Technical specifications for Sugauli cogen

558 Pages·2009·2.34 MB·English

Doc No. : GDP/EPC-BID/09-10/025, R1
Date : June 8, 2009
Assign No. : GPD/SDE/HPCL/08-09/045
Date : September 12, 2008

ENGINEERING, PROCUREMENT & CONSTRUCTION
(EPC) BID DOCUMENT

20 MW Cogeneration Power Plant
Village Sugauli, District East Champaran, Bihar

Technical Basis And Specifications

Prepared For

Hindustan Petroleum Corporation Ltd. (HPCL)
(A Govt. of India Enterprise)
Petroleum House, 17, Jamshedji Tata Road,
Mumbai – 400 022

Prepared By

MITCON Consultancy Services Ltd. (MITCON)
Kubera Chambers, Shivajinagar
Pune - 411 005

June, 2009
Doc No. : GDP/EPC-BID/09-10/025, R1
Date : June 8, 2009
Assign No. : GPD/SDE/HPCL/08-09/045
Date : September 12, 2008

EPC BID DOCUMENT

20 MW Cogeneration Power Plant
Village Sugauli, District East Champaran, Bihar

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Chapter Chapter No. Page No.
No.
1 DESIGN BASIS, SCOPE OF WORK, TERMINAL POINTS, 1 – 174
PERFORMANCE GUARANTEE
1.1 Design Basis 1
1.2 Scope Of Work 172
1.3 Terminal Points 173
1.4 Building Dimensions 174

2 TECHNICAL SPECIFICATIONS FOR MECHANICAL & 175 - 464
ELECTRICAL EQUIPMENTS, INSTRUMENTATION &
CONTROL AND ERECTION AND COMMISSIONING
2.1 Steam Generator &Auxiliaries 175
2.2 Steam Turbine Generator & Auxiliaries 220
2.3 EOT Crane & Hoists 280
2.4 Water Treatment Plant 291
2.5 Air Compressor & Air Dryer 299
2.6 Fuel And Ash Handling System 302
2.7 Cooling Tower & Auxiliaries 314
2.8 Fire Fighting System 322
2.9 Piping & Fittings 326
2.10 Painting 333
2.11 Electrical Evacuation System 335
2.12 Cabling 386
2.13 DCS Based Instrumentation And Control 398
2.14 Uninterrupted Power Supply 438
2.15 Erection & Commissioning 445
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Chapter Chapter No. Page No.
No.
3 CIVIL WORKS 465 - 488
3.1 Major Civil Works 465
3.2 Design Data 466
3.3 System Description & Specifications 466
3.4 Design Criteria 467
3.5 Foundations 468
3.6 Machine Foundations 469
3.7 General Design Considerations 472
3.8 Design Of Miscellaneous Items 477
3.9 Architectural Concepts And Design 478
3.10 Construction 482

4 APPROVED LIST OF VENDORS, LIST OF SPARES AND 489 - 514
LIST OF DRAWINGS / DOCUMENTS
4.1 Approved List Of Vendors 489
4.2 List Of Spares 495
4.3 List Of Drawings & Documents 503

5 DATA SHEETS 515 - 554
5.1 Steam Generator & Auxiliaries 515
5.2 Steam Turbine Generator & Auxiliaries 518
5.3 Water Treatment Plant 521
5.4 Cooling Tower 524
5.5 Fuel & Ash Handling 525
5.6 EOT Crane 533
5.7 Electrical Evacuation 535
5.8 DCS 551
5.9 Building Dimensions 552
5.10 Performance Guarantee 552
5.11 List of Technical Deviations 554
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LIST OF APPENDICES

APPENDIX
APPENDICES
NO.
I SITE LOCATION MAP
II PROXIMATE & ULTIMATE ANALYSIS OF BIOMASS FUELS
III TYPICAL TG HALL LAYOUT
IV PROPOSED MASTER PLAN DEMARCATING COGEN
AREA AND PROVIDING SCHEMATIC OF FUEL
HANDLING SYSTEM
V TYPICAL SCHEMATIC PLANT STEAM SYSTEM
VI TYPICAL SCHEMATIC FOR HP HEATER
VII TYPICAL SCHEMATICS COOLING WATER SYSTEM
VIII TYPICAL SCHEMATICS PLANT WATER SYSTEM
IX TYPICAL BOM, FIRE FIGHTING
X TYPICAL SCHEMATICS SYSTEM CONFIGURATION,
PLANT DCS
XI TYPICAL SINGLE LINE DIAGRAM, ELECTRICAL
EVACUATION & DISTRIBUTION SYSTEM
XII PIPING MATERIAL SPECIFICATIONS
XIII CODES & STANDARDS
XIV TYPICAL PAINTING SUMMARY
XV ELECTRICAL SYSTEM REQUIREMENTS FOR MOTOR
SELECTION
XVI RAW WATER ANALYSIS
XVII HEAT & MASS BALANCE DIAGRAM
XVIII TERMS & CONDITIONS FOR ERECTION &
COMMISSIONING
CHAPTER – 1

DESIGN BASIS, SCOPE OF WORK, TERMINAL POINTS
AND PERFORMANCE GUARANTEE

1.1 DESIGN BASIS

1.1.1 General

The cogen power plant will have installed capacity of 20 MW and will
°
Employ 110 kg/cm2 and 540 C configurations. Bagasse generated from
cane crushing, excluding handling losses and bagacillo requirements will
be available for operation of the high-pressure boiler during season of 130
days. Saved bagasse, cane trash, rice husk will be used during the off-
season period of about 170 days.

The auxiliary steam consumption for the cogen power plant will be for
soot blowing and other auxiliary consumptions like Steam Jet Air Ejector
(SJAE) & Gland Steam Condenser (GSC) at high pressure, for twin type
HP heater at medium pressure and for de-aerator at low pressure. The
auxiliary power consumption for the power plant will be about 8.5% of
generation during season and 9% of generation during off-season periods.

The process steam required for sugar @ 22% on cane or 32.08 TPH during
season, 20 TPH for ethanol plant during season & 10.25 TPH during off-
season will be provided from the cogen power plant. Also, power
requirement of 2.92 MW for sugar process during season & 0.15 MW
during off-season, 1 MW during season & 0.9 MW during off-season
periods for ethanol plant & 0.15 MW both during season and off season
periods for the colony will be provided from the cogen power plant.

Technical EPC Bid Document for Cogen Power Plant at Sugauli, Dist. East Champaran, Bihar 1
The brief design parameters for the cogen power plant will be as follows:

Boiler capacity, TPH : 1 x 100
Pressure, kg/cm2 110.00
Temperature, °C 540
Turbine capacity, MW 20.00
Turbine type Bleed cum double
extraction cum condensing
Season operation, days 130
Off season operation, days : 170
Fuels used for season operation : Mill bagasse
Fuels used for off season operation : Saved bagasse, Cane Trash,
Biomass
Boiler efficiency, %
- On bagasse / bio-mass / cane : 70.00, ±2
trash
Feed water temperature, °C : 210
Captive power consumption, % of : 8.5 during season & 9
generation during off-season

1.1.2 Key performance parameters

The key performance parameters for the cogen power plant are given
below:

Sr. Description Value
No.
1 Steam Generator efficiency, % : 70±2 on bagasse / biomass
/ cane trash
2 Steam to Fuel Ratio, kg : 2.65
bagasse / kg
Technical EPC Bid Document for Cogen Power Plant at Sugauli, Dist. East Champaran, Bihar 2
3 Average Steam to Power
Ratio, kg / kW
Season : 5.08
Off-Season :
3.80
4 Auxiliary Power
consumption, MW (%)
Season :
1.70 (8.5)
Off-Season :
1.80 (9)

Note: The estimated HMBD is provided in Appendix XVII. However, the
Tenderer can optimise the same to maximise power generation at
the required steam flows to process.

1.1.3 Ambient Conditions

Plant Elevation above Mean Sea Level (MSL) : 61 meters

Temperatures:

(a) Maximum Temperature : 46 Deg. C

(b) Minimum Temperature : 5 Deg. C

(c) Plant Design Temperature : 36 Deg. C
(Performance design)

(d) Plant Design Wet Bulb Temperature : 27.0 Deg. C

(e) Plant Design Temperature for Electrical : 50 Deg. C
Equipment

Precipitation:

(a) Average Annual Rainfall : 1241 mm

Wind:

(a) Wind Direction : South - West (May – Sept)
North - East (Oct - Apr)

(b) Design Wind Velocity : As per IS 875

Seismic Coefficient : As per IS: 1893-2002

Seismic Zone : Zone 4
Technical EPC Bid Document for Cogen Power Plant at Sugauli, Dist. East Champaran, Bihar 3
Soil Bearing Capacity* : 12 ton/m² at 2 m
from NGL
* Tenderer will need to carry out required trial pits and other tests to
affirm the SBC and other required soil characteristics

1.1.4 Fuels

a) Design & Guarantee Fuels

During sugar season, the principle fuel will be bagasse and the
steam generator will be designed for 100% MCR on bagasse.
During sugar off-season, the boiler will operate on stored /
procured bagasse and other biomass.

The estimated fuel balance will be as follows :

Sr. Item Value
No. Season Off season
1. Crushing rate, TCH 146 -
2. Bagasse generation at 34% on cane, 49.58 -
TPH
3. Bagacillo / handling loss at 1.0% on 1.46 -
cane, TPH
4. Bagasse available as fuel at 33% on 48.13 -
cane, TPH
5. Biogas available from distillery 2.08 2.08
(equivalent to bagasse), TPH
6. Total equivalent bagasse available, 50.21 0.00
TPH (MT) (156655)
6. Bagasse consumed by new boilers, 37.74 26.60
TPH (MT) (117748)
7. Bagasse saved / available for off 12.47 9.54
season operation, TPH (MT) (38904) (38904)
8. Biomass requirement, equivalent - 17.43
bagasse, TPH (MT) (71114)

Technical EPC Bid Document for Cogen Power Plant at Sugauli, Dist. East Champaran, Bihar 4
The following will be the analysis and the Gross Calorific Value
(GCV) of the design fuel (Bagasse).

Ultimate Analysis:
Carbon : 23.5%
Hydrogen : 3.25%
Oxygen : 21.75%
Moisture : 50%
Ash : 1.5%
GCV with 50% moisture : 2270 Kcal/Kg

The Following gives the Ash Analysis for Bagasse:
SiO2 : 50-60%
Al2O3 : 10-13%
Fe2O3 : 10-12%
CaO : 3-5%
MgO : 3-4%
TiO2 : 2-4%
P2O5 : 1-2%
Na2O : 0.5-1.5%
K2O : 4.5-6.0%
SO3 : Nil

b) Other Fuels

The Cogeneration plant will also be designed to operate with other
fuels like sugarcane trash, rice husk and maize cobs in combination
with bagasse. The operation of the plant during the seasonal
operation will be basically with bagasse and during off season with
saved bagasse and biomass. However during off season bio-mass
fuel sugarcane trash, rice husk and maize cobs are envisaged to be
used depending upon the availability.

Ultimate and Proximate analysis of the other fuels like sugarcane
trash, , rice husk and maize cobs are given in Appendix II
Technical EPC Bid Document for Cogen Power Plant at Sugauli, Dist. East Champaran, Bihar 5
1.1.5 Plant Design Criteria

The estimated cogen plant design criteria is as follows :

Sr. Item Value
No.
Season Operation (130 days)
1. Cane crushing, TCH 146
2. No. of season days, nos. 130
3. No. of hrs / day 24
4. Cane crushing / season, lakh MT / season. 4.55
5. Bagasse generation, % cane (TPH) 34.00 (49.58)
6. Bagacillo / handling loss,% cane (TPH) 1.0 (1.46)
7. Bagasse available for boiler, % cane (TPH) 48.13 (98.60)
8. Bio-gas available from distillery as fuel 2.08
(equivalent bagasse)
8. Total equivalent bagasse available for boiler, 50.21
TPH
9. Total fuel available as fuel, (MT) 156655
10. Bagasse consumption during season, TPH 37.74
(MT) @ 2.65 T/MT of bagasse (117749)
11. Bagasse saved for off season operation TPH 12.47
(MT) (9-10) (38904)
12. Steam generation, TPH (@ 2.65kg steam / kg 100.00
bagasse
13. Steam consumption, TPH
13.1 HP steam @ 110 & 25 kg/cm2
- Gland Steam Condenser & Steam Jet Air 1.00
Ejector (SJAE)
- HP heater I 7.00
13.2 MP steam @ 8 kg/cm2
- Ethanol process 20.00
- HP heater II 8.00
- De-superheating water addition (0.56)
- Total MP steam 27.44
13.3 LP steam @ 2.5 kg/cm2
- Sugar process @ 22% on cane 32.08
- De-aerator 4.60
Technical EPC Bid Document for Cogen Power Plant at Sugauli, Dist. East Champaran, Bihar 6