THE WEST BENGAL POWER DEVELOPMENT CORPORATION LIMITED DETAILED PROJECT REPORT FOR 1 x 660 MW PHASE-III EXTENSION UNIT # 5 SAGARIGHI THERMAL POWER STATION AT SAGARDIGHI, DIST.: MURSHIDABAD, WEST BENGAL MAY, 2016 CONSULTANT DEVELOPMENT CONSULTANTS PRIVATE LIMITED BLOCK DG-4, SECTOR-II, SALT LAKE CITY, KOLKATA – 700 091, INDIA Detailed Project Report 1 X 660 MW Phase-III Extension Unit#5, Sagardighi, West Bengal DETAILED PROJECT REPORT FOR SAGARDIGHI THERMAL POWER STATION 1 x 660 MW PHASE-III EXTENSION UNIT # 5 SAGARDIGHI, WEST BENGAL I N D E X SECTION – 1 : PROJECT BACK GROUND AND EXECUTIVE SUMMARY 1.1 Foreword 1.2 Executive Summary 1.3 Project At a Glance SECTION – 2 : JUSTIFICATION OF THE PROJECT 2.1 Introduction 2.2 All-India Power Scenario 2.3 Power Scenario of Eastern Region 2.4 Power Scenario in West Bengal 2.5 Justification of the Project 2.6 Unit Size Selection Index - 1 - Development Consultants Pvt. Ltd. (PCA.CD-006.16A03-DPR2_INDEX.DOC) Detailed Project Report 1 X 660 MW Phase-III Extension Unit#5, Sagardighi, West Bengal SECTION – 3 : BASIC REQUIREMENTS 3.1 Introduction 3.2 Land – Requirement & Availability for Phase-III Unit 3.3 Water – Requirement & Availability 3.4 Fuel Requirement 3.5 Ash Disposal 3.6 Power Evacuation 3.7 Infrastructural Facilities SECTION – 4 : SITE FEATURES 4.1 Introduction 4.2 Features of the Identified Site 4.3 Meteorological Details SECTION – 5 : POWER GENERATING EQUIPMENT 5.1 Introduction 5.2 Selection of Technology 5.3 Thermodynamic Cycle 5.4 Steam Generating Unit 5.5 Turbine Generator Unit Index - 2 - Development Consultants Pvt. Ltd. (PCA.CD-006.16A03-DPR2_INDEX.DOC) Detailed Project Report 1 X 660 MW Phase-III Extension Unit#5, Sagardighi, West Bengal 5.6 Condensing Equipment & Accessories 5.7 Boiler Feed Water Pumps 5.8 Deaerating Heaters & Closed Heaters SECTION – 6 : AUXILIARY SYSTEMS 6.1 Introduction 6.2 Plant Water System 6.3 Coal Handling System 6.4 Ash Handling System 6.5 Fuel Oil Handling System 6.6 Ventilation & Air-conditioning System 6.7 Compressed Air System 6.8 Fire Protection System 6.9 Piping, Valves, Fittings & Specialties 6.10 Miscellaneous Auxiliaries 6.11 Associated Facilities SECTION – 7 : ELECTRICAL SYSTEM & EQUIPMENT 7.1 Introduction 7.2 Design Parameters 7.3 Electrical System 7.4 Control of Electrical System 7.5 Metering Index - 3 - Development Consultants Pvt. Ltd. (PCA.CD-006.16A03-DPR2_INDEX.DOC) Detailed Project Report 1 X 660 MW Phase-III Extension Unit#5, Sagardighi, West Bengal 7.6 Protection System 7.7 Plant Illumination 7.8 Grounding & Lightning Protection 7.9 In-Plant Cabling SECTION – 8 : CONTROL AND INSTRUMENTATION 8.1 Design Objective 8.2 Plant Control Philosophy 8.3 Design Basis Requirements 8.4 Major Instrumentation & Control Systems 8.5 Control Room / Equipment Room Desk & Panel 8.6 Power Supply System 8.7 Instrument Air Supply 8.8 Instrumentation & Control Cables & Accessories 8.9 Erection Hardware 8.10 Tools & Tackle and I&C Laboratory Instruments 8.11 Spares & Consumable 8.12 Fire Detection & Alarm System 8.13 Plant Communication System 8.14 Closed Circuit Television System Index - 4 - Development Consultants Pvt. Ltd. (PCA.CD-006.16A03-DPR2_INDEX.DOC) Detailed Project Report 1 X 660 MW Phase-III Extension Unit#5, Sagardighi, West Bengal SECTION – 9 : STATION LAYOUT AND CIVIL ENGINEERING ASPECTS 9.1 Introduction 9.2 Plant Layout 9.3 Civil Engineering Aspects 9.4 Description of Building & Superstructure SECTION – 10 : ENVIRONMENTAL ASPECTS 10.1 Introduction 10.2 Environmental Pollution from a Thermal Power Plant 10.3 Basic Information for Environmental Clearance 10.4 Commercial Utilisation of Fly Ash 10.5 Environmental Laboratory SECTION – 11 : CONSTRUCTION FACILITIES 11.1 Introduction 11.2 Construction Features 11.3 Organisational Set-up for Plant Construction 11.4 Safety & Health Hazard Monitoring 11.5 Security 11.6 Labour Welfare & Statutory Regulations Index - 5 - Development Consultants Pvt. Ltd. (PCA.CD-006.16A03-DPR2_INDEX.DOC) Detailed Project Report 1 X 660 MW Phase-III Extension Unit#5, Sagardighi, West Bengal SECTION – 12 : ORGANISATION STRUCTURE 12.1 Philosophy of Plant Design & Operation 12.2 Organisation Set-up for Plant Operation 12.3 Training of Personnel SECTION – 13 : EMPLOYEE FACILITIES AND RESIDENTIAL TOWNSHIP 13.1 Employee Facilities 13.2 Residential Township SECTION – 14 : PROJECT IMPLEMENTATION AND MONITORING 14.1 Introduction 14.2 Project Organisation of the Owner 14.3 Project Execution 14.4 Project Monitoring, Co-ordination & Control 14.5 Role of Consultant 14.6 Project Implementation Schedule Index - 6 - Development Consultants Pvt. Ltd. (PCA.CD-006.16A03-DPR2_INDEX.DOC) Detailed Project Report 1 X 660 MW Phase-III Extension Unit#5, Sagardighi, West Bengal SECTION – 15 : PROJECT COST ESTIMATE AND TARIFF 15.1 Major Assumptions 15.2 Project Cost, Cost of Production and Financial Analysis 15.3 Profitability 15.4 Energy Generation and Revenue 15.5 Interest, Depreciation and Tax 15.6 Financial Evaluation Index - 7 - Development Consultants Pvt. Ltd. (PCA.CD-006.16A03-DPR2_INDEX.DOC) Detailed Project Report 1 X 660 MW Phase-III Extension Unit#5, Sagardighi, West Bengal LIST OF ANNEXURES & DRAWINGS SECTION - 2 Annexure - 2.1 Category & Year-wise Forecast of All India Power Scenario Annexure - 2.2 Demand / Load Growth Trend in West Bengal (Energy) Annexure - 2.3 Demand/ Load Growth Trend in West Bengal (Peak Demand) SECTION - 3 Annexure - 3.1 Raw Water Analysis Annexure - 3.2 Estimation of Consumptive Water Requirement Annexure - 3.3 Analysis of Coal & Ash Annexure - 3.4 Analysis of Heavy Fuel Oil (HFO) Annexure - 3.5 Analysis of Light Diesel Oil (LDO) SECTION - 4 Annexure – 4.1 Climatological Table of Berhampur Drawing No. 16A03-DWG-M-003B Vicinity Map Drawing No. 16A03-DWG-M-003C Site Location Map Index - 8 - Development Consultants Pvt. Ltd. (PCA.CD-006.16A03-DPR2_INDEX.DOC) Detailed Project Report 1 X 660 MW Phase-III Extension Unit#5, Sagardighi, West Bengal SECTION - 5 Annexure - 5.1 Brief Technical Features of Main Plant & Equipment Drawing No. 16A03-DWG-M-0100 Heat balance Diagram (Typical) Drawing No. 16A03-DWG-M-0101 Single line diagram of steam and water system. SECTION - 6 Annexure - 6.1 Salient Features of Auxiliary Plant & Equipment Drawing No. 16A03-DWG-M-0001 Flow Diagram of Plant Water System Drawing No. 16A03-DWG-M-0002 Water Balance Diagram Drawing No. 16A03-DWG-M-0002A Water Balance Diagram (Based on MoEFCC notification dated 7.12.15) Drawing No. 16A03-DWG-M-0003 Flow Diagram for Coal Handling System Drawing No. 16A03-DWG-M-0004 Single Line Diagram for Ash Handling System Drawing No. 16A03-DWG-M-0005 Single Line Diagram for Fuel Oil System Drawing No. 16A03-DWG-M-0006 Single Line Diagram of Compressed Air System Drawing No. 16A03-DWG-M-0007 Typical Flow Scheme of Anhydrous Ammonia Based SCR Drawing No. 16A03-DWG-M-0008 Typical Flow Scheme of LSFO FGD Index - 9 - Development Consultants Pvt. Ltd. (PCA.CD-006.16A03-DPR2_INDEX.DOC) Detailed Project Report 1 X 660 MW Phase-III Extension Unit#5, Sagardighi, West Bengal SECTION - 7 Annexure - 7.1 Technical Particulars of Major Electrical Equipment Drawing No. 16A03-DWG-E-0001 Single Line Diagram for Auxiliary Power Distribution Drawing No. 16A03-DWG-E-0002 Single Line Diagram for 400 KV Substation SECTION - 8 Drawing No. 16A03-DWG-I-0010 Control System Architecture SECTION - 9 Annexure - 9.1 Salient Features of Major Civil Works Drawing No. 16A03-DWG-M-003A Plot Plan SECTION - 10 Drawing No. 16A03-DWG-EV-0001 Single Line Diagram for Waste Water Management Scheme SECTION - 11 Drawing No. 16A03-DWG-M-0102 Organisation Chart (Project Management Team) Index - 10 - Development Consultants Pvt. Ltd. (PCA.CD-006.16A03-DPR2_INDEX.DOC) Detailed Project Report 1 X 660 MW Phase-III Extension Unit#5, Sagardighi, West Bengal SECTION – 12 Drawing No. 16A03-DWG-M-0103 Organisation Chart (O&M) SECTION - 14 Drawing No. 16A03-DWG-PL-0001 Project Schedule SECTION – 15 Annexure – 15.1 Estimated Project Cost Annexure – 15.2 - 15.18 Financial Tables Index - 11 - Development Consultants Pvt. Ltd. (PCA.CD-006.16A03-DPR2_INDEX.DOC) Detailed Project Report 1 X 660 MW Phase-III Extension Unit#5, Sagardighi, West Bengal SECTION-1 PROJECT BACKGROUND AND EXECUTIVE SUMMARY 1.1 Foreword West Bengal is one of the states with highest population density (1030 per sq. km) covering an area of 88,752 sq. km with total population of 9.13 Core as per 2011 census. The state is generally divided in two regions namely, Himalayan north and Alluvial plain. The state has widely diversified farming base with a rich variety of food and crop having 62% of cultivable land under irrigation and 15.3% under forest cover. Agriculture sector accounts for 65% of state’s income and provides livelihood for more than 70% of the population. The state had major investment in engineering industries and other industrial sector till seventies. Lately, again under open economy regime, the investment in industrial sector has picked up accelerated growth. The interest in investment is mainly attributable to suitable industrial infrastructure available. Project Background& Executive Summary S-1 : 1 Development Consultants Pvt. Ltd. (PCA.CD-006.16A03-DPR3_S-1.DOCX) Detailed Project Report 1 X 660 MW Phase-III Extension Unit#5, Sagardighi, West Bengal In order to accelerate growth in the state, particularly in the industrial sector under the open economic policy the state government have taken a number of initiatives including investment subsidies, tax benefit etc. In the energy sector, major steps have been taken to support the accelerated industrial growth and enhanced production in the agricultural sector. The industrial development in the state till date has been concentrated mostly along Gangetic plain viz. Kolkata, Howrah, Haldia and industrial towns in Durgapur-Asansol axis.