steam Flow at Final SH outlet T / hr 680

Steam Pressure at SH outlet kg/cm2 156.6

Steam Temperature at SH outlet 0C 540

Re-heater Steam inlet Pressure kg/cm2 39.04

Re-heater Steam inlet Temperature 0C 345

Steam Pressure at RH outlet kg/cm2 37.07

Steam Temperature at RH outlet 0C 540

Feed Water Temperature at inlet of Economiser

0C 245

Feed Water Temperature at outlet of Economiser.

0C 277

(b) FURNACE:- The boiler is equipped with a water cooled furnace of balanced

draft and fusion welded membrane wall construction. It is

equipped with twenty four (24) numbers of coal burners and

twenty four (24) Nos. of light oil burners and four (4) Nos. of

load carrying burners. The size of furnace is as under:-

Description Units Design Parameters

Type - Membrane Walls of water cooled

Width metre 15.85

Depth metre 10.058

Volume Cu. metre 4763

(c) FUEL BURNING EQUIPMENT:-

The boiler is working on a direct firing system. The pulverized

coal is being dried and transported to the coal burners by means

of hot primary air supplied by primary air fans. The boiler is

having front and rear firing system.


No. of PF Burners Nos. 24

No. of Light up oil Burners Nos. 24

Load carrying Oil Burners Nos. 4


April, 2017


(d) CHARACTERISTICS OF DESIGNED FUEL:-


Parameters

Fixed Carbon % 29.7

Volatile Matters % 24.03

Moisture % 8.0

Ash % 38.8

GCV Kcal/Kg 3750

Grind ability Hard Groove Index 50

(e) SUPER HEATER (HEATING SURFACE):-

The super heaters are composed of three sections, Primary,

Platen section and Final super heater. The sizes are as under:-


Parameters

Primary Super Heater - -

a. Horizontal Bottom Bank M2 1919

b. Horizontal intermediate Bank M2 1328

c. Horizontal Top Bank M2 1743

d. Vertical Section M2 307

Platen Super heater M2 82.1

Final Super heater M2 1530

(f) REHEATER /EFFECTIVE HEATING SURFACE:-

The sizes are as under:-


Parameters

Horizontal Bottom Bank & Intermediate Bank

M2 3374

Horizontal Top Bank M2 1737

Vertical Leg M2 307

Re-heater Pendent above Primary Super heater horizontal bank

M2 608

(g) RAW COAL BUNKERS:-

The boiler is provided with six (6) raw coal bunkers. The total

capacity of the bunkers is to meet 8 hour’s requirement at

maximum mills capacity of the unit. The conical portion is also

having lining of stainless steel. Each outlet of the bunker is


April, 2017


provided with an isolation gate which is motor operated. In

addition to the isolation gates, rod gates have been provided to

control the flow of coal from the bunkers.

(h) COAL MILLS:-

The unit is provided with six (6) numbers of coal mills. The rated

capacity of each mill is 27.4 T/hr. The other parameters are as

under:-


Parameters

Type 8.5 E9

Make ABL

Capacity TPH 27.4

Motor KW KW 225

System - Pressurised

(i) ATTEMPERATORS:-

The relevant parameters are as under:-


Parameters

Type Spray Type

No. of Stages Nos. 2

Medium of Spray - Feed water

(j) ECONOMISER:-

The relevant parameters are as under:-


Type Continuous Loop Type

No. of Sections Nos. 2

(k) AIR PRE-HEATER :-

The air pre-heater is of tube type.


April, 2017


(l) COAL FEEDERS :-

Chain link type of raw coal feeder has been provided for each

coal mill.

(m) PRIMARY AIR FANS:-

Six Primary Air (PA) Fans have been provided for each boiler.

Each PA Fan is designed to meet 60% MCR condition of the

boiler. Details are given below:


Parameters

Type of Fans - BAB11

Number of fans per boiler Nos. 6

Capacity m3/sec 22.7

Discharge Pressure mmwg 1216

Temperature of Hot Air 0C 263

Motor Rating kW 390

Method of Regulation - Axial Vane Control

(n) FORCED DRAFT FANS:-

Two Forced Draft (FD) Fans have been provided for each boiler.

Each FD Fan is designed to meet 60% MCR condition of the

boiler. The FD Fans supply combustion air to the boiler, mill air

through PA Fans and tempering air to control the classifier

temperature of the mills. Details are given below:


Type of Fans - Centrifugal double inlet, backward aerofoil bladed

Number of fans per boiler Nos. 2

Capacity m3/sec 130


Temperature of Air 0C 49

Motor Rating kW 775

Method of Regulation - Vane control

(o) INDUCED DRAFT FANS :-

Two Induced Draft (ID) Fans have been provided for each boiler.

Each ID Fan is designed to meet 60% MCR condition of the

boiler. Each ID Fan evacuates flue gases through parallel paths


April, 2017


of ESP and discharges them into stack through ducting. Details

are given below:


Type of Fans - Centrifugal, double inlet backward aerofoil bladed

Number of Fans per Boiler Nos. 2

Capacity m3/sec 209.8


Temperature of Flue Gases 0C 160

Motor Rating kW 988

Method of Regulation Variable Speed Hydraulic coupling

(p) WALL BLOWERS AND LONG RETRACTABLE SOOT

BLOWERS (LRSBS):-

As per original design, Wall and Long Retractable Soot Blowers

(LRSBs) are available but not being used since commissioning

for cleaning the soot deposited on the heating surfaces of the

water walls and super heaters respectively. Manual soot

blowing system has been provided. The other features are as

under:-


Parameters

Wall Blowers (Available but not in service)

Make and Model of Wall Blowers - Diamond IR 2D single nozzle short retractable

No. of Wall Blowers per boiler at water walls

Nos. 26

Medium of soot blowing at water walls - Steam

LRSBs

Make and Model of LRSBs - Diamond Power 1K-300 LR

No. of LRSBs per boiler at pendant surfaces of pressure parts

Nos. 28

Medium of soot blowing at pendant surfaces of pressure parts

- Steam

No. of LRSBs per boiler at convection pass tube banks

Nos. 4

Medium of soot blowing at convection pass tube banks

- Steam


April, 2017


(q) ESP :-

Electrostatic Precipitator (ESP) has been installed on the cold end

side of the Air Pre-heater to remove the particulate matter from

the flue gases. The ESP has been provided with Gas Distribution

System, Collecting Electrodes, Discharge Electrodes,

Transformer Rectifier Sets and rapping system. Details are given

below:


Parameters

Make and Model of ESP - ACC-Vickers-Babcock Ltd.

Number of fields per pass Nos. 6

Number of Hoppers per ESP Nos. 18

Dust concentration at outlet mg/Nm3 50

Type of Control Analog

Gas Velocity in ESP m/sec 1.05

Storage Capacity of ESP Hoppers hrs 8

19.2. TURBINE & AUXILIARIES:-

(a) STEAM TURBINE :-

The steam turbine is of three cylinder, 3000 rpm, tandem

compound, condensing type designed to operate on a re-heat

and re-generative feed water cycle. The turbine is provided with

HP/LP bypass system of 60% capacity of Boiler MCR. The

turbine is provided with an electro - hydraulic control system,

automatic turbine run up system and turbo supervisory

instrumentation. The condensing system consists of a surface

condenser of single shell and two pass, divided water box

construction. Cooling water being supplied to the condenser is

of raw water/ clarified water quality. The design parameters of

the steam turbine are furnished below:


April, 2017



Parameters

Pressure of Steam at inlet of ESV of HPT kg/cm2 150

Temperature of Steam at inlet of ESV of HPT

0C 535

Pressure of Cold Reheat (CRH) Steam kg/cm2 38.1

Temperature of Cold Reheat (CRH) Steam 0C 334.8

Pressure of Hot Reheat (HRH) Steam kg/cm2 34.3

Temperature of Hot Reheat (HRH) Steam 0C 535

Pressure at the inlet of LP Turbine kg/cm2 7.1

Temperature at the inlet of LP Turbine 0C 315.1

(b) CONDENSER:-

The condenser is a double pass, horizontal, surface type with

integral air cooling section designed to maintain a pressure of 76

mm of Hg at turbine exhaust with a cooling water temperature

of 33 deg C and an outlet temp of 41.33 deg C. The condenser is

capable of operation with 5% tubes plugged and has hot well

storage capacity of 27.5 m3.


Type of Condenser - Water Cooled Surface Condenser

Total Cooling Surface m2 9656

Number of Cooling Water Tubes Nos. 19208

Material of Tubes - 90-10 Cu Ni

Diameter and thickness of tubes mm 25.4 X 1.245

Cooling Water Quantity through

Condenser m3/h 28500

Cooling Water Temperature at the inlet to Condenser

0C 33

Condenser Vacuum mm Hg 76

(c) EJECTORS :-

The Condenser is provided with one quick starting ejector to

remove large volumes of air for raising the initial vacuum

during the starting of the Unit. Two main ejectors of 100%

capacity each have been provided to remove air and non

condensable gases from the condenser to maintain the required

vacuum in the condenser during the normal operation of the

unit.


April, 2017


(d) CONDENSATE EXTRACTION PUMPS:-

Two (2) Nos. Condensate extraction pumps are of vertical,

multistage, centrifugal and canister type with following design

parameters:-


Make and Model - Weir/En5540 D - 30 A

Type - Vertical, Multistage, Centrifugal, Canister type

Capacity TPH 625

TDH Mlc 201

Speed RPM 1480

Motor Rating kW 500

(e) GLAND STEAM CONDENSER:-

A Gland Steam Condenser has been provided to condensate the

leak-off steam from intermediate chambers of end sealing of HP

and IP turbine, thereby heating the main condensate water. The

Gland Steam Cooler consists of shell, tube bundle and

removable water box.

(f) LP HEATERS AND DRAIN COOLERS:-

Steam turbine is provided with three numbers of low pressure

heaters to increase the temperature of the condensate in stages.

LP Heaters are of shell and tube design and have been placed

vertically. An integral drain cooling section is provided in each

LP Heater. The design details of LP Heaters are furnished in the

table below:-

Heater No. 1 2 3

Extraction Steam taken from LP Turbine LP Turbine LP Turbine

Bled Steam Pressure (Bara) 0.216 0.858 2.37

Bled Steam Temperature (deg C) 62 107 200


April, 2017


(g) DEAERATOR:-

The deaerator is of horizontal spray type. It is designed to

remove dissolved oxygen from the condensate in excess of 0.005

cc per liter. The feed water storage tank has a capacity of 125m3.

(h) BOILER FEED PUMPS:-

The boiler feed pumps are horizontal, multi stage centrifugal

pumps of barrel type, motor driven with hydraulic coupling

taking the suction from the deaerator. The boiler feed pumps

discharge feed water through HP heaters to the economizer of

the boiler. The other parameters are as under:-


Parameters

Make and Model - BHEL/200 KHI-

18/6

No of stages Nos. 6

Capacity TPH 395

Head mwc 2095

Feed water temp 0C 163.36

Minimum flow TPH 100

Method of Speed Regulation - Hydraulic Coupling

Pump Input shaft Power kW 2985

(i) HP HEATERS :-

Steam turbine is provided with two numbers of high pressure

heaters to increase the temperature of the feed water in stages.

The Heaters are of shell and tube design and have been placed

vertically. The design details of HP Heaters are furnished in the

table below.

Heater No. HPH-5 HPH-6

Extraction Steam taken from IP turbine extraction

HP turbine exhaust

Bled Steam Pressure (kg/cm2) 16.03 36.52

Bled Steam Temperature (deg C) 240 290


April, 2017


(j) HP/ LP BYPASS:-

HP/LP bypass system has a capacity of 60% of BMCR (Boiler

Maximum Continuous Rating). HP bypass system has been

provided between the Main Steam Line and Cold Reheat Line.

LP bypass system has been provided between the Hot Reheat

Line and the Condenser. HP bypass water spray has been taken

from the discharge of Boiler Feed Pumps. LP bypass water spray

has been provided from the discharge of Condensate Extraction

Pumps.

(k) TURBINE GOVERNING SYSTEM :-

The turbine is equipped with an electro-hydraulic system (with a

back of hydro mechanical system) of automatic governing for

the smooth and stable operation of turbo-set under all

conditions of operation. The system is designed to sustain full

load dump from the generator. The system is provided with a

quick closing Emergency Stop Valve (ESV), to interrupt the

supply of steam from the boiler and stop the turbine under

emergency conditions.

19.3. ELECTRICAL SYSTEM

(a) GENERATOR:-

The Generator is a 15.75 kV, 50 Hz, 0.85 power factor machine,

directly coupled with steam turbine operating at 3000 rpm, with

static type of excitation system and digital programmable

voltage regulator. The Generator has direct water cooled stator

winding and direct hydrogen cooled rotor winding. The stator

winding cooling water is cooled in a closed cycle cooling system

using DM water, while the hydrogen in the machine is cooled in

gas to water hydrogen coolers mounted inside the machine. The

Parameters of the Generator are briefly mentioned below:-


April, 2017



Parameters

Rated MW Capacity MW 210

Rated MVA Capacity MVA 247

Rated Terminal Voltage KV 15.75

Rated Power Factor - 0.85

Rated Stator Current A 9050

Rated Speed RPM 3000

Rated Frequency Hz 50

Efficiency at Rated Power Output and Rated Power Factor

% 98.55

Excitation Current A 260

Excitation Voltage at Rated Power Output and Rated Power Factor

V 310

Short Circuit Ratio - 0.49

Negative Sequence Current Amp 22

Phase Connection - Double star

Type of Excitation - Static

Method of Cooling the Rotor - Hydrogen

Method of Cooling the Stator - Water

Rated Hydrogen Pressure kg/cm2 3.5

(b) STATION TRANSFORMER :-

One Station Transformers have been provided to meet the

station auxiliary loads of the power plant. The Station

Transformers have been provided with on-load tap changers to

keep the station 6.6 kV voltage constant. Cooling of this

transformer is ONAN/ONAF/OFAF and has 2x50 % separately

mounted radiators and 2x50% oil pumps. The Parameters of the

Station Transformers are briefly mentioned below:-


Parameters

Make - Crompton Greaves

Capacity / Rating MVA 30/40

Voltage Ratio - 220/6.9 KV

Type of Cooling - ONAN/ONAF

Quantity Nos. 1


April, 2017


(c) GENERATOR TRANSFORMER:-

The power output from each Generator is being stepped up to

220 kV through a 250 MVA step up Generator Transformer. It

has 2x50% coolers and 2x50% oil pumps. The Parameters of the

Generator Transformer are briefly mentioned below


Parameters

Make - Telk

Capacity MVA 250

Voltage Ratio - 15.75/240

Type of Cooling - ONAN/ONAF/OFAF

(d) UNIT AUXILIARY TRANSFORMER :-

Unit auxiliary transformers have been provided for meeting all

unit auxiliary loads. The transformers are provided with on-load

tap changers. The Parameters of unit auxiliary transformers are

briefly mentioned below:-


Parameters

Make - Volt amp

Capacity MVA 16

Voltage Ratio - 15.75/6.9

Type of Cooling - ONAN/ONAF

Quantity Nos. 2

(e) ELECTRICAL AUXILIARY POWER DISTRIBUTION

SYSTEM :-

Unit auxiliaries receive their normal power supplies at 6.6 kV

through two unit transformer. For lower rating drives, 6.6 kV is

further stepped down to 415 V by two (2) nos. unit service

transformers. The 415 V distribution systems feed a number of

Motor Control Centers (MCCs) for running 415 V drives. 6.6 kV

unit switchgears are connected to station switchgear for start up

and emergency power supply.


April, 2017


(f) CONTROL & INSTRUMENTATION:-

The existing control system consists of Centum XL Control

system of Yokogawa make. The Turbine Control; monitoring &

protection system including ATRS, TSE, ATT etc. is based on

analog discrete cards as supplied by BHEL. The Boiler

Protection & BMS is Allen Bradley PLC 2-17 based system.

19.4. BALANCE OF PLANT (BOP)

(a) COAL HANDLING PLANT :-

Coal Handling Plant is a common facility which is feeding all the

units of the power plant having a total installed capacity of

2X210 MW. Coal is brought through railways by wagons and is

unloaded by track hoppers. One crusher has been provided for

crushing the coal from 200 mm size to 20 mm size. The plant is

provided with one stacker re-claimer to stock the crushed coal.

The coal stock yard has a storage capacity of 20 days. For

feeding the coal to the bunkers of all the units, two streams of

conveyors having a capacity of 1500 TPH have been provided.

The coal handling plant operates for 16 hrs a day. The other

parameters are as under:-


Length of Track Hopper M 170

No. of streams of conveyor Nos. 2

Capacity of each conveyor T/hr 1500

Type of Crushers - Ring Granulator

Number of Crushers Nos. 4

Capacity of Crushers T/ hr 600

No. of Stacker Re-claimer Nos. 1

Stacking Capacity TPH 1500

Reclaiming Capacity TPH 1500

Storage Capacity of Stock Yard days 20


April, 2017


(b) ASH HANDLING PLANT :-

Ash Handling System is of continuous type. The bottom ash

from the furnace falls into bottom ash hopper having a storage

capacity of 160 Tons. The ash is removed with the help of

submerged Scrapper Chain Conveyors. The ash from the air pre-

heater and economizer hoppers is being disposed off along with

bottom ash. The ash in the form of ash slurry is conveyed

through sluice channels to the ash slurry pump house with the

help of high pressure jets, from where, it is pumped to the ash

pond located at a distance of 2.5 KM. The ash slurry pump

house is provided with 8 numbers of ash slurry pumps of rating

630 m3 /hr, out of which 4 pumps are normally working. The

ash slurry disposal system is having 4 numbers of identical

streams of ash slurry pumps connected to two (2) numbers of

ash slurry pipelines going to the ash pond. Fly ash is collected in

dry form below the ESP hoppers and the same is then conveyed

by vacuum system to surge hoppers from where it is either

conveyed through pressurized system to dry fly ash silos or is

sent to ash pond in the form of slurry. From the dry fly ash silos,

the ash is disposed off through the covered trucks.

(c) RAW WATER SYSTEM :-

The consumptive water for the plant is sourced from Johila dam

made on Johila River. The intake water pump house is installed

with 4 nos. intake pumps of capacity 400 m3/hr, out of which 2

pumps are normally working and the remaining 2 pumps are on

standby.

(d) CW / ACW SYSTEM :-

CW system works on once through cooling system. CW pump

house is a common facility for both the units of the power plant.

There are three CW pumps of capacity 10,000 m3/hr provided

for each unit. One common CW pump is standby for both the


April, 2017


units. Three (3) Nos. ACW pumps of capacity 3000 m3/hr are

provided for both the units.

(e) WATER PRE-TREATMENT PLANT :-

Water Pre-Treatment Plant is a common facility for both the

units of the power plant. Pretreatment plant supplies clarified

water to DM plant, cooling water to the auxiliaries of BOP

system, coal handling plant dust suppression and to the

drinking water system. There are two numbers of clarifiers of

capacity 900 m3/hr to meet all the clarified water requirements

of the whole plant, except DM Plant.

(f) DM PLANT :-

DM plant consists of three streams, each of 60 m3/hr capacity. A

common regeneration system has been provided for all the three

streams. There are three DM water storage tanks common for

both units of 7.5 m (dia.) X 12 m (height).

(g) PLANT AND INSTRUMENT AIR SYSTEM :-

Plant and instrument air system is a common facility for both the

units of the plant. For meeting requirement of instrument air , 5

number of reciprocating compressors (2 working and 3 standby),

each of 18 m3/min capacity and discharge pressure of 8 kg/cm2

have been provided along with dryers for each unit. The air

drying plant for the instrument air has been provided to achieve

a dew point of (-) 40 deg C at atmospheric pressure.

(h) FUEL OIL SYSTEM :-

The fuel oil system has been designed for the use of LSHS but at

present HFO is being used. Three tanks of 2500 m3 each have

been provided for the storage of LSHS and two tanks of 1000 m3

each have been provided for the storage of LDO. The system has

been provided with unloading, transferring and pressurization

pumps along with necessary filters. Fuel oil system has been

provided with heat tracing.


April, 2017


20. Efforts made by MPPGCL

Due to the lower availability, higher Auxiliary consumption and

excess Secondary Oil consumption and increased Station Heat

Rates, the Units of SGTPS PH-1 are incurring commercial losses.

Efforts have been made by MPPGCL to improve upon the loss

by the way of improvement in O&M practices, yet the

performance is not as per MPERC norms. Further improvement

in these Units requires Capital Expenditure. Hon’ble MPERC

has specified procedure, wherein a proper study is to be

conducted through expert agency and a proposal then to be

submitted before Hon’ble MPERC for seeking permission for

Renovation and Modernization of the unit.

Accordingly, an order was placed on M/S TŰV-SŰD South Asia

Pvt. Ltd, Pune to carry out Residual Life Assessment (RLA) and

CA studies of Unit 1 & 2 SGTPS Birsinghpur and to submit

Details Project Reports (DPRs) in accordance with the

Guidelines for Renovation and Modernizations /Life Extension

Works of Coal/Lignite based Thermal Power Stations issued by

Hon’ble Central Electricity Authority, New Delhi in October

2009. The copy of the CEA’s Guidelines is enclosed as

Annexure-4.

Consequently, the DPR’s has been prepared by M/S TŰV-SŰD

South Asia Pvt. Ltd, after carrying out intensive Residual Life

Assessment of the Units. The copy of the Details Project Reports

is enclosed as Annexure-5A & 5B.

21. Works suggested in Detailed Project Reports:-

The consultant M/S TŰV-SŰD South Asia Pvt. Ltd, Pune has

suggested following two options in the DPRs for Renovation &

Modernization:-

(a) Option-I :- It involves broadly replacement of Boiler Re-

heater Banks, Refurbishment of Boiler & BoP auxiliaries /


April, 2017


equipments, Overhauling of Turbine and its auxiliaries

and Electrical, C&I works.

(b) Option-II: - It involves broadly replacement of Boiler Re-

heater Banks, Refurbishment of Boiler & BoP auxiliaries

/equipments, Retrofitting of Turbine with complete

replacement of HP, IP & LP Modules of latest and more

efficient technology, Overhauling of Turbine and its

auxiliaries and Electrical, C&I works.

The details of above mentioned two options are well elaborated

in the annexed unit wise DPRs.

22. Approval of Competent Authority for the said R&M Works:-

Based on the recommendation made by the M/S TŰV-SŰD South Asia

Pvt. Ltd, Pune in Chapter-10 of DPRs, MPPGCL has opted for the

OPTION-II. The administrative approval for the same has been

provided by Board of Directors of MPPGCL in the 87th meeting held on

28.12.2016. The copy of BoD resolution granting approval is annexed as

Annexure-6A.

Further, MPPGCL has approached CEA vide letter No. 07-

09/MPPGCL/R&M/SGTPS/217 dated 10.02.2017 for seeking

necessary approval of above mentioned R&M/LE works for execution

during the 13th Plan Period. The copy of letter is annexed as Annexure-

6B.

23. Conclusion of the studies carried out in Unit No.1 (210MW)

On the comparison of actual operating data captured during

various tests with design data, following has been concluded:-

a) HP Turbine efficiency at design condition works out to be

86.84%. Actual HP Turbine efficiency is 86.52%. Though

actual is very close to design, design efficiency is lower

compared to latest available modern turbine in which

cylinder efficiency up to 88% - 90% is achievable. In view

of above, changing HP module with high efficiency

module will result into improved turbine cycle heat rate.


April, 2017


b) IP Turbine efficiency at design condition is 90.80%

whereas actual efficiency is 83.53%. IP Turbine efficiency

restoration up to 7% may not be possible by overhaul

only. In view of this, it is suggested to change the IP

Module with high efficiency module.

c) Superheater & Reheater Spray: It is noted that

superheater and reheater spray has increased

substantially. This increase may be because of:-

(i) Fouled condition of furnace.

(ii) Less heat pick-up in furnace zone due to non

operation of soot blowers.

(iii) High flue gas exit temperature.

(iv) High superheater and reheater spray.

(v) Higher superheater and reheater spray is

resulting into degradation in turbine cycle heat

rate also.

d) Condenser vacuum is not close to design value due to

poor performance of the ejector system. Condenser is also

suffering from tubes fouling and plugging of tubes.

Increase in condenser CW line DP (0.41 kg/cm2) indicates

the tubes plugging and fouling.

e) HPH-6 performance can be considered as satisfactory and

no need any immediate corrective action. HPH-5

performance is satisfactory in all three zones.

24. In view of above, to generate electricity economically and to improve

reliability, R&M works of critical nature were urgently required to be

implemented in these Units so as to improve their performance to

satisfactory levels.


April, 2017


25. Scope of work (Unit No. 1 SGTPS, Birsinghpur)

The detailed Scope of Works at Unit No. 1 along with its estimated cost

has been worked out, which are detailed below:-

Boiler and Auxiliaries - Unit No. 1 SGTPS

S. No.

R&M Works to be carried out Qty Prices

(Rs Crores)

A BOILER (PRESSURE PART)

1 Re-insulation work after replacement/repairing wherever required of following components:

100% 4.60

1.1 Boiler Drum & Root Valves Pipings

1.2 Water wall bottom ring headers including 1st pass

1.3 boiler Feed Water & Down-comer piping

1.4 Attemperator headers & Pipings

1.5 Reheater outlet header

1.6 Main Steam Pipe (LHS, RHS) & BAS Line Pipings

1.7 Cold Reheat and Hot Reheat Piping

1.8 All Super Heaters Headers inside pent house

1.9 Eco Hoppers, Fans, Coal mills, Wind box etc.

1.10 Pent House

2

Replacement/Re-paring of Pent house casing including header Boxes Canopy of top Burner floor by 3/15mm HR sheet

100% 5.30

Canopy of top Burner Floor by 3/15mm HR Sheet

3

Complete replacement of all refractory, Refurbishment of skin casing, insulation & cladding of Boiler 2nd Pass.

100% 2.50 Refurbishment of Dead Chambers at Goose Neck

Plat forms & Railing at different elevation at rear side of boiler 2nd Pass as per site requirement.

4 Complete replacement of Hangers and Supports for MS, HRH and CRH Piping along with Coal pipe hangers.

100% 3.00

5 Replacement of Horizontal Reheater (Top, Middle, Bottom) & Pendent Reheater coils with provision of additional metal temperature measurement instruments for the outlet section to enable proper monitoring

100% 22.00

6 Replacement of Complete Economizer Side wall (LHS & RHS) header to header

100% 2.00

7 Replacement of CBD & EBD including all drain and vent pipes along with insulation and motorised valves & actuators

100% 0.50


April, 2017



S. No.


(Rs Crores)

8 Replacement of 11 nos. Safety valves along with silencer/Muffler and all drain & vents with new insulation materials (Drum:3 nos., BAS: 2 nos., TAS: 2 nos. HP Heaters: 2 nos.& MS: 2nos.)

1100% 1.50

9 Replacement of BAS/TAS control valves including Full Load & Low Load Lines (4 nos.)

400% 0.70

10

Replacement of motorized valves & actuators, Critical valves like Attemperation spray control valves, Sampling valves & Manual isolating valves which are damaged or not having the sufficient lapping space Lump-sum 2.30

(Approx. 48 Nos.) Including replacement of spray nozzles.

11 Replacement of Dipper plates along with seal trough as well as Z shaped Liner in side Bottom Ash Hopper

100% 1.00

12

Erosion Shield for S panels & Goose neck of SS-310 materials (OR Coating).

100% 5.00 Cassette Baffles for Eco & Primary SH Bends of SS-304 and replacement of distorted Water Wall at rear side

13 Replacement of Baffle wall and cage rear wall from bottom (near to economizer) to pent house

100% 4.00

B BOILER (NON PRESSURE PART)

1

Replacement/Repairing of Flue duct from Eco to APH, APH to ESP and ESP to chimney along with re-insulation work after replacement/ repairing wherever required.

100% 13.00

Replacement of all expansion Joints in Flue and Hot air ducts.

Repairing of Air duct-15 T.

2

Replacement of existing drag chain system raw coal feeders with gravimetric feeders having variable speed digital drives for efficiency improvement & statutory requirements and replacement of chute from coal feeders to mills with SS material along with expansion joint and coupling suitable for new gravimetric feeders wherever required

600% 7.00

3 Replacement of old repaired gear boxes of Coal Mills with Planetary gear boxes

700% 10.00

4 Replacement of new modified ignition systems (Ignitor/scanner) along with replacement of burners with modified low NOx swirl burners with special long lasting burner tips

100% 16.00

5 Replacement of complete individual Seal Air System with centralised SA system including retrofitting of supply module and Cabling including control logic

100% 3.60

6 Oil Cooler of PA Fans to be replaced with upgraded/improved one 100% 1.00

7 Replacement of ID Fan Impeller Shaft Assemblies, repair of casing, replacement of casing liners & replacement of expansion joint with fluid coupling

100% 1.00

8 Refurbishment of PA Fan Impeller Shaft Assemblies & repair of casing. 100% 0.50

9 Replacement of Soot blowers including complete electrical, mechanical and C&I items

100% 6.00

10 Supply and replacement of APH tubes including plates (No. of Tubes: 30636)

100% 14.50


April, 2017



S. No.


(Rs Crores)

11

Re-hablitation work to be carried out in ESP by replacement of missing & collecting electrode, lifting device, hammers, gearbox etc. whereas required, complete replacement of GD plates (CS) with GD Plates (SS), replacement of manhole gates and repairing of roof, casing, hoppers with re-insulation and necessary electrical works etc.

100% 12.00

Total (Boiler & Aux.)

139.00

Steam Turbine and Auxiliaries - Unit No. 1 SGTPS

S. No. R&M Works to be carried out Qty Prices

(Rs Crores)

1 Replacement of HP, IP and LP turbine modules with new improved design including Erection & Commissioning

100% 150.00

2

Following works to be carried out in Condenser:

i) CW side of condenser to be repaired and 100%

3.10

Protective coating on tube plate & water box

ii) Installation of Online tube cleaning system along with provision of Debris Filter

1 Set

iii) Replacement of plugged condenser tubes 300

3 Repair/Replacement of internal supports of Deaerator and internal piping for TAS

100% 0.50

4 Replacement of BFPs cartridges with new & improved design (With one spare cartridge)

3 5.40

5 Replacement of complete Turbine drain piping and retrofitting of valves in Turbine Drain System including High Energy Drains

100% 0.70

6 Replacement of existing Pennwalt make Turbine oil centrifuge at MOT by latest design Alfa Laval make oil centrifuge

2 0.80

7 Replacement of Existing Condensate Extraction pumps (CEP) with modified/upgraded pumps having higher capacity (with complete pump set as spare)

2 7.00

8 Booster pumps with modified improved design 3 0.60

9 Screw air compressors with Motors & Accessories for Phase-I 3 9.00

Cost for Turbine & Aux. from Point 2 to 9 27.10

Cost of Erection & Commissioning for item 2 to 9 (@10%) 29.81

Total (Turbine & Aux.) 179.81


April, 2017


Electrical System - Unit No. 1 SGTPS S.

No. R&M Works to be carried out Qty

Prices (Rs Crores)

1 Replace the existing LT boards with draw out type, numerical relay based protection, electronic energy meter for >110 kW motors of LT Switchgear

15 0.60

2 Replacement of all the existing standard induction motors with energy efficient motor of all HT motors for Coal mills, PA Fans etc. (Prefr. BHEL make)

12 5.00

(6 COAL MILLS +

6 PA FANS)

3 Installation of the energy efficient luminaries for the complete plant with LED system

Lump-sum 1.50

4 Overhauling/Servicing of GT & 2 (UATs) by OEM with supply of consumable

1 - GT 0.80

2 - UAT

5 Installation and commissioning of GPS clock 1 0.40

6 Procurement of various testing lab equipments Lump-sum 0.70

7 Replacement of Station/Unit Switchgear Old Bus Transfer Scheme 1 0.60

8 Retrofit the existing 6.6 kV station and unit switchgear with new one (SF6 breaker cum numerical relay protection) considering the unit life extension to another 15-20 years

28 2.10

Total (Electrical System) 11.70

Total (Electrical System including Erection & Commissioning @10%) 12.87

Instrumentation and Control - Unit No. 1 SGTPS

S. No. R&M Works to be carried out Qty Prices

(Rs Crores)

1

Replacement of Complete C&I system with latest full DCS including Boiler and Turbine Protection system, Turbine Controls EHC, Turbine ATRS, Turbo-Supervisory system, HP/LP Bypass system including BMS etc., condition monitoring system and PLC for Ash handling system

100% 20.00

2 Replacement of all Transmitters, Local Gauges, Switches (Pressure, Temperature, Level, Flow) and RTD/ Thermocouple/ Thermowells with new ones

Lump-sum 1.50

3 New mass flow meters with totalizer shall be provided for monitoring liquid fuel at the boiler end & at fuel oil pump house

4 0.50

4 Replacement of all signal, T/C compensating & Control cables as per requirements

Lump-sum 0.40

5 Fire retardant JB's in fire hazardous area Lump-sum 0.20

6 Motorized Actuators & Pneumatic Actuators Lump-sum 0.70

7 Replacement of complete measuring instruments of condenser Lump-sum 0.30

8 All required analyzer, transmitters, flow meters etc. to be provided in DM Plant

Lump-sum 1.50

9 Online Acoustic Measuring Tubes Lump-sum 0.50

Total (Instrumentation & Control) 25.60

Total (Instrumentation & Control including Erection & Commissioning @10%) 28.16


April, 2017


Balance of Plant - Unit No. 1 SGTPS

S. No.


(Rs Crores)

1

Coal Handling Plant:

(a) Cleaning & Protective coating/Painting of all steel structure, repairing of welding wherever abnormalities have been observed as per CA report and deformed & corroded structures of belt conveyors stringers, stringer supports and conveyor galleries including Wagon Tippler area etc.

100%

8.00

(b) Reconditioning, Cleaning and Corrosion resistance painting of Wagon Tippler/Locomotive and Bull Dozers, Shawls etc.

100% Apron feeders, Feeder Pan, Carrying, return rollers drive unit, gear box, drive chain - The aged and worn-out components are to be replaced. Painting & Protective coating. Changing all lubricants

(c) Replacement of supporting structure & reconditioning of Primary Crusher & Secondary Crusher

(d) Supply & Installation of magnetic separator and providing redundant supply for magnetic separator required additionally at conveyor 1A/B.

100%

(e) Stacker-reclaimer system, Travelling Trippers, Paddle Feeders - Refurbishment of complete system and up-gradation of interlocking system.

100%

(f) Complete rehabilitation of fire fighting of CHP-1 including Wagon Tippler area.

100%

(g) Modification of conveyor No. 17A/B and 18A/B as per site

requirement

Sub - Total (CHP) 8.00

2

Ash Handling Plant:

(i) Refurbishment of :-

22.00

(a) Seal plate and dipper plate at bottom ash hopper sealing arrangement. 100%

(b) Construction of new pedestal for ash slurry line & replacement of old pipes.

50%

(c) 18” swing disk valve 50%

(d) Vent valve 50%

(e) Pulse jet valve 50%

(f) Filter bags ( Cloth Material: Nomex) 100%

(g) Seat disk of intake valve 50%

(h) ESP diffuser valve 50%

(i) Feed gate assembly of bottom ash hopper 100%

(j) Combine tube 100%

(k) Water valve 100%

(l) Fly ash Conveying line (i.e. 300 Mtr of 300NB, 200 Mtr of 350 NB & 200 Mtr. of 400 NB)

50%

(m) V Grove pulley of mechanical exhauster 100%

(n) Screw type Air Compressor 3 Nos.

(o) Overflow Transfer Pumps 100%

(ii) Complete rehabilitation of almost one non working stream 1

Sub - Total (AHP) 22.00

3 DM Plant:


April, 2017


Balance of Plant - Unit No. 1 SGTPS

S. No.


(Rs Crores)

(a) Replacement of all existing pipelines for dozing alkali & acids with HDPE or better quality material.

100%

2.00

(b) Storage Tanks - Reconditioning including roof replacement. 3

(c) Regeneration pumps - Replacement 2

(d) Replacement of sludge transfer pump 3

(e) Replacement of measuring tank (acid) with dual laminated HDPE tank 4

Sub - Total (DM Plant) 2.00

4

CW System, ACW System, Raw Water System:

Refurbishment of Travelling Screen & Stop Log Gates 3 nos 0.50

Sub - Total (CW System, ACW System, Raw Water 0.50

5

Fuel Oil Handling System:

(a) Replacement of unloading hoses and pipelines with insulation. 100%

3.00

(b) Replacement of complete heat tracing, insulation and cladding, pipe supports of FO handling pipelines from unloading area to fuel forwarding pump house and from fuel forwarding pump house to boiler of unit-1

100%

(c) Refurbishment of oil heating coils for tanks, heater in pump house, its associated pipe line including tracing lines, control valves, isolating valves strainers/fitters and replacement of damaged parts/equipments

100%

(d)Replacement of insulation, supports, missing instruments like pressure gauges etc. and reconditioning of valves in oil piping.

100%

(e)Reconditioning of strainer of HFO, LDO & Drain Oil Pumps. 100%

(g) Replacement of two HFO storage tank with all accessories like fire fighting, heating and oil draining system.

2

Sub - Total (Fuel Oil Handling System) 3.00

6

Fire Protection System:

Replacement of Diesel Engine driven pump(1no) and Diesel Engine (1 no.) - Reconditioning, replacement of damaged parts, instruments, painting and protective coating and laying the pipeline above the ground

L.S. 4.00

Sub - Total (Fire Protection System) 4.00

7

Air Conditioning & Ventilation System:

Reconditioning of

as required 0.50

(a) Chilled Water Pumps (3 nos.) & Condenser Water Pumps (3 nos.)

(b) Piping & Valves, rectification of support sagging, painting & protective coating

(c) Blowers and chiller assembly

d) Air washer pump ( 5 nos. ) , Air handling unit of control room.

Sub - Total (Air Conditioning & Ventilation System) 0.50

Total Balance of Plant 40.00

Total (Balance of Plant including Erection & Commissioning @10%) 44.00


April, 2017


Civil Works - Unit No. 1 SGTPS

S. No. R&M Works to be carried out Unit Quantity Rate inRs.

Prices (Rs Crores)

1

Epoxy painting of foundations a) Boiler & Mill area m² 3500 1000

1.85 b) TG Building (Below ground level areas/basement) m² 7500 1000

c) Ash Handling Plant m² 1000 1000

d)Water Treatment Plant m² 6500 1000

2

Localised surface repairs with epoxy grouting

a) Boiler & Mill area Kg 1950 1500

3.54

b) TG Building (Below ground level areas/basement) Kg 3000 1500

c) Ash Handling Plant Kg 1200 1500

d)Water Treatment Plant Kg 1950 1500

e) CW Pump House Kg 500 1500

f) Old CHP (Underground Tunnel portion) Kg 15000 1500

3 Concrete work for proper slope of TG basement m³ 110 10000 0.11

Total (Civil) 5.50

Summary of R&M Works at Unit No. 1 SGTPS

S. No. Particulars Amount

(Rs Crores)

1 Boiler and Auxiliaries 139.00

2 Steam Turbine Module 150.00

3 Steam Turbine Peripherals and Auxiliaries 29.81

4 Electrical System 12.87

5 Instrumentation and Control 28.16

6 Balance of Plant 44.00

7 Civil Works 5.50

Grand Total (Supply, Erection & Commissioning) 409.34

Contingency 10.00

15% Taxes & Duties 61.40

Grand Total 480.74

Say 481.00


April, 2017


26. Scope of work ( Unit No. 2 SGTPS, Birsinghpur)

The detailed Scope of Works at Unit No. 2 along with its estimated cost

has been worked out and detailed below:-


S. No.


(Rs Crores)

A BOILER (PRESSURE PART)

1 Re-insulation work after replacement/repairing wherever required of following components:

100% 4.60

1.1 Boiler Drum & Root Valves Pipings

1.2 Water wall complete including bottom ring headers

1.3 Boiler Feed Water piping

1.4 Attemperator headers & Piping

1.5 Reheater outlet header

1.6 Main Steam Pipe (LHS, RHS) & BAS Line Piping

1.7 Cold Reheat and Hot Reheat Piping

1.8 All Super Heaters Headers inside pent house

1.9 Eco Hoppers, Fans, Coal mills, Wind box etc.

1.10 Pent House

2 Replacement/Repairing of Pent house casing including header Boxes including Furnace, Roof, Tubes, Replacement/Alignment. Canopy of top Burner floor by 3/15mm HR sheet

100% 5.30

3

Complete replacement of all refractory, Refurbishment of skin casing, insulation & cladding of Boiler 2nd Pass

100% 2.50 Refurbishment of dead chambers at gooseneck.

Plat forms & Railing at different elevations at rear side of boiler 2nd Pass as per site requirement.

4 Complete replacement of Hangers and Supports for Entire MS, HRH and CRH Piping along with Coal pipe hangers.

100% 3.00

5 Replacement of Horizontal Reheater (Top, Middle, Bottom)including cross over pipes & Pendent Reheater coils with provision of additional metal temperature measurement instrumentsfor the outlet section to enable proper monitoring

100% 22.00

6 Replacement of Complete Economizer Side wall (LHS & RHS) header to header 100% 2.00

7 Replacement of CBD & EBD including all drain and vent pipes along with insulation and motorised valves & actuators

100% 0.50

8 Replacement of 11 nos. Safety valves along with silencer/Muffler and all drain & vents with new insulation materials (Drum: 3 nos., BAS: 2 nos., TAS: 2 nos. HP Heaters: 2 nos. & MS: 2 nos.)

11 1.50

9 Replacement of BAS/TAS control valves including Full Load & Low Load Lines (4 nos.)

4 0.70

10

Replacement of motorized valves & actuators, Critical valves like Attemperation spray control valves, Sampling valves & Manual isolating valves which are damaged or not having the sufficient lapping space (Approx. 48 Nos.) including replacement of spray nozzles.

Lump-sum

2.30


April, 2017



S. No.


(Rs Crores)

11 Replacement of Dipper plates along with seal trough as well as Z shaped Liner in side Bottom ash Hopper.

100% 1.00

12 Erosion Shield for S panels & Goose neck of SS-310 materials (OR Coating). Cassette Baffles for Eco & Primary SH Bends of SS-304 and replacement of distorted Water Wall at rear side.

100% 5.00

13 Replacement of Baffle wall and cage rear wall from bottom (near to economizer) to pent house

100% 4.00

B BOILER (NON PRESSURE PART)

1

Replacement/Repairing of Flue duct from Eco to APH, APH to ESP and ESP to chimney along with re-insulation work after replacement/ repairing wherever required. Replacement of all expansion Joints in Flue and Hot air ducts. Repairing of Air duct-15 T.

100% 13.00

2

Replacement of existing drag chain system raw coal feeders with gravimetric feeders having variable speed digital drives for efficiency improvement & statutory requirements and replacement of chute from coal feeders to mills with SS material along with expansion joint and coupling suitable for new gravimetric feeders wherever required.

6 7.00

3 Replacement of old repaired gear boxes of Coal Mills with Planetary gear boxes.

7 10.00

4 Replacement of new modified ignition systems (Ignitor/scanner) along with replacement of burners with modified low NOx swirl burners with special long lasting burner tips.

100% 16.00

5 Replacement of complete individual Seal Air System with centralized SA system including retrofitting of supply module and Cabling including control logic.

100% 3.60

6 Oil Cooler of PA Fans to be replaced with upgraded/improved one 100% 1.00

7 Replacement of ID Fan Impeller Shaft Assemblies, repair of casing, replacement of casing liners & replacement of expansion joint with fluid coupling

100% 1.00

8 Refurbishment of PA Fan Impeller Shaft Assemblies & repair of casing. 100% 0.50

9 Replacement of Soot blowers including complete electrical, mechanical and C&I items.

100% 6.00

10 Supply and replacement of APH tubes including plates(No. of Tubes:30636) 100% 15.00

11

Rehabilitation work to be carried out in ESP by replacement of missing & collecting electrod, lifting device, hammers , gearbox etc. whereas required, complete replacement of GD plates (CS) with GD Plates (SS), replacement of manhole gates and repairing of roof, casing, hoppers with reinsulation and necessary electrical works etc.

100% 12.00

Total (Boiler & Aux. Including Erection & Commissioning) 139.50


April, 2017


Steam Turbine and Auxiliaries - Unit No. 2 SGTPS S.


Prices (Rs Crores)

1 Replacement of HP, IP and LP turbine modules with new improved design including Erection & Commissioning

100% 150.00

2

Following works to be carried out in Condenser: i) CW side of condenser to be repaired and Protective coating on tube plate & water box

100%

3.50 ii) Installation of Online tube cleaning system along with provision of Debris Filter.

1 Set

iii) Replacement of plugged condenser tubes (approx. 300Nos.) 300

3 Repair/Replacement of internal supports of Deaerator and internal piping for TAS.

100% 0.50

4 Replacement of BFPs cartridges with new & improved design (with one spare cartridge).

4 7.20

5 Replacement of complete Turbine drain piping and retrofitting of valves in Turbine Drain System & including High Energy drains

100% 0.70

6 Replacement of existing Pennwalt make Turbine oil centrifuge at MOT by latest design Alfa Laval make oil centrifuge

2 0.80

7 Replacement of Existing Condensate Extraction pumps (CEP) with modified/upgraded pumps having higher capacity.(with complete pump set as spare)

3 10.50

8 Booster pump with modified improved design. 3 0.80

9 Screw air compressors with motors and accessories for Phase-1 3 9.00

Total (Turbine & Aux. from Point 2 to 9 33.00

Cost of Erection & Commissioning for item 2 to 9 @10% 36.30

Total (Turbine & Aux. including erection & commissioning) 186.30

Electrical System - Unit No. 2 SGTPS S.


Prices (Rs Crores)

1 Replace the existing LT boards with draw out type, numerical relay based protection, electronic energy meter for >110 kW motors of LT Switchgear

15 0.60

2 Replacement of all the existing standard induction motors with energy efficient motor of all HT motors for Coal mills, PA Fans etc. (Prefr. BHEL make)

12 (6 COAL MILLS + 6 PA FANS)

5.00

3 Installation of the energy efficient luminaries for the complete plant with LED system

Lump-sum 1.50

4 Overhauling/Servicing of GT & 2 (UATs) by OEM with supply of consumable. 1 - GT

2 - UAT 0.80

5 Installation and commissioning of GPS clock 1 0.40

6 Procurement of various testing lab equipments Lump-sum 0.70

7 Replacement of Station/Unit Switchgear old Bus Transfer Scheme. 100% 0.60

Total (Electrical System) 9.60

Total (Electrical System including erection & commissioning @ 10%) 10.56


April, 2017


Instrumentation and Control - Unit No. 2 SGTPS

S. No.


(Rs Crores)

1

Replacement of Complete C&I system with latest full DCS including Boiler and Turbine Protection system, Turbine Controls EHC, Turbine ATRS, Turbo-Supervisory system, HP/LP Bypass system including BMS etc., condition monitoring system and PLC for Ash handling system

100% 18.00

2 Replacement of all Transmitters, Local Gauges, Switches (Pressure, Temperature, Level, Flow) and RTD/ Thermocouple/ Thermo wells with new ones

Lump-sum

1.00

3 New mass flow meters with totalizer shall be provided for monitoring liquid fuel at the boiler end & at fuel oil pump house.

4 0.50

4 Replacement of all signal, T/C compensating & Control to cables as per requirements.

Lump-sum

0.40

5 Fire retardant JB's in fire hazardous area Lump-sum

0.20

6

Motorized Actuators & Pneumatic Actuators Lump-sum

0.70

Replacement of complete measuring instruments of Condenser Lump-sum

0.30

All required analyzer, transmitter, flow meters, etc to be provided in DM Plant Lump-sum

7 Online Acoustic Measuring Tubes Lump-sum

0.50

Total (Instrumentation & Control) 21.60

Total (Instrumentation & control including erection & commissioning @ 10%) 23.76

Balance of Plant - Unit No. 2 SGTPS S.


Prices (Rs Crores)

1 Replacement of Hydrogen Generation Plant in new located building Lump-sum 5.00

2 Ash Handling System

2.1 Replacement of Valves (42 nos. in Ash intake pump house), Diffuser (12 nos.) & Clinker Grinder Chains (4 nos.)

Lump-sum

3.00

2.2 Ash Slurry Pump Gear Box (4 nos.) 4 0.50

2.3 AHP Compressed Air System including replacement of 2 nos. screw type air compressors

Lump-sum

5.00

3 DM Plant works including internal checking and rubber lining in Stream-A Lump-sum

0.50

4 CW System, ACW System and Raw Water System Lump-sum

0.50

5 Fuel Oil Handling System- Replacement of Heating Tracing line, insulations & cladding Supports etc.

Lump-sum

0.50

6 Rehabilitation of Fire Fighting system piping etc.(included in Unit-1) Lump-sum

0.00

Total (Balance of Plant) 15.00

Total (Balance of Plant including Erection & Commissioning @ 10%) 16.50


April, 2017


Civil Works - Unit No. 2 SGTPS S.

No. R&M Works to be carried out Unit

Amount (Rs Crores)

1

Epoxy painting of foundations

a) Boiler & Mill area Lump-sum 1.10

b) TG Building (Below ground level areas/basement) Lump-sum

2

Localized surface repairs with epoxy grouting

0.90 a) Boiler & Mill area Lump-sum

b) TG Building (Below ground level areas/basement) Lump-sum

c) Ash Handling Plant Lump-sum

3 Concrete work for proper slope of TG basement Lump-sum 0.10

4 Construction of New Hydrogen Plant Building at new location near CW pump house

Lump-sum 1.00

Total (Civil) 3.10

Summary of R&M Works at Unit No. 2 SGTPS

S. No. Particulars Supply Erection &

Commissioning Amount

(Rs Crores)

1 Boiler and Auxiliaries - - 139.50

2 Steam Turbine Module - - 150.00

3 Steam Turbine Peripherals and Auxiliaries 33.00 3.30 36.30

4 Electrical System 9.60 0.96 10.56

5 Instrumentation and Control 21.60 2.16 23.76

6 Balance of Plant 15.00 1.50 16.50

7 Civil Works - 3.10 3.10


Contingency 3.00

15% Taxes & Duties 56.96


Say 440.00

27. In accordance with Proviso 21 of MPERC Regulations-2015 {RG-26 (III)

of 2015} the instant petition has been prepared and is submitted by

MPPGCL before Hon’ble Commission towards Renovation &

Modernization works of Unit No. 1 & 2 SGTPS, Birsinghpur.


April, 2017


28. Total Proposed Expenditure & Funding there of :-

The total cost of R&M works proposed at PH-1 SGTPS, Birsinghpur

works out to Rs. 966.60 Crores as detailed in respective DPRs. The

Unit wise breakup is as under:-

Rs. Crores

Particulars Unit-1 Unit-2 Total

RLA Study 0.85 0.85 1.70

R&M 481.00 440.00 921.00

IDC on R&M 22.93 20.97 43.90

Total For R&M 504.78 461.82 966.60

Apart from above few essential works of capital nature are already

in progress at these units amounting to Rs. 36.85 Crores. The

details of the same are annexed as Annexure-7. However the

summary of these works are tabulated hereunder:-

Particulars Amount Share of PH-1

Cr Rs Cr Rs

Alternate Coal Path 48.90 24.45

Engine Escape Line 9.00 3.60

DCS system for U#2 2.84 2.84

Up gradation of UPS 0.40 0.40

PLC system for CHP 1.46 1.46

Mill & PA Fan Motors 2.80 2.80

PLCC Carrier panels 0.20 0.20

SF6 Circuit Breakers 0.90 0.90

Bus Bar protection Scheme 0.20 0.20

Total : 66.70 36.85

Accordingly, the total cost considered in the instant petition

towards R&M works out to Rs. 1003.45 Crores (Rs. 966.6 +36.85

Crores).

Proposed Funding details:-

The funding of the proposed R&M works is based on the Debt:

Equity Ratio of 70: 30 as per MPERC Regulations. The funding

details are tabulated hereunder:-


April, 2017


Particulars Funding Details

Unit 1 Unit 2 Total

1 For R&M Works Cr Rs 504.78 461.82 966.60

2 Debt

% 70% 70% 70%

3 Cr Rs 353.35 323.27 676.62

4 Equity

% 30% 30% 30%

5 Cr Rs 151.43 138.55 289.98

MPPGCL is in discussion with various Financial Institutes for

obtaining loan for afore said R&M works. Once the loan amount

gets tied up, Hon’ble Commission shall be suitably intimated.

Apart from above, the funding of essential works detailed above is

tabulated as under:-

in Rs. Crores

Particulars Share of Unit

1 &2

Through PFC Loan 22.01

GoMP Plan funds 12.40

Internal resource 2.45

Total 36.85

29. Operational Parameters of MPERC:-

The Operational Norms permitted by Hon’ble Commission for SGTPS

PH-1 (Unit 1&2) vide its Regulation 2015 are tabulated hereunder:-

Operational Parameters Unit As per MPERC

Regulation 2015

Normative Annual Plant Availability Factor % 80%

Plant Load Factor % 80%

Auxiliary Energy Consumption % 9.00%

Sp. Fuel Oil Consumption ml/kWh 1.30

Gross Station Heat Rate kCal/kWh 2600


April, 2017


30. Phasing of Expenditure:-

The proposed phasing of expenditure as per DPR for R&M works at

Unit No. 1 & 2 are detailed hereunder:-

Phasing of Expenditure of R&M Works Unit No.1 SGTPS

Particulars Total Yr 1 Yr 2

Cr Rs FY-18 FY-19

RLA Study 0.85 0.85

R&M 481.00 30.00 451.00

IDC on R&M works 22.93 1.15 21.78

Total For R&M works 504.78 32.00 472.78

Phasing of Expenditure of R&M Works Unit No.2 SGTPS

Particulars Total Yr 1 Yr 2

Cr Rs FY-18 FY-19

RLA Study 0.85 0.85

R&M 440.00 30.00 410.00

IDC on R&M works 20.97 1.15 19.82

Total For R&M works 461.82 32.00 429.82

31. The Hon’ble Commissioned vide its MYT order dated 14.07.2016 has

determined tariff of SGTPS PH-1(4x210MW) for the Control Period FY

2016-17 to FY 2018-19 on consolidated basis. The Element wise break-

up of proportionate tariff for Unit No. 1 &2 works out as under:-

Elements FY 17 FY 18 FY 19

Fixed Charges (Rs. Crores)

Return on Equity 50.33 50.33 50.33

Interest on Loan 0.00 0.00 0.00

Depreciation 22.09 22.09 22.09

O&M Expenses 101.64 108.03 114.83

Special Allowance 0.00 0.00 0.00

Interest on Working Capital 33.24 33.61 34.01

Compensation Allowance 3.15 3.15 3.15

Total 210.45 217.21 224.41

Energy Charges ex-bus (Rs/kWh) 2.20 2.20 2.20


April, 2017


32. Projected Operational Parameters:-

The performance parameters after completion of the R&M works are

projected as under:

Operational Parameters Unit

As per MPERC

Regulation 2015

Proposed by MPPGCL after

R&M

Plant Availability Factor % 80% 85%

Auxiliary Energy Consumption % 9.0% 8.5%

Sp. Fuel Oil Consumption ml/kWh 1.3 0.5

Gross Station Heat Rate k Cal/kWh 2600 2400

Project Duration Months 18

Shutdown Duration Months 04

Residual Life Extension Years 15-20

Deterioration in performance Years 5

th year

onwards @1%

33. Life Extension:-

The expected Life Extension after completion of R&M works at Unit

No. 1 & 2 shall be 15-20 years.

34. Schedule of Completion:-

MPPGCL is under process of finalization of all the related activities. On

completion of the same, the works will start/initiated and the project

shall be completed in 18 Months as envisaged in DPRs.

35. Cost Benefit Analysis:-

The detailed Cost Benefit Analysis of the proposed R&M works at Unit

No.1&2 of SGTPS, Birsinghpur is elaborated in Section-10 Financial

Analysis of Options of DPRs of Unit No. 1 & 2 annexed as Annexure-

5A & 5B for kind reference. It can be seen that the Pay Back period for

the Unit No.1 works out to 7.09 Years and for Unit No.2 works out to

7.06 Years.


April, 2017


The summary of the same is detailed hereunder:-

Summary of Findings for Unit No. 1 SGTPS, Birsinghpur

Particulars Value

1 Payback of Investment (MPPGCL) Years 7.09

2 Saving in ECR Rs. Crores 555

p/u 0.51

Summary of Findings for Unit No. 2 SGTPS, Birsinghpur

Particulars Value

1 Payback of Investment (MPPGCL) Years 7.06

2 Saving in ECR Rs. Crores 501

p/u 0.48

36. MPPGCL humbly request Hon’ble Commission to permit MPPGCL to

carry out Renovation and Modernization works at Unit No. 1 & 2

SGTPS, Birsinghpur in accordance to proviso 21 read with proviso 36.2

of Regulations, 2015 {RG-26 (III) of 2015} and allow its impact on

generation tariff determined for the control period FY 2016-17 to FY

2018-19 and onwards.


April, 2017


PRAYER

In view of the above submissions, the petitioner respectfully prays that

in accordance with proviso 21 read with proviso 36.2 of Regulations,

2015 the Hon’ble Commission may kindly:-

a. Accord approval for capital expenditure as detailed in para 28,

towards carrying out Renovation and Modernization works at Unit

No. 1 & 2 SGTPS, Birsinghpur.

b. Allow its impact on generation tariff determined for the control

period FY 2016-17 to FY 2018-19 and onwards.

c. Condone any inadvertent omissions / errors / short comings and

permit the applicant to add / change /modify / alter this filing and

make further submissions as may be required at later stages.

d. Pass such orders as Hon’ble MPERC may deem fit and proper and

necessary in the facts and circumstances of the case, to grant relief

to petitioner.

(S.C. Shukla) Date: 27/04/2017 Addl. Chief Engineer & OIC Place: Jabalpur O/o Chief Engineer (R&M)

For & on behalf of M.P. Power Generating Co. Ltd. Jabalpur


April, 2017



April, 2017



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April, 2017


MPERC Fee Details


April, 2017


LIST OF ANNEXURES

Annexure No.

Particulars

1 Copy of Clause 2.3 of Article 2, ‘Scope of the Agreement’ of the Power Purchase Agreement (PPA) dated 29-11-2006

2 Energy Department, Government of MP, letter No.AF-3-20/2014/13 dated 28.01.2017

3 MPPMCL letter No 04-01/128 dated 01.02.2017

4 Guide Lines issued by Hon’ble Central Electricity Authority, New Delhi in October 2009 for R&M/LE Works.

5A & 5B Detailed Project Reports for R&M works at SGTPS Unit-1&2 Birsinghpur prepared by M/S TŰV-SŰD South Asia Pvt. Ltd

6A BoD MPPGCL resolution granting approval for R&M works at SGTPS Unit-1&2 Birsinghpur.

6B Letter No. 07-09/MPPGCL/R&M/SGTPS/217 dated 10.02.2017 to Hon’ble Central Electricity Authority, New Delhi for seeking necessary approval for R&M/LE works at SGTPS Unit-1&2 Birsinghpur.

7 Details of Essential works carried out at SGTPS Birsinghpur.


April, 2017


Annexure-1


April, 2017



April, 2017


Annexure-2


April, 2017


Annexure-3


April, 2017


Annexure-4


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April, 2017


Annexure-5A (DPR of Unit-1 SGTPS)

AND

Annexure-5B (DPR of Unit-2 SGTPS)

{ Placed separately }


April, 2017


Annexure-6A


April, 2017


Annexure-6B


April, 2017



April, 2017



April, 2017


Annexure-7

Documents

SGTPS BIRSINGHPUR, UNIT NO. 1 & 2 (2X210 MW) · 2017-11-25 · SGTPS BIRSINGHPUR, UNIT NO. 1 & 2 (2X210 MW) Petition for Approval of R&M works at Unit No. 1&2, SGTPS, Birsinghpur