Form-I for 660 Mw Captive Power Plant at Jsw Steel Limited, Geetapuram, Dolvi Village, Pen Taluka, Raigad District, Maharashtra

FORM-I FOR 660 MW CAPTIVE POWER PLANT AT JSW STEEL LIMITED, GEETAPURAM, DOLVI VILLAGE, PEN TALUKA, RAIGAD DISTRICT, MAHARASHTRA

Submitted to: Ministry of Environment and Forests New Delhi

Submitted by:

STEEL LIMITED DOLVI VILLAGE, PEN TALUK, RAIGAD DISTRICT MAHARASHTRA

APPLICATION FOR PRIOR ENVIRONMENTAL CLEARANCE (FORM-1)

(As per Gazette Notification dated 1 st December, 2009 only basic information has to be substituted only.)

(I) BASIC INFORMATION

Name of the Project/s 660 MW CAPTIVE POWER PLANT (Coal BASED) AT JSW STEEL LIMITED, GEETAPURAM, DOLVI VILLAGE, TALUKA - PEN, RAIGAD DISTRICT, MAHARASHTRA. S. No. in the schedule 1 (d)

Proposed capacity / area / length / 660 MW Captive Power Plant (Coal Based) tonnage to be handled / command area / lease area / number of wells to be drilled New / Expansion / Modernization New

Existing Capacity / Area etc. NA

Category of Project i.e. ‘A’ or ‘ B’ Category ‘A’

Does it attract the general condition? No If yes, please specify.

Does it attract the specific condition? No If yes, please specify.

Location The proposed plant facility is located in existing plant premises at Geetapuram, Dolvi Village, Pen Taluka, Raigad District, Maharashtra State.

The location of the site and study area map is shown in Figure-1 & Figure-2. Plot/Survey /Khasra No. Land is comprises of Dolvi & Wadkhal Villages

Village Wadkhal Village

Tehsil Pen

District Raigad

State Maharashtra

Nearest railway station /airport along Pen is the nearest railway station at about 08 km with distance in kms. (aerial distance) on the Konkan Railway line connecting Mumbai-Mangalore along the west coast of India. The nearest airport is Mumbai (national and international) located about 80 km in the north direction from the proposed project site.

Nearest Town, City, District Alibag 20 Km Headquarters along with distance in kms.

Village Panchayat, Zilla Parishad Grampanchayat Wadkhal. Municipal Corporation, Local body (complete postal address with telephone nos.

Name of the applicant JSW Steel Ltd

Registered Address JSW Steel Ltd JSW Centre Bandra Kurla Complex Bandra (East) Mumbai – 400051

Tel No 022-42861000 Fax 022- 42863000

Address for correspondence JSW Steel Ltd Geetapuram, Village – Dolvi, Taluka – Pen, District – Raigad. Maharashtra.

Tel 02143 – 277501 to 15 Fax 02143 – 277533 / 42

Name Shri. V. K. Patidar

Designation (Owner / Partner /CEO) Sr. Vice President (Projects, Utilities & Services)

Address JSW Steel Ltd Geetapuram, Village – Dolvi, Taluka – Pen, District – Raigad. Maharashtra.

Pin Code 402 107

E-mail [email protected]

Telephone No. Phone no: 02143 277501 – 15

Fax No. Fax No. : 02143 – 277533 / 42

Details of Alternative Sites examined, Not Applicable if any. Location of these sites should be shown on a topo sheet. Interlinked Project No Whether separate application of Not Applicable interlinked project has been

2 submitted? If yes, date of submission Not Applicable

If no, reason Not Applicable

Whether the proposal involves Not Applicable approval / clearance under: if Yes, details of the same and their status to be given. (a) Name of the Court (b) Case No. (c) Order/ directions of the Court, if any and its relevance with the proposal project.

(II) ACTIVITY

1. Construction, operation or decommissioning of the Project involving actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.)

Sr. Information/Checklist Yes/ Details thereof (with approximate No. Confirmation No quantities/ rates, wherever possible) with source of information data

1.1 Permanent or temporary No The company has already a total of about change in land use, land 1200 acres of land in its possession for its cover or topography including existing operating integrated steel plant increase in intensity of land complex. use (with respect to local Area required to setup the proposed 660 land use plan) MW Captive Power plant (Coal based) is 150 Acres proposed to be setup near existing Jetty.

1.2 Clearance of existing land, No There will be clearance of existing land, vegetation and building? vegetation wherever required. The proposed area is generally plain area.

1.3 Creation of new land uses No The proposed facility will be constructed within the existing Industrial area.

1.4 Pre-construction Yes Detailed land survey, topographical investigations e.g. bore surveys and soil testing / investigation houses, soil testing? studies has already been carried out earlier.

1.5 Construction works? Yes Installation of 660 MW power plant (Caol based) – construction work to be done. 1.6 Demolition Works? No There will not be any demolition works during the construction of the plant.

1.7 Temporary sites used for Yes Temporary construction offices will be set

3 Sr. Information/Checklist Yes/ Details thereof (with approximate No. Confirmation No quantities/ rates, wherever possible) with source of information data

construction works or housing up during the construction stage, which of construction workers? will be removed later. 1.8 Above ground buildings, Yes Excavation works will be carried out for structures or earthworks constructing the civil structures of the including linear structures, industries. The project may require filling, cut and fill or excavations leveling and piling works. 1.9 Underground works including No Not applicable mining or tunnelling? 1.10 Reclamation works? No Not applicable

1.11 Dredging? No Not applicable 1.12 Offshore structures? No Not applicable 1.13 Production and Yes The description of manufacturing process manufacturing Process? and process flow of 660 MW power plant is presented in Annexure-I.

1.14 Facilities for storage of goods Yes Storage facilities are planned for raw or materials? material.

1.15 Facilities for treatment or Yes The wastewater generated from the disposal of solid waste or indirect cooling circuit would be routed liquid effluents? through the cooling tower and pressure filter for recycling purpose.

The plant sanitary w aste water will be treated in sewage treatment plant and the treated whole water will be used for green belt 1.16 Facilities for long term No There will not be colony for construction housing of operational workers. workers? 1.17 New road, rail or sea traffic Yes Augmentation of port, road and rail during construction or facilities for receipt of additional operation? equipments. 1.18 New road, rail, air water or Yes Augmentation of port, road and rail other transport infrastructure facilities for receipt of additional including new or altered Equipments. routes and stations, ports, airports etc? 1.19 Closure or diversion of No Not envisaged existing transport routes or infrastructure leading to changes in traffic movements?

1.20 New or diverted transmission No Not envisaged lines or pipelines? 1.21 Impoundment, damming, The plant drainage network will be culverting, realignment or No planned and designed in line with the other changes to the existing topography and systems. hydrology of watercourses or

4 Sr. Information/Checklist Yes/ Details thereof (with approximate No. Confirmation No quantities/ rates, wherever possible) with source of information data

aquifers? 1.22 Stream crossings? No Not envisaged

1.23 Abstraction or transfers of No The total water requirement for 660 MW water from ground or surface power plant will be waters? Raw water requirement 400 M3/Hour Sea water intake 7475 M3/Hour.

At present JSW Steel Ltd., Dolvi Works has been allocated about 56.0 MLD water from Amba river, Nagothane, K.T.Bandhara.

1.25 Transport of personnel or Yes Construction materials, mechanical and materials for construction, electrical materials will be sourced from operation or different parts of the state and as well as decommissioning? various part of country through road and rail network.

1.26 Long-term dismantling or No Not envisaged. decommissioning or restoration works?

1.27 Ongoing activity during No Not envisaged decommissioning which could have an impact on the environment?

1.28 Influx of people to an area in Yes The requirement of total manpower for either temporarily or power plant will be about 250. permanently?

1.29 Introduction of alien species? No Not envisaged

1.30 Loss of native species or No Not envisaged genetic diversity?

1.31 Any other actions? No -

2. Use of Natural resources for construction or operation of Project (such as land, water, materials or energy, especially any resources which are non-renewable or in short supply).

Sr. Information/Checklist Yes/ Details thereof (with approximate No. Confirmation No quantities/ rates, wherever possible) with source of information data 2.1 Land specially undeveloped No The additional land is required for the or agricultural land (ha) proposed project since the plant will be constructed near the Jetty industrial complex.

2.2 Water (expected source and Yes The total water requirement for 660 MW competing users) power plant will be Raw water requirement 400 M3/Hour Sea water intake 7475 M3/Hour. At present JSW Steel Ltd., Dolvi Works has been allocated about 56.0 MLD water from Amba river, Nagothane, K.T.Bandhara.

2.3 Minerals (MT) Yes Thermal Coal 30,00,000 Tonnes/Year will be used as raw material in 660 MW Captive power plant. Fuel Oil (HFO) 5782 M3/Year 2.4 Construction material – Yes Cement stone, aggregates, and/ soil Coarse aggregates (expected source-MT) Fine aggregates Reinforcement steel Structural Steel 2.5 Forests and timber (source- No No timber use is envisaged in the MT) proposed project.

2.6 Energy including electricity Yes 47.0 MW power will be required and met and fuels (source, competing by the captive power generated by the users) Unit: fuel (MT), energy CPP Complex. (MW)

2.7 Any other natural resources No Not envisaged (use appropriate standard units)

3. Use, storage, transport, handling or production of substances or materials, which could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health

Sr. Information/Checklist Yes/ Details thereof (with approximate No. Confirmation No quantities/ rates, wherever possible) with source of information data 3.1 Use of substances or No Some amount of used/spent oil and materials, which are grease will be generated during hazardous (as per MSIHC maintenance work, which will be sold to rules) to human health or the MPCB authorized vendor. environment (flora, fauna, and water supplies) 3.2 Changes in occurrence of No Not envisaged disease or affect disease vectors (e.g. insect or water borne diseases)

3.3 Affect the welfare of people Yes Standard of living of the population e.g. by changing living surrounding the proposed project area is conditions? likely to be further improved.

6 Sr. Information/Checklist Yes/ Details thereof (with approximate No. Confirmation No quantities/ rates, wherever possible) with source of information data 3.4 Vulnerable groups of people No Not envisaged who could be affected by the project e.g. hospital patients, children, the elderly etc

3.5 Any other causes No -

4. Production of solid wastes during construction or operation or decommissioning (MT/month)

Sr. Information/Checklist Yes/ Details thereof (with approximate No. Confirmation No quantities/ rates, wherever possible) with source of information data 4.1 Spoil, overburden or mine Yes No major spoil or overburden will be wastes generated at the project site during land development. However, the spoil or earthwork generated during construction will be reused for construction.

4.2 Municipal waste (domestic Yes All municipal solid waste generated from and or commercial wastes) the sewage treatment plant will be used within the plant site for plantation as manure. 4.3 Hazardous wastes (as per Yes The used oil sludge from the plant area hazardous waste and used / spent oil & grease removed management rule-s) from the plant will be sold to authorized users/recyclers approved by state pollution control board. 4.4 Other industrial process Yes Coal fines and fly ash will be generated as wastes solid waste during process, Coal fines will be recycle in the process and fly ash will be sold to cement plant, some amount of bottom ash will be generated which is used in road filling for road construction within the plant or sold to outside party. 4.5 Surplus product No Not envisaged

4.6 Sewage sludge or other Yes No Process sludge will be generated from sludge from effluent the plant. treatment The sewage sludge from the STP will be generated and used within the plant premises as organic manure. 4.7 Construction or demolition Yes Small quantity of metallic scrap waste wastes expected and the same will be used as melting scrap in the existing steel making process. Construction material will be used internally for filling and leveling of the sites within the plant site area. 4.8 Redundant machinery or No Not envisaged equipment

7 Sr. Information/Checklist Yes/ Details thereof (with approximate No. Confirmation No quantities/ rates, wherever possible) with source of information data

4.9 Contaminated soils or other No Not envisaged materials 4.10 Agricultural wastes No Not envisaged

4.11 Other solid wastes No Not envisaged

5. Release of pollutants or any hazardous, toxic or noxious substances to air (kg/hr)

Sr. Information/ Yes/ Details thereof (with approximate No Checklist Confirmation No quantities/ rates, wherever possible) with source of information data 5.1 Emissions from combustion of Yes The following air pollutant will be generated fossil fuels from stationary or from combustion of fossil fuel. mobile sources 1. Dust particulate from fly ash in flue gas: The standard for particulate emission applicable to this project is 150 mg / Nm3. The electrostatic precipitators (ESP) proposed to be installed in this project would be designed to limit the emission level of the particulate matter to this limit 100 mg/N m3

2. Sulphur dioxide (SO2) in flue gas:

One stack (chimney) of height 275 M, with twin flues for effective dispersal of SO2 is proposed to be constructed.

3. Nitrogen oxides (NOx) in flue gas:

To reduce NOx emissions, over-fire air system equipment with air ports would be installed for the furnace. Further, the steam generators would be fitted with advanced low NOx burners. The NOx emissions would be checked for ground level concentrations (GLC) as per the above indicated Indian Emission Regulations . 5.2 Emission from production Yes Emission from production processes are as processes follows. • Dust particulate from fly ash in flue gas

• Sulphur dioxide (SO2) in flue gas

8 Sr. Information/ Yes/ Details thereof (with approximate No Checklist Confirmation No quantities/ rates, wherever possible) with source of information data • Nitrogen oxides (NOx) in flue gas

Emission level will be within the prescribed norms. 5.3 Emissions from materials Yes Coal dust would be generated generally at handling including storage or the conveyor transfer points. Hence, coal transport transfer points would be provided with dust suppression / dust extraction facilities. Further, in order to arrest the coal dust generation, all conveyors would be provided with enclosed galleries. Dust collection system would also be provided in coal bunkers to evacuate dust from the coal bunkers. Fly Ash: At the time of unloading fly ash in to the silo, some ash laden air would get vented out. In order to restrict the fly ash dust particles to the limits of 100 mg / Nm3, a vent filter would be installed on top of the fly ash silo at the vents. Apart from that

a) To reduce the dust nuisance while loading the ash into the trucks from fly ash silo, the fly ash would be conditioned with water spray.

b) It is proposed to cover the ash in the open trucks with tarpaulin to prevent flying of fine ash during transportation.

c) Water sprinking system would be provided in the ash disposal area to restrain flying of fine ash due to wind.

d) The Ash disposal area would be lined with impervious lining to prevent seepage of rain water from the disposal area into the ground and pollute ground water. 5.4 Emissions from construction Yes Fugitive Dust. activities including plant and equipment 5.5 Dust or odours from handling Yes Dust emissions from construction materials of materials including are envisaged. Suitable dust suppression construction materials, methods will be followed. sewage and waste There is no possibility of any odour generation. 5.6 Emissions from incineration No Not envisaged of waste

5.7 Emissions from burning of No Not envisaged

9 Sr. Information/ Yes/ Details thereof (with approximate No Checklist Confirmation No quantities/ rates, wherever possible) with source of information data waste in open air (e.g. slash materials, construction debris)

5.8 Emissions from any other No Not envisaged sources

6. Generation of Noise and vibration, and emissions of Light and heat

Sr. Information/Checklist Yes/ Details thereof (with approximate No. Confirmation No quantities/ rates, wherever possible) with source of information data 6.1 From operation of equipment Yes Noise will be generated from the power e.g. engines, ventilation plant, plant which will not be allowed to exceed 85 crushers dB (A). Adequate control measures like acoustic systems will be provided.

6.2 From industrial or similar Yes The expected noise level will not be allowed processes to exceed 85 dBA (A) or proper noise protection systems will be used whenever required.

There will be not be any adverse effect on the ambient Noise.

6.3 From construction or Yes Yes. This will be in the range of about 65-80 demolition dB(A). Regular maintenance of the equipment will help in reducing these noise levels.

6.4 From blasting or piling Yes Some noise <85 dB (A) will be generated.

6.5 From construction or Yes The noise levels are expected to be in the operational traffic range of about 70-75 dB(A).

6.6 From lighting or cooling No Not envisaged systems

6.7 From any other sources No Not envisaged

7. Risks of contamination of land or water from releases of pollutants into the ground or into sewers, surface waters, groundwater, coastal wasters or the sea

Sr. Information/Checklist Yes/ Details thereof (with approximate No. Confirmation No quantities/ rates, wherever possible) with source of information data

7.1 From handling, storage, use No Not envisaged. or spillage of hazardous materials

7.2 From discharge of sewage or No The sewage water will be treated and used other effluents to water or for greenbelt development within the the land (expected mode and premises. Out side discharge is not place of discharge) envisaged.

The wastewater from the plant units will be treated at the individual source of generation and re-used or re-cycled into the processes.

There will not be any external discharge of wastewater, except cooling of sea water.

7.3 By deposition of pollutants No There is no discharge of wastewater outside emitted to air into the land the plant. or into water

7.4 From any other sources No Not envisaged

7.5 Is there a risk of long term No Not envisaged build up of pollutants in the environment from these sources?

8. Risk of accidents during construction or operation of the project, which could affect human health or the environment

Sr. Information/Checklist Yes/ Details thereof (with approximate No. Confirmation No quantities/ rates, wherever possible) with source of information data

8.1 From explosions, spillages, Yes There will not be any possibility of oil spill in fires etc and from storage, the plant. However, suitable risk handling, use or production assessment will be carried out and disaster of hazardous substances management plan will be in place.

8.2 From any other causes No Not envisaged

11 Sr. Information/Checklist Yes/ Details thereof (with approximate No. Confirmation No quantities/ rates, wherever possible) with source of information data

8.3 Could the project be affected No The area is generally flat land. There is no by natural disasters causing record of occurrence of floods, land slides, environmental damage (e.g. cloud bursts etc. floods, earthquakes, slides, could burst etc) The proposed project site falls in Zone-IV as per IS-1893 (Part-I):2002.

9. Factors which should be considered (such as consequential development) which could lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality

Sr. Information/Checklist Yes/ Details thereof (with approximate No. Confirmation No quantities/ rates, wherever possible) with source of information data

9.1 Lead to development of Yes Existing and ancillary facilities will improve. supporting, facilities, ancillary development or development stimulated by the project which could have impact on the environment

Supporting infrastructure Yes Existing infrastructure facilities will be (roads, power supply, waste expanded / extended to take care of the or waste water treatment, project. etc)

Housing development No Utilises the existing facility

Extractive industries No The proposed facilities are captive to JSW Steel Ltd.

Supply industries Yes Existing supply chain will improve

Other --- 9.2 Lead to after use of the site, Yes The proposed project will not have impact which could have an impact on environment. However, these impacts on the environment will be contained by adopting suitable mitigation measures.

9.3 Set a precedent for later Yes Ancillary industries will be developed as a developments consequence.

9.4 Have cumulative effects due Yes The industry is not located in a critical zone. to proximity to other existing There are not many major industries or planned projects with operating in this region. Hence, no major similar effects effects are envisaged.

12 Sr. Information/Checklist Yes/ Details thereof (with approximate No. Confirmation No quantities/ rates, wherever possible) with source of information data

(III) Environmental Sensitivity

Sr. Areas Name Aerial distance (within 15 km) No. / Proposed project location boundary Identity 1 Areas protected under No There are no ecological, landscapes, international conventions, cultural or other related sensitive areas national or local legislation in 15 –km radius. for their ecological, landscape, cultural or other related value

2 Areas which are important or No There are no national parks, sanctuaries sensitive of ecological in 15-km radius from proposed project reasons – wetlands, water site. courses or other water bodies, coastal zone, biospheres, mountains, forests

3 Areas used by protected, Yes Four reserve forests exists in 15 Km important or sensitive species radius area as listed below: of flora or fauna for breeding, • RF near Kharkhara village ( 1- nesting, foraging, resting, km, E) over wintering, migration • RF near Katkariwadi village (5.3- km, NE) • RF near Turmal village (4.6-km, E) • RF near Katvira village(5.1- km, SW) • RF near Dhavte village(8.5-km NE)

Detailed floral and fauna studies will be conducted and details will be incorporated in EIA report

4 Inland, coastal, marine or Yes Amba river 2.0 – km, W underground waters Bhogeswar river 7.8-km, N

5 State, national boundaries No Nil

6 Routes or facilities used by No Not applicable the public for access to recreation or other tourist, pilgrim areas

13 Sr. Areas Name Aerial distance (within 15 km) No. / Proposed project location boundary Identity

7 Defence installations No Nil within 10-km radius

8 Densely populated or built-up Yes Pen Taluka is 6.9-km from the plant area site.

9 Areas occupied by sensitive Yes Pen Taluka has all the facilities such as man made land uses primary schools, middle schools, high (hospitals, schools, places of schools, hospitals health centers, public worship, community facilities) health sub centers, dispensaries and place of worship.

10 Areas containing important, No No scarce resources are present in 15- high quality or scarce km radius resources (ground water resource, surface resources, forestry, agriculture, fisheries, tourism, minerals)

11 Areas already subjected to No This is not a listed or critically polluted pollution or environmental area. damage. (those where existing legal environmental standards are exceeded)

12 Areas susceptible to natural No The proposed project site falls in zone- hazard which could cause the IV as per (As per IS: 1893 (RSM) from project to present 2002). environmental problems (earthquakes, subsidence, No land slides / flooding is envisaged in landslides, erosion, flooding project area. or extreme or adverse climatic conditions)

(IV) Proposed Terms of Reference for EIA Studies – Annexure – II.

I hereby given undertaking that the data and information given in the application and enclosure are true to the best of my knowledge and belief and I am aware that if any part of the data and information submitted is found to be false or misleading at any stage, the project will be rejected and Clearance give, if any to be the project will be revoked at our risk and cost.

Date: 1st April 2014

Place: Dolvi

Mr. V.K. Patidar Sr. Vice President (Projects, Utilities & Services) JSW Steel Ltd Geetapuram, Village – Dolvi, Taluka – Pen, District – Raigad Maharashtra 402107.

15 FIGURE -1 LOCATION MAP

Plant Site

FIGURE -2 STUDY AREA MAP

73° 0' 73° 5' Kalve Johe Sonkhar Tambatshet Mumbai N 98km Bhalpada Tukaramwadi Kanebachapada Hamrapur Kalesri

Varedi Mothe vadhav Shinole Sapoli

Div Borze Kane Khar Sapoli Chinchghar Vadhav Narvel Antora Ramraj Benavle Navgharwadi Tarankhop Vashi 18° Masad Khurd 18° 45' Kaproli Antora R F 45' Patnoli Khalapur PEN B Dhavte 27.8km h Ambeghar Dherankhar Dhondapada og Masad Khurd Pipalpada es hw Umbarde ar Masad Budruk BorgaonR Borve Shirki Pimpalpada . Shahapur Vashinaka Ramwadi Maleghar Bori Vadgaon Uchede Dhakta Shahapur Shinganvat Kandepada Kolve Kashmire Rode Kandale Sutarpada Vadkhal Indranagar Lebhi A m Katkariwadi Khidki KOPAR Wave Virani b a RESERVED FOREST Navegaon R Dharamtar Chari . Kurkundi Dolvi Ghasvadkhar Kamalpada PLANT Divlang Shahabaj RESERVED FOREST Bandhanwadi Bhanghar Pezari Dadaji Talanikar Valvade Kharkaravi Turmal Ambeghar Bangalwadi Poinad Ambepur Bhakhwadi Gadab RESERVED FOREST Dehankoni Khapachiwadi Tadmalwadi Chaphegani VagholiNagjhari Patharmal Dhombi Jirne Navenagar 18° Medhekhar Takachiwadi 18° 40' Sukatrie 40' Kachali Mounepale Shekatmal RESERVED FOREST Bakeghar Katkorwadi Pitkari Kherpale Vadvali Shirgaon Katvira Kusambale Ratalpada Vaghvira Devali Katvaripada RESERVED FOREST Hemnagar Anandnagar Kalad Tadvagle Kharjul Talashet Pedkyawadi Kathodipada Chikhali Karanjatep Burdi Brahmanwadi Kharoshi RESERVED FOREST Kasu Kolghar Khadakwadi

Pandapur Thakurwadi Ruishet Bhomoli Navakar Kurdus Bidbav Chaura Dattawadipada Ananwadi Sutwadi Sambri Mahabalewsaram 133.7km Ruishet Bidwagale Aveti 73° 0' 73° 5' LEGEND Plant Site Settlements Road Forest Boundary Railway Line Nadi/Nala/Water Body

17 ANNEXURE-I 660 MW CAPTIVE POWER PLANT – PROCESS DESCRIPTION

Process Description

Requirement of Raw Materials

The annual (net and dry) requirements of raw materials for 660 MW Captive Power Plant (Coal Based) are given in table.

Annual Major Raw Material Requirement (net & dry basis):

Sl. Raw material Quantity Source No. (TPA)

Australia / South 1. Thermal Coal 30,00,000 Africa / Indonesia

Thermal Coal

18 thermal coal are Australia, South Africa and Indonesia. The requirement of thermal coal is about 30,00,000 TPA on Net and Dry basis considering average GCV value of thermal coal as 5000 kcal/kg and annual plant load factor (PLF) of 85%. 100% imported thermal Coal is proposed to be used in the Captive Power Plant. Considering moisture loss of 10%, handling loss of 5% the annual requirement is about 34,60,000 MT.

The average analysis of thermal coal is expected to be as follows.

Fixed carbon : 54 – 56 % Volatile matter : 20 – 23 % Ash : 10 – 12 % Total moisture : 12 % maximum CV of coal : 5000 kcal/kg (approx.) Size of coal : < 100 mm

Fuel Oil

Heavy fuel oil would be used for start-up and flame stabilization at low loads and LDO would be used for light up and warm up of units.

ANNEXURE-II PROPOSED TERMS OF REFERENCE

Project Implementation :

A detailed description of all elements of the project during the pre- construction, construction and operational phases will be prepared. The elements analyzed will include the infrastructures of the project including: drainage features, roads, waste collection, disposal and management and utility requirements.

Analysis and assessment of designs to ensure environmental soundness, sustainability and regulatory compliance of the designs will be studied and incorporated in the draft and final EIA Report. Field Assessments : Field assessments of the physical, ecological, and socioeconomic aspects of the site and associated environs will be conducted during post-monsoon season. These assessments will be used to determine the potential impacts, if any, of the proposed project. A photographic survey of the proposed site and the nearby environs has been conducted. The survey included a photo- inventory of the physical and biological features of the site and environs, and the areas are viewed with respect to the suitability of the proposed facility. The assessments included: Physical : Climate, air quality, geology, topography, groundwater/surface water hydrology quality, hazard vulnerability, noise levels and land use.

Ecological : Terrestrial and aquatic communities; presence of rare, threatened and endangered species.

Socioeconomic : Demography, regional setting, location assessment, and land uses. The technical scope of work for carrying out the baseline monitoring has been as given below. The baseline monitoring will be carried out in 10-km radius study area around the proposed project site for three months representing the post - monsoon season.

Sr. Attributes Scope of Work No. 1 Ambient Air Quality 4 Locations - 2 days/week for 13 weeks (3

months) PM-2.5, SPM, RPM, SO 2, NOx, and CO will be monitored as per CPCB guidelines.

Design of ambient air quality sampling network with regard to topography, population, sensitive locations, emission sources, background concentrations and possible impact zones, through application of screening air quality models for assessing the maximum GLC zones prior to start of baseline study. 2 Meteorological data 1 Location - 90 days

20 Sr. Attributes Scope of Work No. Wind speed, direction, temperature, humidity, cloud cover and rainfall will be monitored. This is further supported by the meteorological data for the area of interest from the nearest meteorological observatory and Trend analysis of micrometeorological data generated at the site. 3 Water Quality 9 Locations- (Surface and Ground water samples)

– Once during the EIA study

Parameters as per IS-10500, IS:2296 and EPA Act as applicable .

The survey also include estimation of water balance and assessment of impacts on regional water demand and availability of fresh water due to drawl of water for plant, recommendations on water conservation and rain water harvesting measures based on past experience on similar projects; and identification of suitable location and methodology for disposal of waste water form all sources. 4 Soil Quality 6 Locations once during EIA study. Parameters related to afforestation, nutrients, pollutants etc. will be carried out. 5 Noise Levels 8 Locations (Residential, Commercial and Sensitive areas) once during EIA study. Readings will be taken for 24-hr duration at each location 6 Land use Land use as per the district census handbooks as well as with the help of satellite imagery will be presented in 10-km radius study area. 7 Solid waste Characterization of all the solid wastes generated from the plant operations and its disposal including impacts due to disposal. 8 Socio-Economic and Socio-economic and health aspects are covered Demography for 10-km radius study area based on the Census documents and NIC database. 9 Ecological studies Flora and fauna will be studied in 10-km radius (Terrestrial and study area. These studies will be based on Aquatic) primary as well as secondary sources.

The survey also includes assessment of the species diversity, density, abundance etc. in the study area and formulation of ecological indexes, assessment of likely changes on flora and fauna due to the project related activities, suggestions for conservation and protection of flora and fauna in the study area and suggestions for development of new conservation areas locally.

10 Traffic Study Traffic at important points on the approach roads

21 Sr. Attributes Scope of Work No. will be surveyed for the existing total daily traffic, peak hour traffic and traffic composition. Assessment of the change in traffic composition and volumes and suggestions for improvement of traffic flow around the project site and around will be studied 11 Aesthetic/Cultural Identification of all historical/ archeological Aspects sites/monuments in the study area.

Detailed qualitative assessments of the physical, ecological, and socioeconomic conditions associated with the site in the Draft and Final Report. Legislation and Regulatory Considerations Government policies, legislation and regulations relevant to the proposal will be identified. Local plans and policies will also be evaluated. Project characteristics will be analyzed to ensure compliance with these policies, legislation and regulations. Appropriate recommendations will be provided to ensure regulatory compliance. The legislation relevant to the project will be summarized and presented in the EIA Reports. Environmental Impact Assessment

The guidelines suggested and international practices will be reviewed to determine the adverse impacts and critical areas.

There are various qualitative as well as quantitative methods of conducting EIA studies, each having its own merits and demerits. We intend to use the best logical tool to assess the impact of the project.

The baseline data generated from above studies will be analyzed and compared with applicable standards for each environmental attribute, so that the critical environmental areas and also attributes of concern will be identified. The short term and long-term impacts particularly on sensitive targets such as endangered species, plants and historically important monuments will be identified.

The Environmental Impact Assessment of proposed project will be done on above basis to determine the environmental acceptability of this proposed project in absence of control measures and after implementation of the mitigation measures, including worst impact.

A qualitative and quantitative assessment of pollution aspects of proposed project (air and dust, wastewater, noise pollution, wastewater discharges etc.) will also be done to identify the adequacy of the proposed control measures as well as the likely impact on existing critical areas. Mitigation measures to reduce adverse impacts will be suggested.

Air Impacts:

22 Emission Inventory will be carried out in an area of 10-km around the project site. A computer based internationally recognized mathematical air quality model (ISC-ST3) model will be used to predict the concentration of SO 2, NOx and SPM due to the operation of the proposed project. The model would also take into account other sources of pollution and topographical features of the area. The emission of relevant pollutant (SO 2, NOx, PM2.5, PM10) from nearby sources shall be used in the model for more accurate estimate of air quality. The results will be presented for short term (24 hourly) concentrations over a radius of 10-km around the plant site. The dispersion model results will be included in the report using isopleths or other graphical methods, over laying a land use map of the surrounding area. The predicted air quality will be compared with existing regulations and mitigative measures, if any, will be identified. The long term and short term impact at all the monitoring locations shall also be estimated.

Noise Impacts:

Sources of noise and its impact on the environment would be clearly brought out. The noise level at varying distances for multi-sources will be predicted using suitable model. A comparison of measured noise (Leq) at monitoring locations to that of predicted noise levels (Leq) would be made and mitigatory measures required, if any, will be recommended to conform to regulatory ambient air noise standards.

We propose to estimate increase in noise levels over the baseline conditions in different zones like industrial, residential and sensitive areas like hospitals, wild life habitation etc. The potential noise level exposure will be determined and evaluated for acceptable limits of exposure.

Environment Management Plan

For each potential negative impact identified, recommendations will be presented for avoidance, minimization or mitigation of impacts along with costs associated with potential mitigation.

An EIA/EMP, based on three months baseline study, will be prepared for the project. The EMP will address the following:

• Identify and summarize all anticipated significant adverse environmental impacts; • Identify and summarize all mitigation measures, including the type of impact to which it relates and the conditions under which it is required; • Define a set of policies and objectives for environmental performance and continual enhancement of performance; • Recommend monitoring measures including the parameters to monitored, methods to be used, sampling locations, frequency of measurements, detection limits and definition of thresholds that will signal the need for corrective actions; • Recommend monitoring and reporting procedures; • Recommend capacity development and training requirements for implementation of EMP; • Recommend organizational structure for effective implementation of the EMP; and • Draw up an implementation and cost schedule for EMP.

23 Environmental Monitoring

An environmental monitoring and management plan will be developed for the sensitive elements of the environment that may require monitoring during construction and operations of the facility. Recommendations will be made on the institutional arrangements that will be necessary to ensure effective monitoring and management. A detailed management and monitoring program will be developed to reduce the effects of potential negative environmental impacts.

Risk Assessment and Disaster Management Plan

Risk Assessment studies comprising sub-activities such as hazard identification, assessment and quantification of risk for suggesting risk mitigation measures based on Maximum Credible Accident (MCA) Analysis to be carried out for the proposed project. Preparation of the Risk Assessment Report will be followed by Disaster Management Plan (DMP) and Emergency Preparedness Plan (EPP) based on the quantitative Risk Assessment of the proposed activity and associated infrastructure for the project.

Occupational Health and Safety

We will review the existing system of safety management and occupational health surveillance system in the proposed facility plant and recommend for further appropriate measures in view of the proposed plant.

Captive Power Plant 1 x 660 MW At Dolvi Works, Maharashtra Project Report

Mumbai

March 2014

JSW Steel Limited 660 MW Captive Power Plant Maharashtra

Project Report

CONTENTS

Chapter No. Title Page Nos.

From To

01 Introduction 1-1 1-2

02 Market Analysis & Power Scenario 2-1 2-4

03 Process Description & Raw Materials 3-1 3-5

04 Proposed Site 4-1 4-4

05 Plant and Equipment 5-1 5-20

06 Services, Utilities & Manpower Requirement 6-1 6-8

07 Environmental Management 7-1 7-8

08 Project Implementation 8-1 8-1

09 Block Capital Cost 9-1 9-1

LIST OF DRAWINGS

Sl. No. Description Drawing No.

1. Location Map JSW/DW/CPP/PR/001

2. Regional Map JSW/DW/CPP/PR/002

3. Road Linkage JSW/DW/CPP/PR/003

4. Rail Linkage JSW/DW/CPP/PR/004

5. Process Flow Sheet JSW/DW/CPP/PR/005

6. General Layout JSW/DW/CPP/PR/006

7. Water Balance Diagram JSW/DW/CPP/PR/007

8. Implementation Schedule JSW/DW/CPP/PR/008

This document is the property of JSW and contains confidential information and proprietary intellectual property. This is not to be copied or used for other projects unless expressly permitted by JSW.

JSW TECHNO PROJECTS MANAGEMENT LTD.

JSW Steel Limited 660 MW Captive Power Plant Maharashtra Project Report

01 INTRODUCTION

01.01 Preamble

JSW Group, the biggest steel producer in India is ranked amongst India’s top business houses in terms of turnover, size and scale. The Group is a multi-location, multi-product business with interest spanning across Mining, Carbon Steel, Power Generation & Distribution and Ports and Infrastructure. “Growth with a social conscience” is a paradigm the Group lives by. Its strength lies in its individual companies, with each one committed to consolidate its core strength and excelling in its field of specialization.

The JSW group owns and operates, a 3.3 Mt/yr Steel plant at Dolvi, Maharashtra based on BF-DR-CONARC-CSP process route. It also has cold rolling, galvanizing, colour coating plant, galvalume and pipe & tube plant at Kalmeshwar, Nagpur in the state of Maharashtra. The next phase of expansion will take the capacity of this plant to 5.0 Mt/yr by the year 2015.

It is also proposed to expand the capacity of the integrated steel plant from 5.0 Mt/yr to 10.0 Mt/yr at Dolvi. At 10 Mtpa capacity the steel plant would have a power demand of about 900 MW.

The steel plant is presently consuming 300 MW of average power from MSEB grid, at 220 kV from MSEB grid sub-station located near the plant site out of which 55 MW is from a Captive Power Plant.

It is proposed to set up a 660 MW coal based Supercritical Captive Power Plant (CPP) near Geetapuram Port in Dharamtar, in Pen Taluka of Raigad District in Maharashtra State. The power produced from the captive Power Plant will be used in the steel

1-1

JSW Steel Limited 660 MW Captive Power Plant Maharashtra Project Report

plant of JSW Steel Ltd. at Dolvi. Services like supply of water, power & compressed air etc. will be made available at plant boundary limit from the existing steel plant of JSW Steel Dolvi Works.

01.02 Objective of the Report

This project report has been prepared for getting Environmental Clearance for the proposed 660 MW coal based supercritical Captive Power Plant in Dolvi, Maharashtra. This power plant will be used to fulfill the power demand from the various units of the steel plant.

The power plant will have a capacity of 660 MW and the investment will be about Rs. 4500 crores.

1-2

JSW Steel Limited 660 MW Captive Power Plant Maharashtra Project Report

02 MARKET ANALYSIS & POWER SCENARIO

02.01 General

India’s continued economic growth has put massive strain on the country’s existing infrastructure, which has not kept pace with development. Private participation coupled with government support will be the key driver for infrastructure construction. With more than 20% tax-revenue growth over the past four years, central and state government finances are in better shape, and improved public-enterprise profitability supports capex plans.

India’s power-generation capacity is likely to double by 2017. It is expected that the capex will jump from US$48bn in the federal government’s 10th five-year plan (FY03-07) to US$108bn in the 11th plan (FY08-12) and US$171bn in the 12th plan (FY13-17).

India, which has an installed capacity of around 2.28 lakh MW, is estimated to have a deficit of nearly 12% during peak hours. The government has added about 53,000 MW power generation capacity in the past five years (2007-12), around 9,000 MW short of the target of 62,000 MW.

The government had earlier set a target of over 78,000 MW for the 2007-12 period, which was curtailed to 62,000 MW in the Planning Commission’s mid-term review due to lack of environment clearance for the coal blocks allotted for the power projects. The Power Ministry also envisages to add 76,000 MW in the coming five years (2012-17), even though the Planning Commission has proposed a target of above 90,000 MW during the same period.

2-1

JSW Steel Limited 660 MW Captive Power Plant Maharashtra Project Report

NTPC is the largest power producer in the country with an installed capacity of 42,964 MW capacity, plans to add over 14,000 MW. According to industry experts, India needs investment of $120-150 billion over the next five years in the energy sector, and strong private sector participation is required to complement the public sector.

02.02 Indian Electricity Scenario

The electricity sector in India is predominantly controlled by Government of India's public sector undertakings (PSUs). Major PSUs involved in the generation of electricity include National Thermal Power Corporation (NTPC), National Hydroelectric Power Corporation (NHPC) and Nuclear Power Corporation of India (NPCI). Besides PSUs, several state-level corporations, such as Maharashtra State Electricity Board (MSEB), are also involved in the generation of electricity. The intra state distribution is managed by the State Electricity Boards (SEBs) and private companies. Powergrid Corporation of India is responsible for the interstate transmission of electricity and the development of national grid. The sector-wise total installed capacity in India is presented in table – 02.01 below : Table – 02.01 Sector-wise Installed Capacity in India

Sector MW %age State Sector 90,062.14 39.37 Central Sector 65,732.94 28.73 `Private Sector 72,926.66 31.88 Total 228,721.74

2-2

JSW Steel Limited 660 MW Captive Power Plant Maharashtra Project Report

Source : CEA (as on Sept.-2013)

India is world's 4th largest energy consumer, accounting for 4.0% of global energy consumption. Due to India's economic rise, the demand for energy has grown at an average of 3.6% per annum over the past 30 years. More than 50% of India's commercial energy demand is met through the country's vast coal reserves. About 68% of the electricity consumed in India is generated by thermal power plants, 17% by hydroelectric power plants and 2% by nuclear power plants. The country has also invested heavily in recent years on renewable sources of energy such as wind energy. The fuel-wise power generation in India is tabulated in Table-02.02 below: Table - 02.02

Fuel MW %age Thermal 155,968.99 68.19 - Coal 134,388.39 58.75 - Gas 20,380.85 8.91 - Oil 1,199.75 0.52 Hydroelectric 39,788.40 17.39 Nuclear 4,780.00 2.08 Renewable Energy Sources (include Biomass Gasifier, Biomass Power, Urban & 28,184.35 12.32 Industrial Waste Power and Wind Energy) Total 228,721.74 Source: CEA

In September 2013, the installed power generation capacity of India stood at 228,721.7 MW while the per capita power

2-3

JSW Steel Limited 660 MW Captive Power Plant Maharashtra Project Report

consumption stood at 917 kWh as per CEA. The country's annual power production increased from about 190 billion kWh in 1986 to more than 911 billion kWh in 2012-2013. The total demand for electricity in India is expected to cross 950,000 MW by 2030.

02.03 The likely power supply position at the end of 2012-13 is given in the table below. Table – 02.03

Period Peak Peak Peak Peak Energy Energy Energy Energy Demand Met Deficit/ Deficit/ Require Avail Deficit/ Deficit/ (MW) (MW) Surplus Surplus ment ability Surplus Surplus (MW) (%) (MU) (MU) (MU) (%) 2012-13 135,453 123,294 -12,159 -9.0 995,500 908,574 -86,926 -8.7

Despite the sharp increase in capacity addition, India’s power shortages are likely to remain fairly high in the 11th plan and demand-supply may reach close to a balance some time in the 12th plan.

02.04 Conclusions

Thus looking at the demand supply scenario and the plans of the Government to boost the power sector, the proposed captive capacity addition is expedient and economically viable.

2-4

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

03 PROCESS DESCRIPTION & RAW MATERIALS

03.01 Process Description

In captive power plants, water is taken to the boiler or steam generator where coal is burnt. The boiler transfers heat energy to the water in form of latent heat of vaporization or enthalpy by the chemical reaction of burning coal. External fans, such as PA fans and FD fans, are provided to give sufficient air for combustion. The steam generating boiler produces steam at the high purity, pressure and temperature required for the steam turbine that drives the electrical generator. The steam generator includes an economizer, a steam drum, and the furnace with its steam generating tubes, superheater coils and reheater coils. Necessary safety interlocks, fuel purging systems, safety valves are installed to ensure safe operation of the boiler. Steam turbine uses the dynamic pressure generated by expanding steam to turn its blades. The power so produced by the electric generator which is coupled with the rotating steam turbine is transmitted to the main distribution centre (switchyard). The process flow sheet of the proposed process for captive power plant is given in drawing no. JSW/DW/CPP/PR/005. The salient features of major equipment of 660 MW coal based supercritical captive power plant are • Pulverized coal fired, once through, balanced draft super critical boilers with BMCR around 2100 Tons per hour, regenerative type air pre-heater, Bowl/Tube type mills with one spare under worst coal firing, 2x60% duty ID, FD & PA fans etc.

3-1

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

• Tandem, compound, double flow, reheat regenerative & condensing steam Turbine having HP,IP &LP cylinders with TMCR around 1970 Tons per hour, with 3 nos. HP Heaters and 4 nos. LP Heaters • HP&LP Turbine Bypass with capacity 60% TMCR • Horizontal, double pass, surface type, integral air cooling zone condenser with temperature rise of cooling water by 9 degrees at inlet temp.33 degrees C with hot well storage 3 minutes at Turbine V.W.O condition. • 3x50% duty Condensate Extraction pumps • 2x50% duty Turbine driven and 1x30% motor driven Boiler Feed Pumps • Spray cum Tray type Deaerator with storage 10 minutes at V.W.O condition • Condensate polishing plant of full flow, 3 x 50% duty with mixed bed trains • Circulating Water Pumps of 3x50% duty • Auxiliary Cooling Water pumps of duty 2x100% • DM Plant of total 2x70 m³/hr capacity to ensure make-up requirement of heat cycle at the rate of 3% of the BMCR steam flow • Coal Handling Plant of1450TPH belts • Induced Draft Cooling Tower/ Natural Draft Cooling Tower • Control and Instrumentation system with major components :Distributed Control System DCS) with Plant wide Data High way ,Steam Generator Control and Protection System as per manufacturer’s standard design with interfacing with the Plant DCS, Turbine Generator Control and Protection System as per TG manufacturer’s standard design interfacing with the Plant

3-2

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

DCS, Turbine Supervisory Instrumentation system for TG, Vibration monitoring system for major plant auxiliaries including BFP, Master and Slave Clock System, Central Control Room, Measuring Instruments, Stack Emission Monitoring System etc.

03.02 Raw Materials

Raw materials availability is becoming critical due to the heavy demands made and the limited resources. Proper sourcing and appropriate beneficiation combined with logistics planning has become vital for the success of any plant operation. Thermal coal is the major raw material required for the plant. The location and the regional map of the plant site have been shown in the drawing no. JSW/DW/CPP/PR/001 & JSW/DW/CPP/PR/002 respectively.

03.03 Requirement of Raw Materials

The annual (net and dry) requirements of raw materials for 660 MW Captive Power Plant are given in table 03.01. Table-03.01

Annual Major Raw Material Requirement (net & dry basis):

Sl. Raw material Quantity Source No. (t/yr) Australia / South 1. Thermal Coal 3,000,000 Africa / Indonesia

3-3

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

Estimated requirement of raw material have been briefly described in subsequent paragraphs.

03.03.01 Thermal Coal

The steam boiler would be designed for coal firing. The steel plant has no indigenous coal supply linkage. Availability of low ash thermal coal of desired quality is limited in India. Hence, it has been envisaged that requirement of thermal coal will be met through imports. The possible sources of supply of thermal coal are Australia, South Africa and Indonesia. The requirement of thermal coal is about 3,000,000 t/yr on Net and Dry basis considering average GCV value of thermal coal as 5000 kcal/kg and annual plant load factor (PLF) of 85%. 100% imported thermal Coal is proposed to be used in the Captive Power Plant. Considering moisture loss of 10%, handling loss of 5% the annual requirement is about 3.46 Mt.

The average analysis of thermal coal is expected to be as follows. Fixed carbon : 54 – 56 % Volatile matter : 20 – 23 % Ash : 10 – 12 % Total moisture : 12 % maximum CV of coal : 5000 kcal/kg (approx.) Size of coal : < 100 mm

03.03.02 Fuel Oil

The annual requirement for the proposed 660 MW unit would be about 5782 m3 based on consumption of 1ml/kWh (CERC

3-4

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report guidelines) of power generation. The daily average consumption of HFO would be about 15.84 m3 /day.

3-5

JSW Steel Limited 660 MW Captive Power Plant Maharashtra Project Report

04 PROPOSED SITE

04.01 Proposed Site

The 660 MW coal based Supercritical Captive Power Plant is proposed to be set up near Geetapuram Port in Dharamtar, in Pen Taluka of Raigad District in Maharashtra State. The site is at a distance of 100 km from Mumbai, and about 40 km from Panvel by Road. The location map and the regional map of the proposed site have been shown in the drawing no. JSW/DW/CPP/PR/001 & JSW/DW/CPP/PR/002 respectively. The indicative coordinates of the proposed site are given below: Latitudes : 18° 42’ 12.50” N

Longitudes : 73° 01’ 43” E

04.02 Area Requirement

04.02.01 General

The area requirement for the proposed plant has been estimated based on the following factors:

¾ Area requirements of individual technological and service facilities ¾ Smooth and uninterrupted flow of incoming and outgoing materials with minimum counterflow for different technological facilities. ¾ Logistics in location of technological units as well as services facilities. ¾ Safety requirements and statutory provisions. ¾ Adequate green belt all around the plant.

4-1

JSW Steel Limited 660 MW Captive Power Plant Maharashtra Project Report

04.02.02 Existing Area

The total area required for the proposed 660MW coal based Supercritical Captive Power Plant is about 150 acres. The plant layout will contain facilities like Main power block including area for future FGD, Balance of Plant including Sea water intake pump house Cooling Towers, Demineralised Water Plant, Ash mound area including Ash Plant area, 220 KV Switchyard, Clarified water storage, Effluent treatment, lay-down area, green belt development, Coal storage, access roads, etc. The general layout considering recirculation type sea water Induced Draft Cooling Tower (IDCT) is shown in dwg. no. JSW/DW/CPP/PR/006.

04.03 Logistics

The entire thermal coal required for the captive power plant will be sourced from Australia, South Africa & Indonesia.

04.03.01 Road

The National Highway NH-17 (Mumbai-Goa) passes on the east side of the plant. State Highway also passes on the north side of the plant. The Mumbai city is located at about 100 km on the North-West side of the plant. The Road linkage of the proposed site is shown in Drg.No. JSW/DW/CPP/PR/003.

04.03.02 Railways

The nearest railway station Pen is about 8 km from the plant site and is located in the east on the Konkan Railway Mumbai - Mangalore main line. Rail linkage from plant site has to be

4-2

JSW Steel Limited 660 MW Captive Power Plant Maharashtra Project Report

strengthen. The Rail linkage of the proposed site is shown in Drg.No. JSW/DW/CPP/PR/004.

04.03.03 Port Connectivity

The Dolvi complex has a captive port located close to it on the Amba River, which opens into the Arabian Sea. This port can handle barges and mini-bulk carriers up to 4,000 dry weight tonnage (DWT). Moreover, a jetty adjoining the complex is capable of handling cargo of up to 16.2 million tonnes per annum. Raw materials and finished products, to be exported, are being handled through these ports. It is proposed to increase the jetty length to handle the additional raw material.

04.03.04 Air Connectivity

The nearest Mumbai airport is 80 km away from site connected through major road. The proposed Navi Mumbai International airport is 40 km away from plant site.

04.04 Water

The make-up raw water requirement is about 400 m3/hour and sea water intake would be around 7475 m3/hr, consumption is 1275 m3/hr and return back to sea would be about 6200 m3/hr for the proposed 660 MW Captive Power Plant. At present JSW Steel Ltd., Dolvi Works has been allocated about 56.0 MLD water from Amba river, Nagothane, K.T.Bandhara. The water requirement is proposed to be met from the existing allocation to JSW Steel Ltd.

4-3

JSW Steel Limited 660 MW Captive Power Plant Maharashtra Project Report

04.05 Power

The estimated power requirement for the 660 MW Captive Power Plant will be about 47 MW. The total power requirement is proposed to be met by the captive power generated by the CPP complex.

04.06 Township

A township is being constructed to take care of the accommodation facilities of the employees of the plant including the proposed Power Plant.

4-4

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

05 PLANT & EQUIPMENT

The plant and equipment for coal based supercritical captive power plant of capacity 660 MW are briefly enumerated below based on General Layout (Drg. No. JSW/DW/CPP/PR/006). The Committee appointed by CEA to recommend to adopt units of 660-1000 MW size in the country as next higher size in its report of November - 2003. The Committee has examined among other factors, the important aspects of grid reliability to withstand outage of unit of large capacity, future grid inter connections, increase in plant efficiency and reduction in the installation cost of large size power plants, reduction in consumption of coal, reduction in effluents and particulate matter to outside, established reliability of large size units world-wide and environment benefits. For the proposed 660 MW supercritical power project following parameters are selected. Main steam pressure 242.2 bar (a) Main steam temperature 565°C Reheat temperature 593°C

05.01 Steam Generator & Accessories The steam generator (SG) would be once through type and would be designed for firing imported coal of GCV 5000 kCal/kg. The SG would be radiant; two pass / tower type design, single reheat, balanced draft, dry bottom and semi outdoor type. The capacity would be 2 % more than the VWO flow requirement of Steam turbine. Indicative design parameters for the steam generator are as below.

a. Superheater outlet pressure 255 kg/cm2 (a) b. Superheater outlet temperature 568°C

5-1

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

c. Superheater outlet flow 2150 TPH d. Re-heater outlet pressure 51 Ksc(a) e. Re-heater outlet temperature 596°C f. Feed water inlet temperature to 294°C economizer

The steam generator would have a fuel burning system of corner fired or front and rear wall mounted type. The furnace would be appropriately sized to avoid slagging in the water wall section, pendant/platen super heaters and re-heaters and in the heat transfer surfaces in convection pass.

The coal burners would be of proven advanced design to reduce

NOX production and the furnace would also be provided with over fire air ports to further reduce NOX production.

The SG would be provided with circulation system comprising steam separators to remove water moisture from the evaporator outlet and to recirculate the water into economizer inlet, for use during startup. The SG and steam turbine generator (STG) would be designed for modified sliding pressure operation, which would increase turbine cycle efficiency and reduce boiler feed pump power consumption. The load range for sliding pressure operation would be from about 40% TG maximum continuous rating (TGMCR) to 90% TGMCR and constant pressure operation from 90 % to 100 % TGMCR.

The SG would consist of water cooled furnace, radiant and convection superheaters, reheaters, economizer, regenerative air heater, steam coil air preheaters. Sequential / selective type soot blower system would be provided with soot blowers

5-2

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report located at strategic locations for cleaning the slagged and fouled heat transfer surfaces during operation.

The SG would be provided with the required number of vertical spindle medium speed coal mills (MPS mills), preferably with side mill arrangement which will occupy less space than front/rear mill arrangement. The milling system would be so designed that two (2) mills would be spare with unit operating at BMCR capacity firing design coal and one (1) mill as spare with unit operating at BMCR capacity firing worst coal. The coal mills would be provided with dynamic classifiers to control the fineness of the ground coal thereby to control the unburnt carbon losses. The coal mills would be provided with gravimetric coal feeders. The coal mills would be provided with steam blanketing system for the purpose of fire protection.

The SG would be designed to handle and burn HFO as secondary fuel upto about 22.5% SG MCR for start up and for flame stabilization with steam atomization, during low load operation or during mill changeover. For unit light up and warm-up purposes, LDO system having 7.5 % SGMCR firing capability would be used with air atomization.

The draft plant would comprise primary air fans, forced draft fans and induced draft fans. The primary and forced draft fans would be of axial blade pitch controlled axial type. The induced draft fans would be axial blade pitch controlled axial type or speed controlled (VFD) centrifugal type. Electrostatic precipitators (ESP) would be provided for the collection of fly ash. The ESP would be so designed that for worst

5-3

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

coal firing an outlet dust concentration of 100 mg/Nm3 with one field out of service as stipulated by State/Central Pollution Control Boards, would be achieved.

05.02 Steam Turbine Generator & Accessories The steam turbine generator (STG) would be rated for 660 MW maximum continuous output at generator terminals, with throttle steam condition of 242.2bar(a) at 565°C/593°C reheat, 0.1 bar(a) condenser back pressure with 1.5 % make up. The STG output at valve wide-open (VWO) condition would be 5% above the maximum continuous rating.

The steam turbine would be a three cylinder, reheat extraction and condensing turbine. The turbine generator would be complete with all accessories such as protection system, lube and control oil system, seal oil system, jacking oil system, seal steam system, turbine drain system, electro-hydraulic control system, automatic turbine run up system, on-line automatic turbine test system and turbine supervisory instrumentation.

The turbine generator would also have all necessary indicating and control devices to permit the unit to be placed on turning gear, rolled, accelerated and synchronized automatically from the control room.

05.03 Feed Cycle Equipment 05.03.01 Condensate Pumps The condensate from the condensate hotwell would be pumped by 3x50% capacity condensate pumps (two working

5-4

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

and one stand by) to the deaerator through the gland steam condenser, drain cooler and low-pressure heaters.

05.03.02 Boiler Feed Pumps Feed water would be pumped from deaerator to the steam generator through high-pressure heaters by means of 2x50% capacity steam turbine driven boiler feed pumps. A 30% capacity duty AC motor driven standby boiler feed pump would be provided to facilitate start-up of the unit.

05.03.03 Low Pressure Heaters The low pressure (LP) heaters would be of shell and tube with stainless steel U-tubes (seamless/welded) welded with their ends rolled in carbon steel tube sheets.

05.03.04 De-Aerator The deaerating feed water heater would be a direct contact, variable pressure type heater with spray-tray type or spray type of deaeration arrangement.

05.03.05 High Pressure Heaters The high-pressure (HP) heaters would be of shell and tube with stainless steel U-tubes (seamless/welded) welded with their ends rolled in carbon steel tube sheets.

05.03.06 Gland Steam Condenser A surface type gland steam condenser would be used to condense the gland steam exhausted from turbine glands.

5-5

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

05.03.07 Condensate Polishing Unit In order to maintain high purity of the feed water, 3X33% capacity condensate polishing units (CPU) are envisaged in the condensate system for each unit.

05.03.08 Fuel Oil System The annual requirement for the proposed 660 MW unit would be about 5782 m3 based on consumption of 1ml/kWh (CERC guidelines) of power generation. The daily average consumption of HFO would be about 15.84 m3 /day.

05.03.09 Chemical Dosing System AVT (All volatile treatment) and oxygenated treatment is considered. Ammonia dosing system would be provided to ensure chemical conditioning of the condensate/feed water for controlling the alkalinity. The ammonia solution would be injected into the condensate at the condensate extraction pump discharge during start ups. To reduce iron pick up from the boiler, during normal operation of the plant, oxygenated treatment is also proposed during normal operation of the unit. Under this treatment gaseous oxygen would be injected at CPU outlet and suction of feed water pump and maintain about 150 - 250ppm. Feed water pH is maintained in the range of 7.0-8.5.

05.04 Instrumentation And Control System 05.04.01 Plant Control System The instrumentation and control (I&C) system for the plant is proposed to be a comprehensive system integrating the functions of plant monitoring, control and protection to

5-6

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report facilitate the task of integration, co-ordination and autonomous operation of the plant sub systems/equipment namely Steam Generators (SG), Steam Turbine Generator (STG) and their associated auxiliaries, balance of the plant equipment / systems, plant electrical system, utility plants like coal handling plant, Ash handling plant, DM water plant, compressed air plant, Station common electrical systems including Switchyard.

Separate & independent microprocessor based STG Integral Control system proposed for steam turbine governing, protection, sequential logic control (ATRS, ATT, TSE, TSI etc.), HP/LP bypass control, turbine integral system modulating control( lube oil, gland steam system etc.), load shedding logic & Generator auto synchronizing

The control requirements of the main power plant comprising SG, STG with associated auxiliaries (except for BMS & Boiler Protection system for SG & STG Integral control systems), and all other balance of plant system/equipment required for functioning of main plant like CW / ACW / Miscellaneous water systems, chemical dozing system (both HP & LP bypass), plant electrical system, BOP auxiliaries control & regenerative system controls including control/monitoring for ESP, Condenser Polishing Unit (CPU) & Mill reject system will be implemented in plant Distributed Control System (DCS). Control of plant utility systems like fuel oil un-loading, handling / storage & forwarding, cooling tower, misc. water systems & Station common electrical system etc. also will be covered in plant DCS.

Separate & independent PLC based control systems are

5-7

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

envisaged for major utility plants like Coal Handling / Ash Handling Plant (both Bottom Ash & Fly Ash Handling system) / Raw Water & Pre-treatment (as applicable) / DM Water and effluent treatment Plant (as applicable / Switchyard SCADA, compressed air plant etc. & other auxiliary systems like DG set, A/C & Ventilation system, Fire protection & Detection system etc.

SG Integral control system for BMS & Boiler Protection system, STG Integral control systems, major utility & auxiliary plant system PLC based controls are envisaged to be interfaced with plant DCS through redundant bi-directional OPC link with Ethernet based TCP-I/P protocol. Other auxiliary systems PLC based controls are also to be interfaced with plant DCS through suitable redundant communication links.

05.04.02 Plant Operation Philosophy -

Operation from Central Control Room (CCR) All equipment/system associated with complete power plant viz. SG, STG and their associated auxiliaries, auxiliary systems like chemical dozing systems (HP & LP) etc. & plant electrical system, fuel oil handling / storage & forwarding, CW / ACW / Misc. water systems, station electrical system & other main plant related auxiliary plants will be operated / monitored from CCR. Electrical system will include all breakers including generator synchronising breakers for of 415V, 6.6 kV and 11 kV switch gear. CCR operation includes unit, functional group / drive level control and operation of equipment/system.

5-8

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

CCR operation/ monitoring facility will also include facility for complete monitoring of important utility & auxiliary plants like Coal /Ash Handling / DM Plant (as applicable) / Raw Water & Pre-treatment (as applicable) / Effluent Treatment Plant etc. & other auxiliary plants/ systems as an additional facility, which will be primarily operated and monitored from respective utility plant located local control room.

Complete operation & monitoring of utility & auxiliary plants like Switchyard SCADA etc.are envisaged to be carried out from CCR.

CCR operation/monitoring facility to include limited operation (start/stop) & complete monitoring of compressed air system & DG set.

Only monitoring of fuel oil unloading operation will be carried out from CCR. Relevant operation will be carried out locally near to the system/equipment

DCS/PLCs will be provided with following additional facilities and the equipments pertaining to the same will be located in the respective control room (CCR/LCR):

(a) Maintenance engineer's equipment (MEE) for DCS/PLC/ SG Integral Control System /STG Integral Control System program modification. (b) Historical data storage & retreaval facility in 2 x 100% configuration. (c) Shift in charge Engineer's Monitoring Equipment. (d) Station Incharge’s Monitoring Equipment

5-9

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

Operation from Local Control Room (LCR) The utility and auxiliary systems viz., Coal handling plant / Ash handling plant / DM Water plant & Effluent treatment plant / Raw Water & Pre- Treatment Plant / A/C & Ventilation System etc., will be primarily operated & monitored locally from respective utility plant located local control rooms (LCR) together with facility for operation and monitoring facility from CCR as detailed above is envisaged

05.04.03 Other I&C System Facilities / Features Following special features / facilities are envisaged for I&C system: (a) Boiler tube leak detection system: To provide early warning of boiler tube leak conditions using number of acoustic type sensors. The system will be independent for each unit and interfaced with DCS (b) Furnace Flame monitoring & thermographic analysis system: To provide thermographic analysis of the flame in the furnace and also for each burner to provide details of flame conditions on continuous on-line basis. (c) Vibration Monitoring and analysis system: The vibration monitoring and analysis system will provide critical analysis ofhealth of rotating machines on continuous on-line basis and provide guidance to the plant maintenance personnel regarding the nature of fault and the maintenance action required. The system will provide condition monitoring/analysis of bearings of all critical machines like STG/ Turbine driven BFP &Other HT drives / rotating equipment (d) Management Information System (MIS): MIS will be able to

5-10

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

provide processed information to management personnel related to the Plant Operation, Plant Maintenance, Environmental Information. (e) Steam & Water Analysers (SWAS): Adequate number of analytical instruments are envisaged for continuous monitoring of de-mineralised water, condensate, feed water and steam. (f) Environmental monitoring System Analysers comprising Stack monitoring, Ambient Air Quality & Metereological monitoring systems. (g) Plant Security & Surveillance System. A complete integrated plant security and surveillance system (PSS) is envisaged. The system will include Perimeter Intruder Detection, CCTV Monitoring of Plant area/ equipment, Security card access and Patrol Guard Monitoring System. Suitable monitoring and alarming facility are also envisaged. (h) Station LAN: A /gigabit type LAN encompassing and interconnecting all plant buildings and rooms are envisaged for usage with CMMS & MIS system. For security surveillance system a separate terabyte LAN is envisaged.

05.05 Auxiliary Systems 05.05.01 Compressed Air System For the requirement of instrument air and service air to meet the plant air requirement adequate number of compressors (working and standby) with suitable capacity will be installed. The requirement of the compressed air for the ash handling system would be met through separate dedicated compressors.

5-11

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

05.05.02 Air Conditioning System It is proposed to air-condition the unit control room, electronic cubicle room, shift charge engineers room, printer room, maintenance engineers room, UPS room, ESP control room, static excitation cubicle room, analyser panel room, coal handling control room, DM plant control room and switchyard control room. Inside design conditions of 24.5 ± 1.50C dry bulb temperature and relative humidity not exceeding 60% would be maintained in all air-conditioned areas.

05.05.03 Ventilation System For the ventilation of the station building, evaporative cooling system (Air washer type) is envisaged. This system consists of air washers, supply air fans, air washer circulating water pumps, centrifugal fans and air distribution system for distributing the supply air inside the station building. The exhaust of hot air out of the station building would be achieved by provision of roof extractors and wall mounted exhaust fans. For ventilation of other buildings, supply air fans or louvers, exhaust air fans, roof extractors or a suitable combination of these complete with louvers, filters, ducting & grilles would be provided.

05.05.04 Cranes and Hoists

Two nos. Overhead, cabin / pendent operated electric overhead traveling (EOT) cranes, of 125 / 20 tons capacity would be provided for the proposed Unit also for handling of various main plant equipment. Turbine & generator erection would also be carried out by using the above cranes.

5-12

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

Mobile crane would be provided to facilitate erection and maintenance of pump components and drive motors.

An EOT crane of 12 tons capacity crane is proposed to be provided for maintenance of BFPs for the proposed Unit.

Miscellaneous Lifting Tackles / Hoists

For the equipment, which weighs above 1000 kg, electrically operated type of hoists and trolleys would be provided. For the equipment weighing less than 1000 kg, manually operated hoists and trolleys would be provided.

Workshop Equipment

It is proposed to utilize the work shop equipment available in the existing power plant and no separate work shop equipment are proposed to be procured for the expansion plant.

05.06 Electrical Systems

05.06.01 Generator

The generator would be rated to deliver 660 MW at 21 kV, 50 Hz, 0.85-power factor, at 3000 rpm. The generator would deliver rated MVA within permissible limits of voltage and frequency as per IEC 60034.

05.06.02 Generator Bus Duct

The terminals of the generator would be connected to the generator transformer through Isolated Phase Bus Duct (IPBD) of adequate short circuit withstand capability. Generator Circuit Breaker (GCB) shall be provided at 21 IPDB.

5-13

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

05.06.03 Generator Transformer

The GT would be 3 Nos. 21 kV / 220/√3 kV, 275/220/165 MVA ONAN / ONAF / OFAF cooled 2 winding single-phase banks with on load tap changer. The generator transformer would step up generator voltage of 21 kV to the switchyard voltage of 220 kV

05.06.04 Auxiliary Power Supply System Various auxiliaries would be supplied at the following nominal voltages depending upon their ratings and functions: (a) 11000 V, ± 10%, 50 Hz ± 5%, 3 phase, 3 wire, medium resistance grounded AC supply for motors rated 1500 kW and above. (b) 6600 V, ± 10%, 50 Hz ± 5%, 3 phase, 3 wire, medium resistance grounded AC supply for motors rated 200KW and above up to 1500KW. (c) 415 V, ± 10%, 50 Hz ± 5%, 3 phase, 3 wire, solidly grounded AC supply for motors rated below 200 kW and other L.T. services. (d) 240 V, ± 10%, 50 Hz ± 5%, 1 phase AC supply for lighting, space heating of motors and panels, single phase motors (below 0.22kW), etc. (e) 220 V, ungrounded DC supply for protection, control and indication. (f) 110 V, 1 phase, grounded AC supply for AC control circuits of L.T motors. (g) 240 V, 1 phase AC uninterruptible power supply for panel- mounted recorders, CRT units, printers, analysers, etc., forming a part of the plant instrumentation and control

5-14

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

system. The auxiliary system loads would be segregated as unit loads and common station loads. 2 x 50% rating Unit Transformers (UTs) would cater to the unit load & 1 x 100% rating station transformers (STs) would cater to entire station loads under normal operating conditions. The start-up power for the auxiliaries would be derived by means of station transformer or by unit transformer. The unit can be synchronised with grid by either closing 220kV GT CB or GCB at 21 kV.

05.06.05 Unit Transformer (UT) Two (2), two winding unit transformers would be provided. These would be 32/40MVA, rating, 21/11.5 kV, 3 phase, 50 Hz, with ±5% OCTC in steps of 2.5% on the HV side. The unit transformers would supply power to the 11kV unit switchgear. The unit loads would be distributed equally on each 11kV unit switch gear so that in case of outage of any one bus, it would still be possible to operate the unit at partial load.

05.06.06 Station Transformers (ST)

Two Station Transformers of rating 40/50 MVA, 21/11.5kV, 3 phase, 50Hz with OLTC +5% to -15% in steps of 1.25% on HV side would be provided to feed the station auxiliary load requirement for complete station loads including the Coal and Ash Handling package loads.

05.06.07 Unit Auxiliary Transformers (UAT) Two (2), unit auxiliary transformers would be provided to feed

5-15

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

6.6kV unit auxiliary motor loads. These would be min. 10 MVA, 11/6.9 kV, 3 phase, 50 Hz, with +5 % off-circuit taps in steps of 2.5% on the HV side.

05.06.08 Station Auxiliary Transformers (SAT) Two (2), Station auxiliary transformers would be provided for feeding 6.6kV Station auxiliary loads. These would be min. 15 MVA (catering to ash handling system loads and only internal coal handling system loads), 11/6.9 kV, 3 phase, 50 Hz, with +5 % off-circuit taps in steps of 2.5% on the HV side.

05.06.09 Service Transformers The required number of transformers would be provided depending on service / location / segregation of the loads. These transformers would be rated at 2500 / 2000 / 1600 / 1250 kVA, 11kV/433V or 6.6kV/433V They would supply power to the 415 V auxiliaries of the unit and station loads.

05.06.10 11000 V & 6600V Switchgear The switchgear would be rated for symmetrical fault current of 40 kA for 3 seconds. The 11kV & 6.6kV switchgear would comprise draw-out type Vacuum circuit breakers housed in indoor, metal-enclosed cubicles would cater to all 11kV, 6.6kV motors, 11kV / 6.9 kV & 11kV / 433V transformers. The switchgear would be equipped with control, protection, interlock and metering & communication features as required.

05.06.11 415V System The 415V, 3 phase, 3 wire power for the 415V auxiliaries

5-16

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

would be obtained from 11kV/433V transformers and 6.6kV/433V transformers. All power and motor control centres would be compartmentalised and would be of single / double front execution as needed. They would be of fully draw- out design. The circuit breakers would be of air break type. Motor starting would be direct on line

05.07 DC System DC loads would be divided into two categories ie, Unit DC loads and Station DC loads. Each category of loads would be catered by separate battery and charger system. Two (2) nos. 220V 100% rated batteries with associated float cum boost chargers would be provided for each system. Each battery would be capable of catering to 100% of power and control loads of Unit and Station systems respectively.

05.08 Emergency Power Supply To enable the unit to shutdown safely during complete A.C supply failure in the station, certain important plant auxiliaries would be provided with a reliable A.C power supply through a separate source. For this purpose, one (1) 415V quick starting diesel generator set with automatic mains failure (AMF) would be provided for each unit additional one (1) no. standby DG set shall be provided as per CEA regulations. Total no. of DG sets will be 2 nos. The diesel generator would feed a separate emergency 415V Emergency switch gear. This switchgear in turn will feed the Normal/Emergency PMCCs of the unit. All the essential loads

5-17

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

such as the A.C emergency bearing lube oil and seal oil pumps, turning gear motor, battery chargers, emergency lights, and essential instrument power supply feeders would derive power from this Normal/Emergency PMCC.

05.09 Un-Interruptible Power Supply System For panel mounted instruments, CRTs, printers, analysers, recorder, etc., 240 V single phase A.C uninterruptible power supply would be made available. This power supply would be derived from parallel redundant with static bypass uninterruptible power supply system having two (2) sets of converters, inverters & 2 X 100 % battery banks. Also a standby AC supply would be provided as a back up to the inverters, which would be switched on through static switch in case of inverter failure. One UPS each shall be provided for unit loads and station loads with the above configuration.

05.10 Electrical Equipment Protection Systems & Control The selection of the protective scheme would be based mainly on reliability, sensitivity, selectivity and technical merits. All main protections would be of fast acting type in order to isolate the faulty system from the healthy system in the shortest possible time, to minimise damage to the equipment and ensure continuity of power supply, if possible.

05.11 Cabling System Power cables would be selected based on the following criteria: a) Continuous circuit current rating b) De-rating factors for ambient temperature and grouping c) Short circuit rating of the circuit

5-18

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

d) Voltage dip e) Standardisation of cable sizes to reduce inventory.

05.12 Lighting System Suitable illumination necessary to facilitate normal operation and maintenance activities and to ensure safety of working personnel would be provided.

05.13 Safety Earthing And Lightning Protection A safety earthing system comprising buried steel conductor earthing grid would be provided for the 220kV switchyard and other outlying areas. This would be connected to the earth grids in various buildings. The buried earth grids would be further connected to earthing electrodes. The selection of earth conductor sizes would be based on the applicable fault levels & IEEE-80.

05.14 Communication System For effective communication in the plant, public address system, Electronic private automatic branch exchange system (EPABX), landlines with ISDN / PSTN facility, wakie-talkie, OPGW (Optical fibre ground wire) communication link along with necessary terminal equipments will also be provided to ensure fast communication between Switchyard & Local Dispatch Centre (LDC).

05.15 Fire Detection / Alarm And Fire Proof Sealing System Addressable type multi criteria detector based fire detection and alarm system would be provided to facilitate visual and audible fire detection at the incipient stage of fire in strategically

5-19

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

important areas of the power station. This system would comprise manual call points located at strategic locations in areas which are normally manned and automatic addressable type multi-criteria detectors located in plant areas, such as control room, switchgear room, battery rooms, etc., to detect fire at an early stage. Linear heat detectors would be provided for the cable gallery and conveyors. Infrared type amber detector would be provided for the conveyor gallery. Fireproof sealing would be provided for all cable penetrations through walls and floors to prevent spreading of fire from one area / floor to another.

05.16 Elevators One freight-cum-passenger elevator of capacity 2000 kg and speed of 0.55 m/sec will be provided in the steam generator area to serve major platforms of the steam generator.

05.17 Clock System A clock system with one Master clock and 16 clocks located at various strategic locations of the power plant will be provided.

05.18 Evacuation of Power The power generated from proposed 660 MW captive plant would be connected to 400 KV switchyard and power will be evacuated to the steel plant through two Nos. of 210MVA 400/33KV transformers and through two numbers of 315 MVA -

400KV/220KV inter connecting transformers.

5-20

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

06 SERVICES, UTILITIES & MANPOWER REQUIREMENT

06.01 General

Besides raw materials i.e. coal, other major requirements of the plant are water, power and fuel.

06.02 Water System

Sea water will be used for condenser cooling. Cooling water system will be installed to transfer heat from turbine condenser and other plant auxiliaries. The cooling water will be cooled either at Natural draught cooling tower (NDCT) or Induced Draft Cooling Tower (IDCT) will be decided after Techno-Economic analysis. In case of adapting NDCT/IDCT for cooling, the sea water intake would be around 7475 m3/hr, consumption is 1275 m3/hr and return back to sea would be about 6200 m3/hr. Raw water consumption shall be 400 m3/hr. The source of raw water would be clarified water from the existing steel plant. The raw water will be used in demineralised water plant for SG makeup, potable water, service and fire protection system etc. There shall be storage of clarified raw water for 7 days. The condenser cooling will be achieved by Natural Draught Cooling Tower (NDCT) or Induced Draught Cooling Tower (IDCT) in closed sea water cooling system. The cooling tower will be designed to cool the water from 42°C to 32°C at a design atmospheric wet bulb temperature of 28°C. The water balance of the proposed plant is shown in Drg. No. JSW/DW/CPP/PR/007.

6-1

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

06.03 Clarified Water Chemical Dosing System Chemical dosing system would comprise of chemicals with anti- scaling / anti-corrosive and dispersant properties. For each type of chemical the dosing system would consist of dosing pumps with PP / SS material of construction with one dosing tank. Acid dosing system with 1 No. bulk acid storage tank and dosing pumps would be provided to control the alkalinity in the system. To prevent / control algae growth in the CW system, chlorine dosing would be provided. Continuous dosing will be done at the rate of 1 ppm and shock dosing will be done at a rate of 3 ppm. Chlorine leak detection and absorption system will be provided to trap chlorine leakage.

06.04 Water Treatment Plant The water treatment plant broadly consists of a filtration plant, DM plant and an Ultra Filtration plant. The Filtration plant consists of pressure sand filter to remove turbidity and suspended solids. Alum would be dosed at the inlet to filters to aid filtration process.

06.05 Demineralisation (DM) Plant It is proposed to provide two (2) x 100% streams DM plant (1 Working + 1 Standby), each stream designed for a net output of 1300 m3/day. The DM water storage tank will be sized to cater to the one day requirement. The DM water will be used for condenser cooling system, cooling of SG and TG auxiliaries and plant service : The quality of SG make up water required is as follows:

Total Silica as SiO2 Not greater than 0.02 ppm Conductivity ≤ 0.1 µmho/cm at 25oC pH 6.8- 7.2

6-2

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

06.06 Service and Potable Water Systems The service water system supplies water required for HVAC system and misc. requirements of station building. Potable water system will be derived after required filtration and chlorination.

06.07 Chemical Laboratory Equipment The quality control laboratory, with modern equipment, shall be provided for the proposed Captive Power Plant. The main functions of the laboratory will be to analysis the coal, water and steam samples from the plant.

06.08 Fire Protection System Fire protection system would be provided covering all the buildings of the proposed power plant boundary. The water would be drawn from the raw water storage tank and reserve capacity of 2000 m3 earmarked for the system. The following fire protection systems are proposed: a) Hydrant system b) Automatic High Velocity Water Spray (HVWS) system for the protection of transformers and manual HVWS system for the protection of turbine oil tanks. c) Automatic Deluge/ Medium Velocity Water Spray (MVWS) system for the protection of cable vaults and over head conveyors. d) Heavy duty portable or trolley mounted fire extinguishers for the protection of control rooms. e) Portable fire extinguishers for different areas.

6-3

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

Adequate number of pumps will be provided and system would be designed to conform to the rules and regulations of fire safety standards as per NFPA.

06.09 Power System The total annual power consumption for the 660 MW Captive Power Plant is 47 MW considering 7% auxiliary power consumption. The power generated from proposed 660 MW captive power plant would be connected to 400 KV switchyard and power will be evacuated to the JSW Steel Plant through two Nos. of 210MVA - 400/33KV transformers and through two numbers of 315 MVA - 400KV/220KV inter connecting transformers

The loads will be segregated as unit loads and common service loads. The unit auxiliary loads will be supplied through unit auxiliary transformers connected directly to the generator through isolated phase bus ducts. Start-up for the auxiliaries will be supplied through station transformer with GT breaker kept open. Once the unit is started and the generator picks up rated speed & voltage, GT breaker is closed after synchronising with grid. Tie feeder will be provided from 6.6 kV station switch gear to 6.6 kV unit switch gears of the unit so that during non availability of one unit auxiliary transformer, the station transformer will feed the loads connected to that unit auxiliary transformer.

An uninterrupted power supply (UPS) system would be provided to cater to 220V AC, single phase, 50 Hz, 2 wire power supply requirements of instrumentation and control systems viz. man- machine interface equipment, analysers, receiver instruments,

6-4

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

Closed loop controls, sequence controls, protection and interlock system, annunciation system and sequence of events recording system

To enable the unit to shutdown safely during complete A.C supply failure in the station, certain important plant auxiliaries will be provided with a reliable A.C power supply through a separate source. For this purpose, one (1) 415V quick starting diesel generator set with automatic mains failure (AMF) will be provided for the unit.

The diesel generator will feed an emergency 415V switch gear, to which all the essential loads such as the A.C emergency bearing lube oil and seal oil pumps, turning gear motor, battery chargers, emergency lights, and essential instrument power supply feeders will be connected. When the station A.C supply is healthy, the emergency switchgear will be fed from the unit service switchgear. When the station A.C supply fails, the DG set will start automatically and will feed the loads connected to the emergency switchgear. When the normal A.C supply is restored, these essential loads will be manually changed over to the normal power supply.

06.10 Instrumentation and Control System The Automation, Instrumentation and Control System (I&C) shall be sufficient to monitor and control all significant variables in accordance with the process requirement, provide all operating requirements and necessary sequencing, interlocking and safety functions including alarms for abnormal conditions of the proposed Captive Power Plant.

6-5

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

06.11 Process Automation System The automation system for process control and monitoring will be based on a modern Distributed Control System latest version (hereafter referred to as DCS). The DCS system structure is based on an integrated distribution system with inherent open type architecture. The system will have mainly two functional levels.

06.12 Communication System The telephone system will be provided for communication inside as well as outside the plant. Telephone system shall comprise one Electronics Private Automation Branch Exchange (EPABX) of required line capacity and associated cable network along with Press-to-talk system, CCTV, VHF wireless system as required.

06.13 Repair and Maintenance Facilities The repair and maintenance facilities will be centralized to take care of routine repair and periodical maintenance work of the captive power plant. Major repairing works involving machining, fabrication and assembly of heavy and critical jobs of specialized nature are envisaged to be contracted to outside agencies.

06.14 Warehouse A central warehouse will be utilised to keep spares of equipment, hardwares and consumables. A Part of the building will be utilised for easy manual loading and unloading of the materials from trucks. Forklifts will be used for movement of materials inside the stores building.

6-6

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

06.15 Ancillary Facilities Necessary ancillary facilities such as administrative building, canteen, car park, cycle and scooter stand, first-aid station etc. shall be provided based on the manpower requirement for the plant.

06.16 Drainage and Sewerage System Open type drain has been envisaged for the plant storm water drainage. The drains will be laid generally by the side of the roads. Storm water run-off, collected through arterial and trunk drain, will be discharged suitably for minimum pollution.

Sanitary faecal sewage will be collected from the ablution blocks through pipeline and the same will be connected to a sewage treatment plant. The effluent from the sewage treatment plant will be utilized for the development and maintenance of greenery

06.17 Roads Adequate plant road system will be provided. The road system will be integrated with the existing roads.

06.18 Manpower Requirement The proposed plant will not only require management and executive manpower but also, skilled, semi-skilled, unskilled and clerical manpower. However, a number of jobs like major repair and maintenance, cleaning, transportation and loading / unloading of bulk materials, etc. will be outsourced. The total manpower requirement for the proposed 660 MW Captive Power Plant, covering both works and administration is estimated at 250 persons given below

6-7

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

The category wise break-up of manpower is indicated in table – 06.02. Table – 06.02 Category wise break-up of manpower

Sl. No. Category Requirement 1. Managerial 10 2. Executive 20 3. Skilled 80 4. Semi-skilled 70 5. Unskilled 50 6. Clerical 20 Total 250

6-8

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

07 ENVIRONMENTAL MANAGEMENT

The proposed plant would result in air, water and land pollution of varying nature and degree. This chapter briefly outlines the nature and sources of pollution and also suggests broad environmental protection measures to be adopted for limiting pollution within permissible levels.

07.01 Nature of Pollution

The inputs to the Power Plant will comprise raw materials i.e. coal along with water, fuel and power. These would therefore lead to release of emissions to the air, generation of wastewater and solid wastes. The Process would not be generating any Hazardous Waste, as there is no Hazardous Chemical involved in the process. The sources of pollution from the proposed project and the types of environmental pollution likely to occur are summarized as below.

Pollutants released Type of pollution

SO2, NOx, dust, heat, noise Air pollution, Noise pollution and Water pollution

Pollution Prevention and Control Measures

In consideration of the above stated pollution potential of the power plant, the following mitigation schemes are envisaged in order to control environmental pollution within the permissible norms and keep the environment fairly clean.

Ambient Air Quality Stations will be installed for monitoring the continuous Ambient Air Quality based on meteorological

7-1

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

conditions, wind direction pattern, etc. for measurement of following parameters in the ambient air.

• Suspended Particulate Matter • Respirable Particulate Matter

• SO2

• NOx

• CO2 • CO

Provision for checking Ambient Air Quality outside the plant boundary will also be made. High volume samplers with attachments for gaseous sampling and particulate matter sampler will be envisaged for this purpose

07.02 Air environment protection

The air polluting emittants from the power plant are as follows: • Dust particulates from fly ash in flue gas

• Sulphur dioxide (SO2) in flue gas • Nitrogen oxides (NOx) in flue gas • Coal dust particles due to handling of coal • Fly ash dust particles from ash silos and ash disposal area • Ash Handling and Disposal • Ash Generation

Dust particulates from fly ash in flue gas The standard for particulate emission applicable to this project is 150 mg/Nm3. The electrostatic precipitators (ESP) proposed to be installed in this project would be designed to limit the emission level of the particulate matter to this limit 100 mg/Nm3

7-2

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

Sulphur dioxide (SO2) in flue gas

One stack (chimney) of height 275 m for effective dispersal of SO2 is proposed to be constructed.

Nitrogen oxides (NOx) in flue gas To reduce NOx emissions, over-fire air system equipment with air ports would be installed for the furnace. Further, the steam generators would be fitted with advanced low NOx burners. The NOx emissions would be checked for ground level concentrations (GLC) as per the above indicated Indian Emission Regulations.

Coal dust particles due to handling of coal Coal dust would be generated generally at the conveyor transfer points. Hence, coal transfer points would be provided with dust suppression / dust extraction facilities. Further, in order to arrest the coal dust generation, all conveyors would be provided with enclosed galleries. Dust collection system would also be provided in coal bunkers to evacuate dust from the coal bunkers. Collected dust would be returned to either the associated belt conveyor or to the coal bunker. The dust collector outlet emission would be restricted to 100 mg / Nm³.

Fly ash dust particles from ash silos and ash disposal area Fly ash storage silo for the unit is proposed to be provided. Fly ash evacuated from the ESP collecting hoppers would be transported in closed pipe lines by pneumatic means. At the time of unloading fly ash in to the silo, some ash laden air would get vented out. In order to restrict the fly ash dust particles to the limits of 100 mg/Nm3, a vent filter would be installed on top of the fly ash silo at the vents.

7-3

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

The following pollution control measures would be installed for ash disposal : a) To reduce the dust nuisance while loading the ash into the trucks from fly ash silo, the fly ash would be conditioned with water spray. b) It is proposed to cover the ash in the open trucks with tarpaulin to prevent flying of fine ash during transportation. c) Water sprinkling system would be provided in the ash disposal area to restrain flying of fine ash due to wind. d) The ash disposal area would be lined with impervious lining to prevent seepage of rain water from the disposal area in to the ground and pollute ground water

Ash Handling and Disposal • Collection of Bottom ash in dry form. • Collection of fly ash in dry form to facilitate utilization for cement plants. • Disposal of un-utilized ash in conditioned form combined with bottom ash to the ash pond. • Dust collection hoppers at all strategic locations will have a minimum storage capacity of eight (8) hours. • Pneumatic conveying system (either vacuum system or pressurized system) will be employed for extraction of fly ash from the electrostatic precipitator hoppers in dry form. • During emergency, when ash utilization is not possible, fly ash will be transported from fly ash silo to ash mound area located inside the plant boundary by closed trucks with conditioned ash. • One common chimney with two flues is envisaged for the

7-4

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

unit. The chimney height will be 275 m as per environmental norms.

Ash Generation Considering ash content of 20% in the coal, approximately 72 t/hr ash is likely to be generated and in total 0.60 Million tons of ash per year is likely to be generated from 660 MW coal based supercritical power plant.

07.03 Noise environment protection

The plant is expected to increase the noise level in the surrounding due to operation of plant and machinery. The main sources of noise in a power plant are: • Steam turbine generator • Other rotating equipment • Combustion induced noises • Flow induced noises • Steam safety valves Necessary noise control and abatement measurers will be adopted to minimize the noise level from the plant during construction and operation phase to a maximum of 85 db(A) as per the requirement of OSHA (Occupational Safety and Health Administration) Standards.

All rotary equipment like fans, blowers, pumps & compressors would be of low noise design. The grouting of these equipments will be made free from vibrations. Noise absorbing cladding around drying ball mill will be provided to reduce the noise level.

7-5

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

The work zone noise exposure of the operating personnel would be avoided by remote operation from the control rooms by using required safety equipments.

07.04 Water environment protection

The waste water from Demineralised Plant shall be treated and led to the guard pond.

Waste water from process blowdown will be recycled and used to be extent possible. The plant drains which are likely to contain oil will be first separated of oil in the oil water separator and then used for preparation of ash slurry or spray in the coal yard to contain fugitive emissions.

Wash water from Air Pre-heater would be first collected in a settling basin for the collection of ash particles and then pumped to the Guard Pond. The treated effluent from the Guard Pond would be used for gardening, green belt development and plantation work. Sewage from various buildings in the power plant would be conveyed through various drains to septic tanks.

07.05 Solid Waste 1. During construction phase, solid waste such as excavated soil, debris, some metal waste and very small amount of oil & grease from construction machines will be generated. This waste may contaminate soil at plant site temporarily and would be restricted to a small area. 2. Used/Spent oil and grease will be generated during maintenance of equipment and machine.

7-6

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

3. Solid waste consisting of coal fine particles, fly ash and bottom ash will be generated in the plant. Coal fine particles will be reused in the plant, fly ash will be sold to the cement plant and bottom ash will be used for road filling within the plant and some part of bottom ash will be sold out. 4. Thus solid waste generated will not be having any negative impact on the environment.

07.06 Plant safety

Plant safety measures would form an integral part of the environment protection plan of the proposed plant. Workers’ safety would be of highest degree of concern so as to avoid any form of personal injury or untoward accident. In-build safety features of the plant and machinery would be made adequate in order to avoid hazardous events causing damage to the life and property. Efforts would be made to afford the best safety measures and health services with a view to keep the workplace free of hazards to the extent possible. Standard programs will be framed and followed for regular medical check-up, lung function test, audiometry, vision test, etc. for the workers on a regular basis so as to prevent and to detect occupational diseases and to promote their general well being.

07.07 Greenbelt and landscaping

Adequate space would be reserved for gardening and tree plantations at the site. This would improve the plant aesthetics as well as prevent the fugitive dust emissions. Unpaved areas, if any, within the plant boundary would be provided with grass

7-7

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report cover. This would not only act as ‘lung space’ but would also improve the plant aesthetics.

7-8

JSW Steel Limited 660 MW Captive Power Plant Maharashtra Project Report

08 PROJECT IMPLEMENTATION

08.01 General

Implementation of a Captive Power Plant is a challenging task and calls for meticulous planning, scheduling and monitoring to realize the project goals in budgeted time frame.

JSW has experience of erecting and commissioning Power Plants at Vijayanagar, Jaigarh & Barmer. This experience will be utilised in speedy implementation of the project.

08.02 Schedule

The implementation schedule for installation of the proposed 660 MW Captive Power Plant is indicated in the form of bar chart in the drawing no. JSW/DW/CPP/PR/008. The overall schedule shows that from the date of start of the project (Zero date), the plant will be commissioned in 33 months. The schedule as presented is based upon conventional project implementation logics for power plant, preliminary vendor information available and in-house analysis.

08.03 Zero Date

The date of start of project activities has been assumed as “zero date” for installation of the proposed Captive Power Plant in Maharashtra.

8-1

JSW Steel Limited

660 MW Captive Power Plant Maharashtra Project Report

09 BLOCK CAPITAL COST

The estimated block capital cost for the 660 MW coal based supercritical captive power plant is estimated as Rs. 4500 crores.

9-1

660 MW CAPTIVE POWER PLANT - JSW STEEL LTD. - DOLVI WORKS PROJECT IMPLEMENTATION SCHEDULE

SL. ACTIVITIES DURATION OF D U R A T I O N I N M O N T H S NO. ACTIVITY 2202246810 12 14 1618 24 26 28 30 3234 36

1 Project Approval 0 Month

2 Basic Design 4 Months

3 Detailed Engineering 10 Months

4 Tendering, Scrutiny and order placement 8 Months

5 Planning & construction of Infrastructure facilities 16 Months

6 Civil works 20 Months

7 Fabrication & Erection of Structures 22 Months

8 Delivery of Equipment 12 Months

9 Erection of Equipment 10 Months

10 Testing & Commissioning of Plant 3 Months

11 Power Generation to commence -

DRG No. - JSW/DW/CPP/PR/008