Brief Summary of the Project 1. Introduction Bokaro Steel Plant (BSL) was set up and commissioned in the year 1972-73 for production of 1.7 Mtpa of flat rolled products. Subsequently, the plant was further expanded to 4.0 Mtpa for which EC was obtained in 1991. BSL had obtained EC for expansion of crude steel production from 4 MTPA to 7 MTPA vide F.No. J-11011/99/2007-IA-II(I) dated 16.10.2008. However, BSL had amended the same for change in expansion capacity from 7.0 MTPA to 4.606 MTPA vide F.No. J-11011/99/2007-IA- II(I) dated 28.11.2014. BSL is currently producing 4.606 MTPA crude steel. As part of modernization of the existing plant, Addition of a 2.0 Mtpa Pellet plant and 7m tall top charged Coke oven battery of 0.768 MTPA production capacity were also proposed within the same plant premises without increasing the approved production capacity of the existing plant. EC application for the same has been submitted to MoEFCC. The required raw water for BSL plant operations and township is being drawn from Tenughat Dam which is built on upstream of Damodar River at a distance of about 35 Km from Plant site. The maximum limit for drawal of water from Tenughat Dam is 23140 m3/hr. At present, the raw water drawal by BSL is about 17500 m3/hr. Water is supplied through a Gravity Canal which is controlled by WRD, Govt. of Jharkhand (Tenu canal which is about 35 km long from the dam). The canal discharges water into the Cooling Pond-l (which serves as the recirculating basin for the plant). The Canal is mainly built with earthen embankments, has PCC lining and has intermittent civil structures like RCC aqueducts or cross drainages over the nalas, small seasonal rivers, low lying land etc. The canal is more than 50 years old. Its condition has deteriorated considerably. At many places the canal lining is damaged. The problem is more pronounced at junction points of aqueducts and canal. The canal's water discharge capacity has also reduced due to siltation over the entire length of the canal. There was a major breach in the canal, due to poor condition, causing complete disruption in water supply to BSL, which is effecting plant operations very often. BSL is therefore, contemplating an alternate pipeline route for water drawl from Damodar River via Baidhmara Weir near Bokaro (approx. 5 km), to meet the water requirements of the plant and the township as an alternate route (same source) of raw water, which is found out to be the most suitable and feasible solution. On completion of the proposed project, Tenu canal can be taken up for repair. In future, this will serve as a standby arrangement to Tenu canal during exigencies. The amount of water which is being released from Tenughat Dam will be diverted through Damodar River and same water will be drawn from the upstream of Baidhmara weir by creating a pumping facility with pipe lines up to cooling pond - 1 for which NOC from Govt. of Jharkhand, Ministry of Water Resource Deptt. has already been obtained on January 06,2017. Central Water and Power Research Station, Pune (CWPRS) was consulted for studying the feasibility of drawing the required quantity of raw water from upstream of existing Baidhmara weir and installing requisite intake facilities. CWPRS opined that proposed site is suitable for creating an intake and pumping facilities. 2. Site Location The existing BSL plant is located in Bokaro Steel city, Sub-division Bokaro of Bokaro District in Jharkhand, between longitude 86o 02’ to 86o10’E and latitude 23o38’ to 23o42’ N near River Damodar. Baidhmara Weir is located North of the existing plant at a distance of about 5 Km. The exact GPS coordinated of the weir are 23o44’XX” N and 86o3’XX” E. 3. Environmental Setting The route survey has already been carried out and the land of ROW (right-of way) does not involve any eco-sensitive area and forest land. 4. Land The total land for the proposed route and facilities is already under possession of SAIL/Bokaro Steel Plant and no further acquisition of land is required. 5. Water There shall be no change in the present water required for the existing Steel Plant complex and township. 6. Facilities Envisaged For the intake and pumping facilities at Baidhmara weir following major facilities are envisaged- Water intake facility Water Pumping facility along with Electrical System Pipeline and spillway from intake pump house to Cooling pond-1 of BSL. 7. Project Cost Estimates The capital cost of the proposed project is estimated arounf Rs 118.45 Crores. 8. Project Implementation Period The proposed project is envisaged to be completed in Nine(9) months. Tenughat Dam Proposed Pump House Proposed New Pipeline Existing Tenu Canal (35 Km Long) Bokaro Steel Plant FEASIBILITY REPORT DEVELOPMENT OF ALTERNATE SYSTEM FOR DRAWAL OF RAW WATER FROM DAMODAR RIVER FOR BOKARO STEEL PLANT AND TOWNSHIP BOKARO STEEL PLANT STEEL AUTHORITY OF INDIA LIMITED CENTRE FOR ENGINEERING & TECHNOLOGY RANCHI - 834002 CET/02/RN/4264/FR/CE/01/R=0 MARCH, 2017 Experience that delivers This document has been prepared for Bokaro Steel Plant by: Centre for Engineering & Technology R. M. Chattopadhyay – HOD Lead section H. Toppo, Civil (Task Force Leader) S. Mukherjee, Structural S. S. Biswal, Civil V. Bharti, Mechacnical Neeraj, Electrical Suman Saurabh, Electrical P. K. Mishra, Cost Techno-Economics & Budget S. P. Das, PFC S. K. Verma , BOSC -Utilities S.K. Kachhap, BOSC -Process Control & Automation R.K. Sokey, BOSC -Electrical R. Hemrom, BOSC -Civil Rajiv Ranjan, BOSC -Civil Document Identification No. CET/02/RN/4264/FR/CE/01 REVISION HISTORY Revision No. Brief Description Revision Date R0 NA NA Disclaimer This documeent is the property of CET and is exclusively for the use of the intended client. This document has been prepared based on the inputs provided by the client. No part of this report shall be reproduced or transmitted in any form whatsoever without the written permission from the owner. Experience that delivers UPSHOT Water requirement of BSL plant & township is fulfilled from Tenughat dam on Damodar River. Water is supplied through Tenu canal from the dam approx. 35 km away. To arrange an alternate system of supply of raw water from Damodar river to BSL, in addition to the existing Tenu canal which is the only supply route for raw water, a new Intake Facility near Baidhmara Weir along with necessary pipeline has been proposed. This project will be commissioned in 9 months from the date of stage II approval. The estimated capital cost is Rs.118.45 crores. BSL i CET/02/RN/4264/FR/CE/01/R=0 Drawal of raw water from Damodar River Experience that delivers CONTENTS - CHAPTERS Chapter no. Description Page no. 1 Summary 1.1 2 Background 2.1-2.3 3 Selection of Alternatives 3.1 4 Project Description 4.1-4.15 5 Implementation Schedule & Strategy 5.1-5.3 6 Capital Cost & Financial Analysis 6.1-6.2 7 Recommendations 7.1 Annexures Drawings BSL ii CET/02/RN/4264/FR/CE/01/R=0 Drawal of raw water from Damodar River Experience that delivers ANNEXURES Annexure No. Description No. of pages 2.2.1-1 Central Water Recirculation Scheme of BSL 01 2.2.9-1 Changes in water levels of Cooling ponds vis a 02 vis break down of Tenu canal 2.5-1 Client’s Assignment Letter 01 2.6-1 CET’s Assignment Acceptance Letter 01 2.8-1 Minutes of Meeting Between BSL, CET & 03 CWPRS 2.9-1 Permission Letter from Govt. of Jharkhand 02 5.1.2-1 Implementation Schedule of Pre-ordering 01 activities after Stage-I Approval 5.1.2-2 Implementation Schedule for Post-Ordering 01 Activities after Stage-II Approval 6.1.1-1 Capital Cost Estimate - Summary 01 BSL iii CET/02/RN/4264/FR/CE/01/R=0 Drawal of raw water from Damodar River Experience that delivers DRAWINGS Sl. No. Drawing No. Description 1. CET BK 4264 UT0 00 001 Alternate Raw Water Supply Arrangement - R=0 Pumping Scheme from Pump House to Cooling Pond # 1 2. CET BK 4264 UT0 00 002 Alternate Raw Water Supply Arrangement - R=0 Typical General Arrangement of Pump, Rotary Screen, Sealing Gate & Bar Screen 3. CET RN 4264 CE0 00 004 Alternate Raw Water Supply Arrangement - R=0 Proposed Intake Works - Layout 4. CET RN 4264 CE0 00 005 Alternate Raw Water Supply Arrangement - SH 1 R=0 Proposed Pump House - General Arrangement 5. CET RN 4264 CE0 00 005 Alternate Raw Water Supply Arrangement - SH 2 R=0 Proposed Pump House - General Arrangement 6. CET RN 4264 CE0 00 005 Alternate Raw Water Supply Arrangement - SH 3 R=0 Section-1-1 7. CET RN 4264 CE0 00 005 Alternate Raw Water Supply Arrangement - SH 4 R=0 Section-2-2 8. CET RN 4264 CE0 00 005 Alternate Raw Water Supply Arrangement - SH 5 R=0 Section- 3-3 9. CET RN 4264 CE0 00 006 Alternate Raw Water Supply Arrangement - R=0 Key Plan 10. CET RN 4264 CE0 00 007 Alternate Raw Water Supply Arrangement - R=0 Proposed Electrical Substation, MCC & Panel Room - GA 11. CET RN 4264 CE0 00 008 Alternate Raw Water Supply Arrangement - R=0 GA Office Room Cum Control Room 12. CET RN 4264 CE0 00 009 Alternate Raw Water Supply Arrangement - R=0 Route Map of Tenu Canal BSL iv CET/02/RN/4264/FR/CE/01/R=0 Drawal of raw water from Damodar River Experience that delivers 13.