EPC Quotation-15th May 2011

EPC Quotation Page 1 of 16 15th May 2011

ENGCON ENERGY PTE LTD Company Registration Number: 200301783C N0. 4, Bunga Rampai Place, Singapore 539700 Tel: (65) 62818726 Fax: (65) 68584595 E-mail: [email protected]

Mr. Leoncio Tan Managing Director Golden Season Grains Center Inc. Barangay Dadap, Luna Isabela, Philippines

Date: 15th May 2011

EPC PROPOSAL

6.5MW RICE HUSK FIRED POWER PLANT



Index 1. EQUIPMENT SUPPLY PORTION 2. LOCAL PORTION 3. ENGINEERING AND PROJECT MANAGEMENT 4. EXCLUSION 5. PRICE & PAYMENT TERMS 6. WARRANTY & SCHEDULE



1. EQUIPMENT SUPPLY PORTION

1.1 One (1) unit rice husk fired boiler and steam generation equipment

Please see Annex A for technical specification. 1.2 One (1) unit steam turbine generator and condensing equipment

Please see Annex B for technical specification.

1.3 One (1) lot power plant electrical system consist of:

a. One (1) unit 15kV, 630amp generator VCB switchgear panel, b. One (1) unit MV metering and bus PT panel, c. One (1) unit 1250kVA, 13.2kV / 440V station transformer, d. One (1) unit 15kV, 630amp station transformer VCB switchgear panel, e. One (1) unit 15kV, 630amp power plant outgoing feeder VCB switchgear panel, f. One (1) unit 440V, 2000amp station feeder ACB switchgear panel, g. One (1) unit boiler & auxiliary equipment MCC panel, h. One (1) unit black start generator control, synchronizing and ACB switchgear panel, i. One (1) unit PLC and SCADA (Siemens Step 7). j. One (1) One (1) unit 75KVA single phase 220V lighting transformer.

1.4 One (1) lot 13.2kV substation equipment consist of:

a. One (1) unit 15kV, 630amp VCB switchgear panel, b. One (1) lot system protection & control instruments, c. One (1) unit metering complete with necessary PTs, CTs, d. One (1) lot electrical MV, LV and control cables and wires, e. One (1) lot concrete pole complete with cross-arm, supports, insulators etc.

1.5 One (1) lot water treatment system consist of:

a. Three (3) units of 17.5 cu.m/hr each multi media filter & twin softener system each consist of:

i. Multi Media Filter

Design Flow rate: 20 m3 / hr Feed water Quality: Deepwell water Required Feed Pressure: 60 - 80 psi Product Water Quality: Filtered to less than 20 µm Design Cycle Time: 24 operating hours Regeneration: approx. 30 minutes, manual

ii. Softener

Design flow rate: 17.5 cu.m/hr Feed water quality: Deepwell water



Fee water hardness: less than 200mg/L as CaCO3 Product water hardness: less than 2.0mg/L as CaCO3 Design cycle time: approx. 16 hrs Regeneration cycle time: approx. 120 minutes

iii. Key components

FRP Composite Resin Tank: 3 nos. Manual Operated Valve: 1 set Automatic 5-cycle Multiport Softener Valve: 2 set Multi-Media Graded Filter Media: 1 lot Purolite C100 Softener Resin: 2 lot Top distributor, bottom hub, lateral assembly: 3 sets Feed water Control Valve: 1 set Feed water Variable Flow meter: 1 set Liquid filled 2 ½" SS Pressure gauge: 1 lot Isolation and bypass valves: 2 sets Brine tank in polyethylene c/w brine valve: 1 set Grundfos Multistage SS Feed Pump: 1 set Control Panel: 1 set

b. One (1) unit water de-mineralizer consists of:

i. One (1) unit activated carbon filter as De-mineralizer pretreatment:

Design flow rate: 5 cu.m/hr Feed water quality: Deepwell water Product water quality: Organics free, filtered to less than 50µm Regeneration cycle time: 30 minutes automatic for MMF and ACF

60 minutes automatic for softener

ii. One (1) unit 2 bed de-mineralizer:

Design flow rate: 3.5 cu.m/hr Feed water TDS: 900mg/L Product water TDS: < 10mg/L Product water hardness: < 0.0mg/L Design cycle time: >12 hurs Design throughput: >60 cu.m NaOH (as 100%) used per cycle: 35.0 ltr HCI (as 100%) used per cycle: 30.0 ltr Effluent generated per regent: 5 cu.m

iii Key components:

Anion and cation narrow bead resin: 1 lot FRP composite tanks c/w internals air‐operated diaphragm valves: 1 lot



Flowmeter c/w flow control valves: 1 lot Pressure gauges: 1 lot Air pressure regulator c/w solenoid valve assembly: 1 lot SS multistage pump c/w VSD control: 2 units Acid & caustic tanks: 1 lot Pressure relief valve: 1 lot Digital conductivity analyzer: 1 unit PLC based controls with keypad interface, audio & visual alarm, IP55 weather proof control panel: 1 set FRP composite resin tank for MMF & ACF: 2 units Automatic 3-cycle multiport filter valve: 2 sets Media for MMF & ACF: 2 lots Feed water control valve: 1 set Top distributor, bottom hub, lateral assembly: 2 sets Feed water pump: 1 unit Feed water variable flow meter: 1 lot Liquid filled 2.5” pressure gauge: 1 lot Isolating and by-pass valves: 2 sets Electrical actuated motorized valve: 2 sets Pressure switchers: 1 lot PVC SCH 80 plumbing on epoxy coated carbon steel: 1 lot

1.6 One (1) lot condensate cooling system consists of:

a. Four (4) unit FRP Natural Draft parallel flow cooling tower:

i. Design Conditions:

Cooling water flow: 800 cu.m/hr Hot water temperature: 40°C Cold water temperature: 32°C Design wet bulb temperature: 27.78ºC Evaporation losses: approx. 1.35% of water circulation Drift losses: approx. 0.3% of water circulation

ii. Frame Works: Hot dipped galvanized M.S. iii. Louvers: Fiber glass reinforced plastics. iv. Water Distribution Header: Galvanized pipe. v. Water Distribution Nozzles: PVC / Nylon-6 vi. Bolts, Nut, Misc. Hardware: Electroplated M.S. & PVC

b. Four (4) units condensate cooling pumps each:

Horizontal centrifugal pump, cast iron casing, bronze impeller and stainless steel shaft capable of delivering 800m3/hr against 20mtrs, coupled to 100Hp., 440volts, 3 phase, 60



hz., mounted on a common base-plate and rubber coupling. Suction and discharge size 12 x 10 inches diameter.

c. One (1) lot isolating valves, strainers and fittings.

1.7 One (1) lot power plant auxiliary equipments:

a. Two (2) unit air compressor, b. One (1) unit 750KW Black Start generator (re-conditioned), c. One (1) unit 10 ton SWL overhead traveling crane (to be installed in Turbine House), d. Two (2) units 40 cu.m/hr deepwell & pump.

1.8 One (1) lot power plant erection materials:

a. One (1) lot piping and fittings, b. One (1) lot electrical MV, LV and control cables and wires, c. One (1) lot steel materials.



2. BALANCE OF PLANT

The power plant shall be designed and constructed as per attached layouts. 2.1 Mechanical Installation Works

a. Boiler and Turbine Generator Installation Works

i. Prepare necessary importation documents & permits, ii. Perform custom clearing, iii. Land transportation from port of discharge to project site. iv. Site assembly & installation works. v. Jacking, mounting and alignment on foundation blocks. vi. Grouting of turbine generator on foundation block.

b. Auxiliary Equipment Installation Works

i. Prepare necessary importation documents & permits, ii. Perform custom clearing, iii. Land transportation from port of discharge to project site. iv. Site assembly & installation works. v. Mounting and installation of all auxiliary equipment on the foundation. vi. Grouting of all auxiliary equipment using normal non-shrink cement.

c. Piping Installation works

i. Supply of necessary cranes, lifting equipment, welding machines, gas cutters, bending

machines, drill press, hand drills, welding electrodes, grinders, hand tools, etc. ii. Fabricate, layout and installation of all system piping in accordance with Approved For

Construction Drawings. iii. Fabrication, layout and installation of all steel bracket and support structures for all

piping systems. iv. Chemical cleaning, flushing and pickling of piping system including the supply of

chemical and anti-corrosion oil if necessary. v. Pressure testing of piping system in accordance with manufacture requirement. vi. Paintings of all piping systems include supply of paint materials. One coat primer and

one coat final finishing. vii. Supply & installation of rockwool insulation and sheet steel cladding.

d. Supply, fabricate and installation works

i. Fabricate and install of 25 meters exhaust chimney.



ii. Drilling and construction of 2 x 35cu.m/hr deepwell.

e. Supply and installation of the following water tanks:

i. One (1) unit approx. 25 cu.m raw water storage tank (elevated tank), ii. One (1) unit 20 cu.m boiler feed water storage tank, iii. One 91) unit 20 cu.m boiler feed water tank with deaerator and steam heating system.

2.2 Electrical Installation Works

a. Mounting and installation of all electrical equipment, transformers, panels and switchgears include the supply of anchor bolts and necessary shim plates.

b. Supply, layout and installation of all cable tray systems in accordance with approved plans

include the supply of mounting bolts and necessary steel brackets.

c. Supply, layout, installation and termination of all high voltage cables in accordance with approved plans; include the supply of all cables and termination kits.

d. Supply, layout, installation and termination of all low voltage and control cables in

accordance with approved plans include the supply of all cables and termination kits. 2.3 Civil Construction Works

a. Engineering Design

Complete engineering design of Power Plant with control room, foundations, roadwork, storm drainage etc. Engineering work includes: -

i. Soil testing and geotechnical evaluation (5 bore holes shall be drilled at site) ii. Architectural drawings, iii. Structural drawings, iv. Material / test certifications for concrete, v. As-built drawings.

b. Site Development

i. Clearing and leveling, ii. Excavating of foundations and footings.

Note: The site should be backfilled and leveled by Owner before handling over to the

contractor.

c. Construction of Boiler House

i. The Boiler House shall be designed and constructed to house the boiler and associated equipment in accordance with the boiler supplier recommendations and requirements. The floor area of the boiler house shall be approx. 28m x 6.6m.



ii. Construction

1. Foundation, footings, floors slabs - - Reinforced concrete. 2. Columns, beams, girders, stair ways - - Structural Steel. 3. Masonry - - Combination of steel louvers and ribbed steel sheet. 4. Roof - - Ribbed steel roofing sheets gauge 24 with 25mm thick fiberglass wool

thermal insulation and aluminum foil backed. 5. Roof framing - - Structural steel trusses and purling. 6. Lightings and emergency lightings. 7. Lightning protection and earthling system.

d. Construction of Turbine House

i. The Turbine House is a two stories building annex to the Boiler House, the upper level

(approx. 6m above ground) shall house the turbine generator and control room, the ground level shall housed the condenser, station transformer & turbine auxiliary equipments The floor area of the rooms are:

1. Turbine Generator Room: approx. 10m x 18.5m (+8m level) 2. MCC panels / Control Room: approx. 8m x10m (+8m level) 3. MV panels & Transformer Room: approx. 8m x 10m (+4.5m level) 4. Condenser & Auxiliary Room: approx. 10m x 18.5m (+0m level)

ii. Construction

1. Foundation, footings, floors slabs - - Reinforced concrete. 2. Columns, beams, girders, stair ways - - Structural Steel. 3. Masonry - - Combination of steel louvers and ribbed steel sheet. 4. Roof - - Ribbed steel roofing sheets gauge 24 with 25mm thick fiberglass wool

thermal insulation and aluminum foil backed. 5. Roof framing - - Structural steel trusses and purling. 6. Lightings and emergency lightings. 7. Lightning protection and earthling system 8. Control Room shall be installed with window type or split unit type air-

conditioner.

iii. Architectural

1. Masonry (Control Room only) - - Cement plastering on both side with painting. 2. Doors - - Steel or metal doors with painting. 3. Windows - - Double swing glass window with steel or metal casement. Viewing 4. window between Control Room and Turbine generator Room shall be sliding

glass panel type size 2m by 1.5m. 5. Floors - - Plain concrete finishing. 6. Washroom - - Unglazed ceramic tiles. 7. Ceilings - - Suspended ceiling with acoustic board and fiberglass wool Insulation

in Control Room, no ceiling in other areas.



e. Construction of 2 stories Workshop / Store & Admin. Office

A 2 stories building shall be constructed to house the Workshop / Warehouse on the ground floor and Admin. Office on the 2nd floor. Each floor shall have a floor area of approx. 6m x 18m. Workshop / warehouse: i. Construction

1. Foundation, footings, floors slabs - - Reinforced concrete. 2. Columns, beams, girders, stair ways - - Structural Steel. 3. Roof - - Ribbed steel roofing sheets gauge 24 with 25mm thick fiberglass wool


ii. Architectural

1. Masonry - - Cement plastering on both side with painting. 2. Doors - - Steel roller shutter door of 2m x 2.5m with manual operation. Other

areas shall be installed with steel or metal doors with painting. 3. Windows - - Double swing glass window with steel or metal casement. 4. Floors - - Plain concrete finishing.

(Workshop equipment, tools, storage facilities, office equipment and stationary are not in the scope of supply).

Admin. Office: The admin. office shall be designed and constructed with the following rooms:

1. Conference Room, 2. Plant Manager Office, 3. Engineer’s office, 4. Admin Staff office, 5. Panty / CR / Rest Area:

i. Construction

1. Foundation, footings, floors slabs - - Reinforced concrete. 2. Columns, beams, girders, stair ways - - Structural Steel. 3. Roof - - Ribbed steel roofing sheets gauge 24 with 25mm thick fiberglass wool




7. CR complete with 1 x toilet, 1 x shower and 1 x wash basin. 8. Office space shall be installed with window type air-conditioner.

ii. Architectural

1. Masonry - - Cement plastering on both side with painting. 2. Doors - - Workshop shall be installed with steel roller shutter door of 2m x 2.5m

with manual operation. Other areas shall be installed with steel or metal doors with painting.

3. Windows - - Double swing glass window with steel or metal casement. 4. Floors - - Plain concrete finishing. 5. Washroom - - Unglazed ceramic tiles. 6. Ceilings - - Suspended ceiling with acoustic board and fiberglass wool Insulation

in air-conditioned spaces, other areas shall be installed with suspended ceiling with plaster board (gypsum).

(Furniture, telephone, office equipment and stationary are not in the scope of supply).

f. Foundation & Other Works:

i. Foundation & Structural Support Works – Boiler, ii. Foundation & Structural Support Works – Turbine Generator, iii. Foundation & Structural Support Works – Chimney, iv. Foundation & Structural Support Works – ESP, v. Foundation & Structural Support Works – Water tanks, vi. Foundation & Structural Support Works – Cooling tower & pumps, vii. Foundation & Structural Support Works – Electrical panels and equipments, viii. Supply and erection of Water Treatment Plant shed, ix. Supply and erection of cooling water pump shed.

g. Storm Drain System

“U” shape concrete lined canal of various sizes with concrete cover where necessary.

h. Road Works

i. Road - - Road within the power plant to be Portland cement concrete. ii. Curb and gutter - - Concrete. iii. Walkway - - Concrete.



3. ENGINEERING AND PROJECT MANAGEMENT 3.1 Project Management Team

Engcon Energy Pte Ltd shall be the leader of the project and shall organize and form a Project Management Team which includes the project teams from the 3 main suppliers.

The Project Management team shall be responsible to ensure that the installation of the power generation equipment is completed according to agreed time schedule and meet all technical specifications and performance guarantees as stipulated in this quotation.

3.2 Project Team Organization & Responsibilities

The Project Management Team shall be organized based on engineering disciplines and trades. It shall be led by a competent, responsible and experience project manager (PJM) supported by the project manager of the 3 main suppliers and a team of experience engineers, supervisors, specialists and supporting staffs.

The PJM shall coordinate with the Owner project team and owner’s contractors to ensure the smooth execution and timely completion of the project.

To ensure the smooth execution of the design, engineering, manufacturing, assembling, packaging, delivery, installation, testing & commissioning of the power generation equipment, the Project Management Team shall:

a. Integrate and interface all design and engineering information from the suppliers to prepare

necessary engineering drawings for the installation of the power generation equipment; b. Review all engineering documents to ensure that local requirements, rules and regulations

are met;

c. Prepare necessary engineering data, information & drawings for the installation, testing and commissioning of the equipment;

d. Ensure the timely dissemination of engineering and installation information to the suppliers

and contractors to ensure the installation of the equipments are done accurately and correctly;

e. Formulate detail equipment delivery schedules to ensure the timely delivery of all equipment

to site;

f. Formulate detail construction schedule to ensure the timely completion of the installation work;

g. Formulate necessary installation, QA/QC, safety and security procedures to ensure the

smooth and safe execution of the project;



h. Ensure the quality of supplies, materials and works comply with approved standards and in compliance with the contract requirements,

i. Coordinate and conduct regular meeting with the Owner’s project team and owner’s

contractors to ensure all parties are kept updated on the latest status and development of the project;

j. Prepare and submit regular progress report to all concern parties to record the progress,

status, developments, certifications etc. on the installation of the power generation equipment.



Project Manager Engcon Energy Pte Ltd

Engcon Project Tem

1. Design/Engineering Team 2. Procurement Team 3. Packing & Shipment 4. Site Project Team:

a. Site Project Manager b. Civil Engineer c. Mechanical Engineer d. Electrical / Instrumentation

Engineer e. Piping Engineer f. QA / QC Team g. Safety Engineer 5. Testing & Commissioning Team

IJT Project Tem Boiler Supplier

1. Project Manager 2. Design/Engineering Team 3. Procurement Team 4. Factory Assembly 5. Packing & Shipment 6. Site Erection Team a. Erection Supervisor b. Electrical / Instrumentation Supervisor c. Piping Supervisor d. Welding Supervisor e. QA / QC Team f. Safety Engineer g. Local Contractor 7. Testing & Commissioning Team

Triveni Project Tem Turbine Generator Supplier

1. Project Manager 2. Design/Engineering Team 3. Procurement Team 4. Factory Assembly 5. Packing & Shipment 6. Site Erection Team:

a. Installation Supervisor b. Electrical / Instrumentation

Supervisor c. Piping Supervisor d. QA / QC Team e. Local Contractor

7. Testing & Commissioning Team

Project Tem 69kV Substation Supplier

2. Project manager 3. Design/Engineering Team 4. Procurement Team 5. Packing & Shipment 5. Site Erection Team a. Installation Supervisor b. Electrical / Instrumentation Supervisor c. Local Contractor 6. Testing & Commissioning Team



4. EXCLUSION

The following are not included in our price and shall be supplied by Owner or others contractors:

1. Construction water and electricity for the whole duration of the project, 2. Pilling works, 3. Clearing, back filling (reasonably compacted) and leveling of the project site with an area of

approx. 100m x 100m, 4. Open rice husk storage areas, rice husk weighing and ash disposing facilities, 5. Perimeter fencing, 6. Construction equipment such as bulldozer, excavator, loader, dump-trucks, forklift etc. 7. First fill of lube oil, gear oil, misc. grease and chemical 8. Import tax and duty, VAT and all local government tax and fees, 9. Working VISA for foreign workers and engineers.

5. PRICE & PAYMENT TERMS

5.1 Price (See attached for details cost breakdown)

a. Equipment Supply Portion

US$5,850,000.00 (US Dollars Five Million, Eight Hundred and Fifty Thousand Only)

b. Balance Of Plant

1. Balance Of Plant #1

Php72,000,000.00 (Philippines Peso Seventy Two Million Only)

2. Balance Of Plant #2 – can be handled directly by Golden Season

Php36,900,000.00 (Philippines Peso Thirty Six Million and Nine Hundred Thousand Only)

The quoted price is net to the Contractor, any local tax such as VAT, income tax and any other government tax shall be paid by the Owner on behalf of the Contractor.

5.2 Payment Terms

a. Equipment Supply Portion

i. 25% down payment on contract signing by direct bank TT, ii. 65% on shipment covered by LC, iii. 10% on completion of testing and commissioning covered by LC.



b. Balance Of Plant

i. 30% down payment on contract signing by direct bank TT, ii. 70% on monthly progress payment covered by LC.

6 WARRANTY & SCHEDULE

6.1 Warranty

Unless otherwise specified, the warranty period shall be 12 months commencing from the date so certified in the Taking Over Certificate or 240 months after the date of shipment whichever occurs first.

6.2 Project Schedule

The project completion schedule shall be 24 months from the received of down payment and LC, This validity of this quotation is 2 months until 15th July 2011. Albert Yap Director

EPC PRICE ESTIMATION - 6.5MW15th May 2011

S/No. Item Description Unit Unit Cost Total Cost

1 Boiler - Supplied By IJT - CIF Manila 1 Lot $2,950,000.00 $2,950,000.00

a. Main boiler, furnace & traveling grate 1 Lot - -

b. Induce air & combustion air system 1 Lot - -

c. Husk feeding system & service tank 1 Lot - -

d. Ash evacuation system 1 Lot - -

e. Feed water supply system 1 Lot - -

f. Feed water deaeration system 1 Lot - -

g. Turbine control steam supply system 1 Lot - -

h. Feed water chemical dosing & treatment system 1 Lot - -

i. Fly ash filtration system - Electro-Static-Precipitator 1 Lot - -

2 Turbine Generator - By Triveni India 1 Lot $1,900,000.00 $1,900,000.00

a. Multi stage turbine 1 Lot - -

b. Water cooled AC generator 1 set - -

c. Vacuum Condenser & condensage pumps 1 set - -

d. Turbine control & PLC panel 1 set - -

e. Generator control & syn. panel 1 set - -

3 Electrical System - by Engcon 1 Lot $450,000.00 $450,000.00

a. Generator switchgear panel 1 set - -

b. MV metering and Bus PT panel 1 set - -

c. 13.8KV / 440V Station transformer 1 unit - -

d. 13.8kV Station transformer MV switchgear panel 1 set - -

e. 13.8kV Outgoing feeder switchgear panel with metering 1 set - -

f. Station main LV feeder switchgear panel 1 set - -

g. Boiler MCC and DC starter panel 1 set - -

h. PLC / SCADA 1 set - -

i. Black start switchgear & syn. panel 1 set - -

j. Testing & Commissioning 1 set - -

4 Other Power Plant Equipments & Materials - By Engcon 1 Lot $550,000.00 $550,000.00

a. Water Treatment System - Demin. (2 x 2.5 cu.m/hr) 1 set - -

b. Water Treatment System - MMF & Softener (3x20m3/h) 3 - -

c. Cooling Water Pumps (3 x 1000 m3/hr) 3 - -

d. Cooling Tower (3 x 1000 m3/hr) 3 - -

e. Overhead Crane 1 set - -

f. Piping & Fittings - for cooling system only 1 set - -

g. Piping & Fittings - for turbine & others 1 set - -

h. Electrical cables 1 lot - -

i. Steel materials 1 lot - -

5 13.2kV Substation 1 Lot $15,000.00 $15,000.00

a. 15kV Fuel Cutoff Switch with Lightning Arresters 1 set - -

b. PTs, CTs & Metering 1 lot - -

c. Steel pose, insulators, conductors etc. 1 lot - -

Subtotal: $5,865,000.00

Discount: $15,000.00

Discounted Price: $5,850,000.00

Page 1 of 3

Balance Of Plant #1 - M&E

S/No. M&E Installation Works Unit Unit Cost (Php) Total Cost

1 M&E - Boiler 1 lot 24,000,000.00 24,000,000.00

2 M&E - Turbine Generator / cooling system / others 1 lot 8,000,000.00 8,000,000.00

3 Tools, trucks and crane etc (see # 01). 1 lot 4,000,000.00 4,000,000.00

4 Consumables & paint etc. 1 lot 1,000,000.00 1,000,000.00

5 Misc. Equipment & Materials

a. Compressor & dryer 2 units 350,000.00 700,000.00

b. Battery Panel 1 unit 150,000.00 150,000.00

c. Lighting transformer 150kVA 1 unit 150,000.00 150,000.00

Subtotal: 38,000,000.00

Balance Of Plant #2 - Civil

S/No. Civil Construction Works Unit Unit Cost (Php) Total Cost

1 Design & Engineering 1 lot 500,000.00 500,000.00

2 Boiler foundation & firing floor 1 lot 12,000,000.00 12,000,000.00

3 ESP (deduster) foundation & footings 1 lot 2,000,000.00 2,000,000.00

4 ID fan foundation 1 lot 300,000.00 300,000.00

5 Exhaust chimney, support structure & foundation 1 lot 3,000,000.00 3,000,000.00

6 Turbine generator house & control room 1 lot 20,000,000.00 20,000,000.00

Subtotal: 37,800,000.00

Total BOP #1: 75,800,000.00

Discount: 3,800,000.00

Discounted Price: 72,000,000.00

Page 2 of 3

Balance Of Plant #2

S/No. M&E Installation Works Unit Unit Cost (Php) Total Cost

1 Custom clearing & transportation to site (# 01) 1 lot 5,000,000.00 5,000,000.00

2 All risks insurance 1 lot 1,750,000.00 1,750,000.00

3 Equipment Rental (# 03) 1 lot 300,000.00 300,000.00

4 Black start engine - 1000kw (Reconditioned) 1 lot 2,500,000.00 2,500,000.00

5 Rice husk supply conveyor & elevator 1 lot 1,500,000.00 1,500,000.00

6 Ash conveyor & elevator 1 lot 800,000.00 800,000.00

7 Deepwell and pump (2 x 35m3/hr) 2 400,000.00 800,000.00

8 Cooling tower basins 1 lot 2,750,000.00 2,750,000.00

9 Water treatment shed (4m height) 1 lot 500,000.00 500,000.00

10 Cooling water pump foundation & shed (Roof only) 1 lot 250,000.00 250,000.00

11 Rick husk storage bunker 1 lot 8,500,000.00 8,500,000.00

12 Ash storage bunker 1 lot 1,500,000.00 1,500,000.00

13 Road, side walk, car park & drainage 1 lot 1,500,000.00 1,500,000.00

14 Deepwell water storage tank, support tower & foundation 1 lot 750,000.00 750,000.00

15 Admin. Office / Workshop / Warehouse (6m x 18m) 1 lot 5,000,000.00 5,000,000.00

16 O&M staff dormitory 1 lot 3,500,000.00 3,500,000.00

Subtotal: 36,900,000.00

US$ To Php: 43.500 Total BOP #2: 36,900,000.00

In US$ In Peso

Total Price - Equipment: $5,850,000.00 254,475,000.00

Total Price - BOP#1: $1,655,172.41 72,000,000.00

Total Price - BOP#2: $848,275.86 36,900,000.00

$8,353,448.28 363,375,000.00

Balance Of Plant #2 (BOP#2) can be handled directly by Golden Season.

# 01 Use of necessary construction equipment available in Golden Season. Only heavy lift crane need to rent from Manila.

# 02 Use the empty rice trucks to carry imported or local purchase equipment & materials to site from Manila. Only oversize items shall use special trucks and carriers rental from special transportation contractor.

# 03 Use necessary construction equipment available in Golden Season.

Page 3 of 3

1-75

6.5MW Rice Husk Fired Power Plant Layout8th May 2011

Existing 2MWPower Plant

Approx. 70 m

eters

Approx. 80 meters

Water TreatmentPlant

(6m x 16m)

Admin./Workshop Building (6m x 18m)

ControlRoom

(8 x 10m)

TG Room

HuskLoadingStation

(10m x 18.5m)

Garden

AshBunker

RiceHusk

Bunker(2 Days

Capacity)

Co

olin

g T

ow

ers

1-75

6.5MW Rice Husk Fired Power Plant Layout

Approx. 80 meters

Approx. 70 m

eters

Water TreatmentPlant

(6m x 16m)

Admin./Workshop Building (6m x 18m)

ControlRoom

(8 x 10m)

TG Room

HuskLoadingStation

(10m x 18.5m)

Garden

AshBunker

RiceHusk

Bunker(2 Days

Capacity)

Co

olin

g T

ow

ers

125

Layout Plan - 2 Stories Admin. / Workshop Building

Plant ManagerOffice

Workshop

6m

Pantry

CR

Admin. Office

Tool Store / Warehouse

18m

Engineer Office

Conference Room

CR

75-1:15

1m4m

O&M Staff Dormitory

4m

16m

Co

okin

gA

rea

Ref.

Po

ol

Tab

le

4m x 2.5m

4m

4m x 2.5m

4m x 2.5m

4m x 2.5m

4m x 2.5m

4m x 3m

4m x 3m

4m x 3m

4m x 3mTable

CR

, Sh

ow

erW

ashin

g A

rea

4m x 3m

30

Conceptual Rice Husk Feeding Design

Husk Bunker

PDF created with pdfFactory trial version www.pdffactory.com

http://www.pdffactory.com

PDF created with pdfFactory trial version www.pdffactory.com

http://www.pdffactory.com

75-1:15

18m

14m

Annex A

Boiler

Technical Specification & Scope Of Supply

Page 1 of 24

Scope Of Supply & Technical Specification For A 40 TPH Rice Husk Fired Traveling Grate Boiler

SECTION DESCRIPTION

SECTION – 1 SALIENT FEATURES OF PROPOSED STEAM GENERATOR

SECTION – 2 DESIGN BASIS

SECTION – 3 SCOPE OF EQUIPMENT SUPPLY AND SERVICES

SECTION – 4 TECHNICAL DATA SHEETS

SECTION – 5 PERFORMANCE GUARANTEES

SECTION – 6 LIST OF MAINTENANCE TOOLS AND TACKLES

1. ISGEC JOHN THOMPSON (IJT) is amongst India's leading manufacturer of Industrial

Boiler, Sugar plant, Raw Syrup Plant for Ethanol. IJT hold a significant market share of our products/projects in India as well as in overseas market. IJT has supplied over 550 boilers and 56 Complete Sugar Plants and major expansions to date in India and several overseas markets.

2. IJT is part of over US$ 450 million turnover Public Limited Company. IJT is ISO 9001-2000

certified. IJT works is amongst the most sophisticated and modern manufacturing facilities in India. IJT has have overseas offices in USA and Germany.

3. Currently IJT is executing a number of contracts overseas, some of which are listed below:

• USA- 1 No. 70 TPH Gas Fired Boiler for Longview Power Project. • Chile- 1 No. 140 TPH Coal Fired Boiler for Methanex Group.

• Spain- 1 No. 28 TPH biomass fired Boiler for Aldebaran Energy.

• Brazil- 2 Nos. 100 TPH Oil and gas Fired Boilers for Petroquimicasuape.

• Senegal – 1 No. 150 TPH Travelling Grate Boiler for Compagnie Sucriere

Senegalaise

• Thailand- 1 No. 95 TPH Travelling Grate Boiler for Mid-Siam Sugar Co. Ltd. (Mitr Phol Group) and 2 Nos. 150 TPH Travelling Grate Boilers for Khon Kaen Sugar Power Plant Co. Ltd. 1 No. 10 MW Power Plant with rice husk fired boiler for U thong Biomass project.

ISGEC John Thompson

Page 2 of 24

• Philippines - Cane Milling & Raw Syrup Plant of 1650 TCD, Multi-fuel fired boiler on

turnkey basis (excluding civil work). This is for a Greenfield Ethanol Plant Project as a Joint Venture with Bronzeoak, U.K. a British Company commissioned in Nov 2008..

• Sudan- 4 Nos. 130 TPH bagasse /oil fired Boilers on turnkey basis for While Nile

Sugar, Sudan Project.

• Kenya- Complete Sugar Plant of 1650 TCD capacity to Kibos Sugar & Allied Industries Ltd., Kenya for plantation white sugar by double sulphitation process.

• Complete Sugar plant of 1650 TCD capacity to Butali Sugar Mills Ltd. for plantation

white sugar by double Sulphitation process.

• 170 TPH, 87 kg/cm2g, 515 Deg C bagasse fired Boiler and Bagasse Handling system for Mumias Sugar, Kenya.

• Zambia - 31 MW Power Plant which includes a 160 TPH bagasse fired Boiler, TA

set and associated works for Nakambala Sugar, Zambia.

• Expansion of Complete Sugar Plant originally supplied by us at Consolidated Farming Ltd. from 1500 TCD to 2500 TCD capacity. This Plant produces both plantation white and raw Sugar.

Page 3 of 24

SECTION – 1

SALIENT FEATURES OF PROPOSED STEAM GENERATOR I. DESIGN FEATURES:

1. Conservative grate area loading to ensure the efficient combustion of fuel.

2. Temperature elements are provided on the skid bar, cross beam and riddling hoppers with temperature indication in the control room. Also alarm is provided to alert when the temperature reaches around 3000 C.

3. Conservative volumetric loading of furnace. a. Ensures adequate residence time for efficient fuel combustion. b. Ensures lower furnace exit gas temperature to avoid fouling due to alkali content in the

fuel.

4. Higher furnace cross section to reduce flue gas velocity in the furnace, hence reduced fuel carry over and less suspension / localized combustion in the upper furnace.

5. Convective Super heater Design. a. Super heater placed in radiant zone faces burning fuel particles. b. Fouling of ash in Super heater due to high temperature in radiant zone. c. Causing overheating of radiant Super heater during boiler start up due to higher metal

temperature.

All the above problems are eliminated by placing super heater in convective zone. (Refer General Arrangement drawing enclosed).

6. Conservatively designed Steam drum / Water drum a. To keep drum steam loading rate low. b. To enable boiler operation with rapid load swings and fast response to load changes.

7. Efficient drum internals consisting of cyclone separators and demisters to ensure high steam purity at all loads.

8. Single pass, inline boiler bank without baffles, hence lower flue gas velocities, lower tube erosion and less draft loss.

9. Over fire air system with higher secondary air pressure to provide better air penetration across furnace cross section thereby minimizing un burnt carbon loss. The secondary air nozzles are staggered providing turbulence and air curtain to minimize escape of un burnt fuel particles.

10. Optimum steam side pressure drop in superheater circuit to ensure proper steam distribution and cooling of superheater coils.

11. Optimum flue gas velocity levels in pressure parts to minimize erosion due to ash.

12. High circulation ratio at all loads ensuring efficient cooling of water wall tubes and also preventing departure from nucleate boiling.

Page 4 of 24

II. CONSTRUCTION FEATURES

1. The material of construction of grate bar is Spheroidal Graphite Iron. This is moderate silicon, low alloy ductile (nodular cast iron with ferrite matrix).

2. Self lubricated graphite bearings (Morganite bearings) are provided for the stoker shaft. The

Morganite carbon bearing is self lubricating, chemically inert, dimensionally stable, non-hygroscopic and highly resistant to wear characteristics which makes it ideal for hostile environment.

3. Drum internals of bolted construction for easy removal / replacement.

4. Water-cooled membrane wall construction with optimum fin width.

• To have maximum absorption of heat. • Lower fin tip to base differential temperature. • Structural rigidity.

5. Inline, single pass boiler bank tube, hence optimum draft loss, ease in cleaning.

6. Wide pitching of superheater assemblies to minimize fouling.

7. Plain tube economizer with in line arrangement ensures ease of cleaning and inspection.

8. Air heater air side bypass arrangement with manual damper and corten steel tubes will be

provided for first 6 rows on air entry side to prevent corrosion during low load operation and start up of the boiler.

9. Adequate soot blowers in superheater, boiler bank and economizer region for efficient on-

load cleaning of heating surfaces.

10. Pressure parts tubes made of hot finished seamless steel construction to ensure high tube life and hence higher boiler availability.

11. Provision of adequate access doors / observation doors for inspection and repair.

12. Location and arrangement of heating surfaces ensures good accessibility for inspection and

repairs.

13. Minimum use of refractory, thereby eliminating cumbersome maintenance.

Page 5 of 24

SECTION – 2 DESIGN BASIS ISGEC JOHN THOMPSON, BI DRUM, NATURAL CIRCULATION, BALANCED DRAUGHT, SEMI OUTDOOR, WATER TUBE TYPE, BOTTOM SUPPORTED, CONTINOUS ASH DISCHARGE TRAVELLING GRATE BOILER suitable for A. BOILER PARAMETERS MCR Evaporation (Gross) kg / hr 40,000 Peak Generation ( ½ hour once in a shift of 8 hours )

kg / hr 40,000

Steam Pressure at Boiler Main Steam Stop Valve outlet

bar(g) 38

Super heated steam temperature at Main Steam Stop Valve outlet

Deg. C 370 ± 12

Super heated steam temperature Control range

% BMCR 60-100

Feed Water Temperature at inlet of Economizer / outlet of deaerator

Deg. C 105

Number of boilers Nos. One

B. SITE CONDITION

Ambient Temperature Deg.C 30 Relative Humidity % 60 Seismic Zone Zone IV As per UBC 1997 Wind velocity m/s 56 Plant elevation 627 m above mean sea level

Plant location Philippines

Page 6 of 24

Area classification Safe, Non Hazardous &

Non Corrosive * Client to confirm C. DESIGN / PERFORMANCE CODES Pressure part ASME Boiler Integral & External Piping ASME Other auxiliaries and non pressure parts including steel structural

Indian standards.

Performance testing of the boiler (efficiency)

ASME PTC 4.1-1964 (R1991) by Indirect heat loss method

Electrical IEC / IS Control and Instrumentation ISA D. FUEL Fuel for Load carrying 100% MCR– Rice Husk Rice Husk Natural

E. UTILITIES 1. Cooling water (Fresh, filtered circulating cooling water)

Supply pressure 3.5 bar (g) Supply temperature 30 Quality of water Filtered and Clarified.

2. Instrument air

Pressure 6 bar (g) Temperature 30 Dew Point (-) 40 Deg. C Quality Moisture and oil free, clean air.

3. Plant air

Pressure 6 bar (g) Temperature 30 Quality Oil free clean air.

4. Electric Power: Motor Voltage 440V +/- 10% Frequency 60 Hz +/- 5% Combined variation 10% Type 3 phase, AC supply Instrumentation

Page 7 of 24

Voltage 220 V Frequency 60 Hz Type 1 phase, AC

Field transmitters Voltage 24 V Type DC F. RECOMMENDED FEED WATER AND BOILER WATER REQUIREMENT

As per BS 2486 G. Drive Turbine Steam Parameters

Inlet Steam Condition

Pressure 38 bar (g) Temperature 365 0C

Page 8 of 24

SECTION – 3

SCOPE OF EQUIPMENT SUPPLY AND SERVICES

Mechanical

1. Pressure parts

• Steam drum of fusion welded construction provided with necessary nozzle and with dished ends on both side with man ways.

• Steam drum internals comprising cyclones, scrubbers & demisters. (Drum internals are of carbon steel construction except demister, which is of SS construction).

• Mud drum of fusion welded construction with dished ends on both side with man ways.

• Furnace water wall tubes of fin welded water-cooled membrane wall construction together with inlet and outlet manifolds provided with necessary stubs. Necessary openings in the furnace for access doors peep holes and fuel distributor.

• Single stage Superheater system with all inter connecting piping and headers.

• Boiler bank tubes of single pass design.

• Economizer complete with inlet and outlet manifolds and coil support.

• All pressure parts tube material will be of hot finished seamless tube.

2. Feed Water system

• Feed water piping from deaerator storage tank outlet to boiler feed pump suction including suction header and from boiler feed pump discharge including discharge header.

• Feed water piping from boiler feed pump discharge header to feed control station inlet and from feed control station outlet to economizer inlet header.

• Feed water piping from economizer outlet header to steam drum.

• Cooling water supply / return piping from terminal point near boiler front row column to all equipment within the boiler island requiring cooling water.

• Service water supply / return piping from terminal point near boiler front row column to all equipment within the boiler island requiring service water.

• Boiler initial filling line from terminal point near boiler front row column to the water wall drain header.

• Spray water piping from boiler feed pump discharge to PRDS for deaerator initial heating.

• Hangers and supports for piping, as required.

3. Steam system • Circulating system including down comers and risers. • Saturated steam piping from steam drum to super heater inlet header.

Page 9 of 24

• Steam piping from superheater outlet header to main steam stop along with integral bypass valve.

• Soot blower steam piping from super heater header outlet to respective soot blowers in

superheater, boiler bank and economizer. • Upstream piping for deaerator pressure reducing desuperheater station from main

steam line (Max. 5 m length considered). • One no. initial heating deaerator steam pressure reducing and de-superheating station

(fixed orifice type) including pressure control valve and temperature control valve (1 x 100% pneumatic pressure control valve and 1 x 100% pneumatic temperature control valve with manual isolation valve at inlet & outlet and manual by pass valve). Pressure Reducing & De-Superheater capacity of 4 TPH considered.

• Steam piping from PRDS outlet to deaerator. (Max. piping length of 50 m considered).

• Target plate and temporary piping required for steam blowing.

• Hangers and supports for piping, as required.

4. Drain and Vent piping • Safety valve exhaust & Start up vent piping up to a safe elevation. • High pressure boiler blow down piping up to continuous blow down tank.

• Drain piping from individual drains to drain header and from drain header to intermittent

blow down tank.

• Drain piping from continuous blow down tank to intermittent blow down tank with level control valve.

• Blow down piping from outlet of intermittent blow down tank to nearest trench in boiler

area.

• Each One no. blow down tank for continuous & intermittent blow down.

• Flash steam piping from continuous blow down tank to deaerator.

• Raw water quenching line for Intermittent Blow Down tank from terminal point. 5. Non Pressure parts

• Tubular Mild Steel airheater (with ERW tubes and gas flow through tubes) to preheat the

combustion air and comprising of tube sheet, casing and associated supports and structures. (First 6 rows of tubes at cold end will be of corten steel tubes to avoid cold end corrosion during boiler starting and part load operation).

• Airheater provided with bypass arrangement with manual damper.

Page 10 of 24

• Over Fire Air nozzle at required elevation in furnace wall along with necessary ducting, if required.

• Pre dust collector is provided upstream of air heater in the flue gas path to collect the

larger unburnt carbon / ash particle from the gas stream and prevent fire hazard in ESP. Casing & Hoppers:

Carbon steel casing (5 mm thick) with stiffeners and supports for economizer.

Furnace front ash discharge chute submerged into submerged ash conveyor along with manually operated plate gates.

Bottom ash riddling hoppers with manually operated plate gates and rotary air

lock valve.

Fly ash hoppers below economizer/air preheater and ESP with manually operated isolation plate gate and rotary air lock valve.

Boiler Supporting Structures, Plat forms, Stair case & operating floor:

Buck stays, tie bars as required.

Boiler steel supporting structure from operating floor. The structure up to operating floor and operating floor will be RCC which has to be done by the customer.

Galleries, ladders and stairways with hand rails providing access to the essential

levels of the boiler, fuel feeders and soot blower etc. Gratings are of open bar type. (Gratings, platforms, handrails, staircase are of Galvanized Iron construction).

One no. staircase from firing floor level to steam drum operating floor level as

shown in General arrangement drawing.

Canopy (Galvanized sheet of 24 SWG thick) over boiler furnace and side cladding (Galvanized sheet of 24 SWG thick) for boiler up to steam drum operating floor level from top. Roof structure and structures for side cladding sheets.

G.I weather protection hoods for outdoor motors.

Rain water down pipes.

Support and suspension steel, access platform for all equipments, piping and

ducting.

Air and Flue gas ducting:

Air ducting with required stiffeners, carbon steel expansion joints, resin bonded mineral wool insulation, cladding and necessary fixing components (plain Aluminium cladding thickness of 24 SWG for hot air ducting) for the following.

o Forced draft air fan cold air suction ducting.

Page 11 of 24

o Cold air ducting from Forced draft air fan to air heater. o Hot air ducting from air heater to furnace bottom. o Secondary air fan cold air suction ducting. o Cold air ducting from Secondary air fan to air heater. o Hot air ducting from Secondary air fan outlet to over fire air nozzle / fuel

pneumatic spreader.

Flue gas ducting with required stiffeners, carbon steel expansion joints, resin bonded mineral wool insulation, cladding & necessary fixing components (plain Aluminium cladding thickness of 24 SWG) for the following:

o Flue gas ducting from boiler outlet to economizer. o Flue gas ducting from economizer to air heater. o Flue gas ducting from air heater to Electrostatic Precipitator. o Flue gas ducting from Electrostatic Precipitator to Induced draft fan inlet. o Flue gas ducting from Induced draft fan outlet to inlet of chimney.

(All the above duct plate material will confirm to IS2062)

Travelling grate:

Continuous ash discharge travelling grate complete with variable frequency electric drive, reduction gear box.

The grate assembly will include the key, seals, bottom air compartment and tensioning mechanism.

Self lubricated bearing (graphite bearings) are provided for the travelling grate stoker shaft.

Thermocouples are provided on the skid bar, cross beam and riddling hoppers.

Refractory & Insulation: Lightly resin bonded mineral wool Insulation (Designed for 20Deg C differential

temperature between ambient and surface temperature with an air velocity of 1.0 m/sec over the surface) and plain aluminum cladding thickness of 24 SWG for electro static precipitator, ducting, piping and other auxiliaries as required along with fixing material. Corrugated aluminum cladding thickness of 24 SWG for boiler furnace.

• Chimney counter flanges, expansion joint near chimney and fasteners for the

connection. • Casting for access doors and peep holes.

6. Auxiliaries • One no. horizontal, radial and backward curved blade, cold Secondary Air (SA) fan with

constant speed electric drive motor including foundation bolts, base frame, coupling, coupling guard, suction silencer ( if required) and suction hood. Fan will be provided with pneumatically operated Inlet Guide Vanes (IGV) / Damper. Speed of the fan will be 1800 rpm. Grease lubrication is provided for the fan bearings.

Page 12 of 24

• One no. horizontal, radial and backward curved blade, Forced draught (FD) fan with constant speed electric drive motor including foundation bolts, base frame, coupling, coupling guard, suction silencer (if required) and suction hood. Fan will be provided with pneumatically operated Inlet Guide Vanes (IGV)/Damper. Speed of the fan will be 1800 rpm. Grease lubrication is provided for the fan bearings.

• One no. horizontal radial, backward curved blade, simply supported Induced Draught

(ID) fan with variable speed electric drive motor & pneumatically operated Inlet Damper Control (IDC) including base frame coupling, coupling guard speed of the fan will be 1200 rpm. Impeller will be provided with hard facing / replaceable liners to minimise erosion. Grease lubrication is provided for the fan bearings.

• Manual isolation damper at SA/ FD/ ID fan outlet.

• RTD for measuring the bearing temperature of fans.

• Individual base frame and foundation bolts for fans & motors.

• Sample coolers complete with SS coils, sampling piping and cooling water piping for

superheated steam, saturated steam, boiler feed water and blow down water.

• Valves, mountings and fittings including the following:

o Two nos. Spring loaded safety valves on steam drum and one no safety valve on super heated main steam line.

o Silencers for startup vent valve and superheater safety valve to limit the noise level to 110 dBA at 1m distance.

o One x 100% pneumatically operated feed control valves with manual isolation valves at upstream and downstream.

o One x 100% motorized by pass for feed control valves

o One no. non return valve in steam line at boiler outlet.

o Required nos. manual isolation in main steam line. • List of Motorized isolation valves:

o One no motorized main steam stop valve with motorized integral bypass at superheater outlet.

o One no pneumatic start up vent valve (with inching facility) with motorized isolation valve.

o Two nos. motorized isolation valve at feed pump discharge.

o Each one no. motorized continuous blow down & intermittent blow down valve.

7. Soot Blowers • Electrically operated long retractable soot blowers for superheater zone and rotary soot

blowers for boiler bank and economizer zone complete with pressure reducing station

Page 13 of 24

and other accessories, valves/fittings. Sequential operation of soot blowers will be realized in distributed control system.

• One x 100 % pneumatically operated soot blower pressure control valve with manual isolation valve at upstream and manually operated isolation valve at downstream and one no. 100% manually operated bypass valve.

8. Deaerator cum storage tank, Boiler Feed water pumps ,Feed water storage tank & transfer pumps & Chemical dosing system:

Deaerator cum storage tank:

o One no. Spray cum tray type deaerator of 48 TPH capacity and

De-aerated water tank of 20 minutes storage of MCR generation capacity between NWL to trip level.

o Deaerator is to be mounted on top of control room. (Refer enclosed General

Arrangement drawing for the location of deaerator) o One x 100% pneumatically operated deaerator pressure control valve with

manual operated isolation valve at up stream and downstream and one no. manual by pass valve.

o One x 100% pneumatically operated deaerator level control valve with manual

operated isolation valve at up stream and downstream and one no. manual by pass valve.

o Steam piping from pressure control valve to deaerator.

o Feed water piping from level control valve to deaerator.

o Condensate piping from terminal point to deaerator.

o Over flow piping from deaerator terminated near deaerator with level control

valve.

o Ladders or staircases, as required.

o Lightly resin bonded mineral wool insulation with plain aluminum cladding of 0.80 mm thick.

o Valves and fittings, as required.

Boiler feed water pumps:

o 2 x 100% MCR Capacity centrifugal, single section, multistage, ring section

type boiler feed pump (1W+1S) along with constant speed drive motor complete with coupling, connection flange, automatic recirculation valve, suction strainer, mechanical seals, lift off device and ring oil lubrication.

o Upsteam piping for drive turbine from main steam line and exhaust steam piping from turbine exhaust to deaerator.

Page 14 of 24

o Minimum re-circulation piping and balance leak-off piping from boiler feed water pumps to inlet of deaerator tank.

o RTD for measuring the bearing temperature of pumps.

o Individual base frame and foundation bolts for pump & motor. Chemical Dosing System:

o One no Skid mounted Low Pressure dosing system comprising of one no.

mixing cum storage tank (stainless steel) with motorized agitator and 2 nos. positive displacement pumps(1W+1S).

o One no Skid mounted High Pressure dosing system comprising of one no.

mixing cum storage tank (stainless steel) with motorized agitator and 2 nos. positive displacement pumps(1W+1S).

o Low Pressure Dosing piping (stainless steel) from Low Pressure dosing tank

to Boiler feed pump suction.

o High Pressure Dosing piping (stainless steel) from High Pressure dosing tank to Steam drum.

o Valve and fittings as required. o High Pressure / Low Pressure dosing system dilution water line from one

point near boiler front row column to respective dosing tanks.

9. Fuel Storage Bunker & feeding system :

Rice Husk storage bunker & feeding system: o One no. carbon steel bunker of 50m3 (water volume) capacity for storing Rice

husk along with supporting structure, manual plate gates at bunker outlet. o Three nos. surge hoppers at feeder inlet.

o Three nos. of screw feeder with variable frequency drive for feeding the Rice

Husk to furnace through pneumatic spreaders along with necessary connecting chutes.

o Three nos. pneumatic spreaders.

10. Pollution control equipment

Electrostatic precipitator:

One no. Electrostatic precipitator of single stream type to limit the outlet dust concentration to 150 mg/Nm3 at the outlet of ESP with all fields working.

Complete accessories including emitting & collecting electrodes, casing, hoppers, hopper level indicators, hopper heater, rapping mechanism, T/R sets, supporting structures, stairways, walkways, handrails, housing, carbon steel expansion joints,

Page 15 of 24

Lightly resin bonded mineral wool insulation with plain aluminium cladding of 24 SWG thick, inlet and outlet funnels, gas distribution screens, electrical and mechanical interlock system, manually operated isolation gates at hopper discharge. Hopper heaters are thermostatically controlled. (Stairways, walkway, handrails are of Galvanized Iron construction).

11. Instrumentation

Local field instruments

11.1 Temperature elements to measure

− Flue gas temp. at furnace outlet (K type thermocouple)

− Flue gas temp. at superheater outlet (K type thermocouple)

− Flue gas temp. at outlet of boiler bank (K type thermocouple)

− Flue gas temp. at outlet of economizer(RTD)

− Flue gas temp. at outlet of Air preheater (RTD)

− Flue gas temp. at outlet of ESP(RTD)

− Air temp. at outlet of Air preheater(RTD)

− Air temp. at riddling hopper (K type thermocouple)

− Feed water temp. inlet & outlet of economiser(RTD)

− Steam temp. after superheater(K type thermocouple)

− Feed water temp. at Deaerator outlet (RTD)

11.2 Pressure gauges to measure

− Steam pressure at Steam Drum and at the outlet of Super Heater.

− Feed Water pressure before & after Feed Water control station.

− Feed water pressure at economiser inlet and outlet.

− Soot blower pressure

− Feed pump suction & discharge pressure

− CBD tank pressure

− Instrument air pressure

11.3 Draught gauges to measure

− Furnace pressure

− Flue gas pressure at superheater outlet

− Flue gas pressure at economiser inlet & outlet

− Flue gas pressure at outlet of air preheater

− Flue gas pressure at ESP outlet

− Flue gas pressure at chimney inlet

− Air pressure before and after air preheater

− Air pressure at SA fan discharge

Page 16 of 24

− Air pressure at riddling hopper

11.4 Temperature gauges to measure

− Steam temp. at superheater outlet

− Flue gas temp. at outlet of air preheater

− Air temp. at SA fan discharge

− Flue gas temp. after ESP

− Air temp after air preheater

− Feed water temp before & after economizer.

11.5 Pneumatically operated control valves

Feed water 100% control valve (1 no.)

De-aerator level control valve. (1 no.)

De-aerator pressure control valve. (1 no.) Soot blower pressure control valve. (1 no)

11.6 Pneumatically operated power cylinder

FD Fan inlet - 1 no ID Fan inlet - 1 no SA Fan inlet - 1 no

12.0 Field instruments required for PLC based control system (PLC is quoted optionally)

12.1 Field instruments required for the following control loops:

12.1.1 Three Element Drum Level Control No.

− Drum Level Transmitter(2 out of 3 logic) 3

− Drum pressure transmitter 1

− Steam Flow Transmitter. 1

− Feed flow Transmitter. 1

− Nozzle for steam flow 1

− Orifice for water flow 1

− I / P Convertor for FCV 1

− Feed control valve 1

12.1.2 Furnace Draught Control

− Furnace Pressure Transmitter 2

− I / P Convertor 1

− Power Cylinder 1

12.1.3 Auto Combustion Control

− Steam pressure Transmitter 1

− Air Flow Transmitter 1

− Aerofoil meter 1

Page 17 of 24

− O2 analyser 1


− Power Cylinder 1

12.1.4 Deaerator level Control

− Level Transmitter 1


− Level Control valve 1

12.1.5 Deaerator pressure Control

− Pressure Transmitter 1


− Pressure Control valve 1

12.1.6 Blow down tank level control

− Level Transmitter 1


− Level Control valve 1

12.1.7 Soot blower steam pressure control

− Pressure Transmitter 1


− Pressure Control valve 1

12.1.8 Deaerator initial heating PRDS control

12.2. Compensating cables from thermocouples to junction boxes (Junction box is located within

the boiler house)

12.3 Control and instrumentation cables from field instruments to local junction boxes (junction

boxes is located within the boiler house)

12.4 Impulse piping wherever necessary for the items which are under our scope of supply.

12.5 One no. O2 analyzer in flue gas line placed after economizer

13. Electrical

• Drive motors of all auxiliaries covered under the scope

• Variable frequency drive for fuel feeders, stoker drives and ID Fan.

• Electric actuators for valves as applicable.

14. General

• Initial fill of lubricants and grease.

• Chemicals for alkali boil out.

Page 18 of 24

• Suitable operating mechanism complete in all respect with access for operation of all manual and power cylinder operated dampers.

• Two coats of red oxide primer painting at shop prior to dispatch.

• Commissioning spares as required.

• Special tools and tackles, as per enclosed list.

• Two years Operational and Maintenance spares, as per enclosed list. (Quoted separately).

15. Scope of Services.

• Supervision of Erection / Testing & commissioning of mechanical, Electrical, C&I

equipments as included and scope of supply.

• Performance test of boiler.

• Training of purchaser’s operating personal (schedule to be mutually discussed).

Page 19 of 24

SECTION - 4 TECHNICAL DATA SHEETS

Furnace

Width : 4400 mm Depth : 4312 mm Height : 13500 mm Type : Membrane wall construction Tube diameter : 63.5 mm Tube thickness : 4.00 mm Material : SA 210 Gr A1

Steam Drum

Material : SA 516 Gr. 70 ID : 1372 mm Thickness : As per ASME

Water drum

Material : SA 516 Gr 70 ID : 914 mm Thickness : As per ASME

Water wall headers

Material : SA 106 Gr. B No of Headers : Six

Superheater (Counter flow type)

OD x T (mm) : 38.1 x 4.0 Material : SA 210 Gr A Inlet header material : SA106 Gr B. Outlet header material : SA106 Gr B.

Boiler Bank

Type : Single pass, in line arrangement. Tube OD x T (mm) : 51 x 4.0 Material : SA 192

Economiser

Type : Inline, horizontal Location : Between boiler bank outlet and Air

heater. Tube OD x T (mm) : 38.1 x 4.0 Tube material : SA 210 Gr A1

Air heater

Type : Tubular, gas through tubes. Tube OD : 63.5 mm Thickness : 2.3 mm Material : BS 6323 ERW & Corten Steel for first 6 rows of tubes at cold end of

airheater block.

Page 20 of 24

Effective Heating Surface Areas (Sq. M.)

Furnace (EPRS) : 225 Boiler Bank : 340 Economiser : 365 Superheater : 140 Air heater : 980

FD Fan

No of fans : 1 x 100% Type : Centrifugal, Backward curved, simply

supported. Design volume m³/s : 16.00 Design head mmwc : 200 Motor rating KW : 55 Speed rpm : 1800 Type of Control : Inlet guide vane, pneumatically

operated

ID Fan


supported. Design volume m³/s : 27.00 Design head mmwc : 200 Motor rating KW : 132 Speed rpm : 1200 Type of Control : VFD / Pneumatically operated inlet

damper

SA Fan


supported. Design volume m³/s : 8.6 Design head mmWC : 690 Motor rating KW : 90 Speed rpm : 1800 Type of Control : Inlet guide vane, pneumatically Operated

Boiler Feed Water Pumps

No. of pumps : 2 x 100% (1W + 1 S) Type of pump : Multi Stage, Centrifugal, Ring section Design Flow m³/hr : 52.20 Design head MWC : 590 Motor rating KW : 132 Speed rpm : 3600 Deaerator cum storage tank Type : Spray cum Tray Deaerator capacity : 44 tph (120% MCR) Deaerator storage tank : 20 minutes storage between NWL & LWL

Page 21 of 24

LP Dosing System

No of dosing pumps : 2 x 100% (1 W + 1 SB) Type of pump : Positive displacement No. of agitator : 1 (motorised) Dosing chemical : Hydrazene / Erythorbate

HP Dosing system

No. of dosing pumps : 2 x 100% (1W +1SB) Type of pump : Positive displacement. No. of agitators : 1 (motorised). Dosing chemical : Trisodium phosphate

ELECTROSTATIC PRECIPITATOR

Design flow m³/sec : 26.50 Inlet dust concentration gm/Nm³ : 25 Outlet dust concentration mg/Nm³ : 150 (with all fields in service)

Flue gas outlet temperature Deg.C : 150

Predicted Performance Data 100% MCR – Rice Husk

Flow

Superheated steam t/hr : 38 Feed water t/hr : 41 Temperatures Saturated steam temp. °C : 252 Superheated steam temp. °C : 370 ± 12 Feed water temp. at eco. Inlet °C : 105 Feed water temp. at eco. Outlet °C : 210 Ambient air temp. °C : 30 Air at air heater outlet temp. °C : 145 Flue gas temp. at combustion chamber °C : 830 Outlet (FEGT) Flue gas temp. at SH inlet °C : 830 Flue gas temp. at SH outlet °C : 690 Flue gas temp. at Boiler Bank inlet °C : 685 Flue gas temp. at Boiler Bank outlet °C : 455 Flue gas temp at Eco inlet °C : 455 Flue gas temp at Eco outlet °C : 240 Flue gas temp. APH inlet °C : 240 Flue gas temp at APH outlet °C : 150 Flue gas temp ID fan inlet °C : 150

Gas velocities m/s Superheater : 6-7 Boiler bank : 7-8 Economiser : 7-8 Air preheater : 12

Page 22 of 24

Fuel Storage bunker feeding system Type of feeder : Screw feeder Number of feeders : 3 Type of control : VFD Motor rating KW : 2.2 Bunker storage capacity m3 : 100 Material of fuel bunker : IS 2062 (Carbon steel) Insulation Type : Lightly resin bonded mineral wool Cladding : Plain aluminum sheets (24 SWG thick) Density of insulation : 100-120 kg/m³ Ducting Air duct thickness : 4 mm Material : IS 2062 (Carbon Steel) Flue gas duct thickness : 5 mm Material : IS 2062 (Carbon Steel) Technical data sheets are tentative only and may undergo changes during detailed engineering without affecting performance of the boiler.

Page 23 of 24

SECTION – 5 PERFORMANCE GUARANTEES

Performance guarantee for Rice Husk at 100% BMCR We shall guarantee that under test conditions and provided the Boiler is operated and maintained in accordance with our operating and maintenance instructions, the Boiler plant when working with its associated equipment shall be suitable for giving the following performance: BOILER

PERFORMANCE GUARANTEE PARAMETERS

MCR evaporation (Gross) : 40 TPH

Superheated Steam Temperature at main steam stop valve outlet

: 370 ± 12 0C

Superheated Steam Pressure at main

steam stop valve outlet : 38 bar (g)

Boiler efficiency at 100% BMCR : 86% (on LHV basis)

The above guarantee is based on feed water temperature of 1050C at economizer inlet, 300C ambient temperature, 60% relative humidity, feed and boiler water quality and fuel analysis as specified in “Design parameters” of our technical offer. Performance test shall be carried out to per ASME PTC 4.1 – 1964 (R 1991) by Indirect heat losses method.

Particulate emission at the outlet of

Electrostatic Precipitator(with all fields in service)

: 150 mg / Nm3

Page 24 of 24

SECTION – 6

LIST OF MAINTENANCE TOOLS AND TACKLES Sl.No. Component Description Quantity Application

01. Tube Expander Set (Mandrel & Ratchet) 1 Set Main bank and air

heater

02. Torque Wrench 1 Set Level Guage

03. D-Meter for measuring thickness 1 No. Tubes, Headers, Pipes

04. Portable Noise level meter 1 Nos. Rotary Equipment

05. Set of Spanners 1 Set As required

06. Coupling puller 3 Set FD / ID / SA Fans

07. Lapping tools 1 Set Valves, Safety

Valves

Annex B

Turbine Generator

Technical Specification & Scope Of Supply

Page 1 of 26

Technical Specification & Scope Of Supply:

6.5MW Full Condensing Turbine Generator

I N D E X

Chapter – 1 : Scope of Supply

Chapter – 2 : Technical Specifications

Chapter – 3 : Performance and Guarantee Data

Chapter – 4 : Utilities

Chapter – 5 : QAP

Chapter – 6 : List of Tools and Tackles

Page 2 of 26

CHAPTER – 1

SCOPE OF SUPPLY

PART-A - MECHANICAL Steam Turbine

Multistage, Nozzle governed, Horizontal spindle, two bearings, Impulse fully condensing steam Turbine with:

- Hydraulically operated Stop & Emergency Valve with integral steam strainer for inlet

- Hydraulically operated Throttle/Governing valves for inlet steam flow control steam flow control.

Lubrication System

Forced feed lubrication system, combined for Turbine, Gearbox and Generator comprising of:

- Lube oil tank cum base plate provided with cleaning doors, air breather and AC motor driven vapour extractor. The provision for connecting oil centrifuge is provided.

- Shaft driven Main oil pump (MOP)

- AC motor driven Auxiliary oil pump (AOP) with auto cut-in & cut-out facility

- DC motor driven Emergency lube oil pump (EOP) with auto cut-in & cut-out facility

- Suction strainers for MOP, AOP & EOP

- Pressure relief valves for discharge of MOP & AOP lube oil line

- Oil coolers (1 working + 1 standby) with on-line change-over arrangement

- Oil filters (1 working + 1 standby) with on-line change-over arrangement

- Pressure regulating valve to achieve desired lube oil pressure

- Interconnecting lube oil piping Governing System

- Electronic governor (Woodward 505) complete with electro-hydraulic actuator, magnetic speed pick-ups.

- Hydraulic accumulator of bladder type in the turbine control oil circuit to take care of any surges in control oil line and suitably pre-charged with gas.

- Control oil filter 10/15 micron size. - Control oil pressure-regulating valve to achieve desired control oil pressure in the control oil

system. - Interconnecting control oil piping. Safety devices

- Over speed trip and alarm

- Low lube oil pressure trip and alarm

- Low control oil pressure trip and alarm

- High thrust wear trip and alarm

- High exhaust/condenser pressure trip and alarm

- Manual trip (Hand trip)

Page 3 of 26

- Remote emergency trip (Solenoid trip)

- DP across lube oil filters high alarm

- High Vibration trip thru Vibration Monitoring system for high speed train (Turbine front bearing, turbine rear bearing, turbine rotor axial shift, gear box high speed pinion shaft front bearing, gear box high speed pinion shaft rear bearing)

Gearbox

- Double helical, single reduction Gearbox with hardened & ground gears

Couplings

- Non-lubricated, steel laminated, flexible type, high speed coupling and low speed couplings with coupling guards.

Accessories

- Motorised barring gear arrangement

- Gland sealing system complete with : Gland Vent condenser with motor driven air blower Valves and piping within specified battery limits for header line

- Common base plate for turbine and gearbox

- Insulation for Turbine hot parts (lagging & cladding)

- Set of tools & tackles for maintenance

- Set of foundation bolts

Condensing System

Condensing system comprising of :

- Shell & Tube type, horizontal, divided water box type condenser with integral hotwell

- Rupture disc for condenser protection

- Expansion bellow with spool piece between turbine exhaust and condenser inlet

- Stand pipe & flash pipe

- Sacrificial Anodes in water boxes - Condensate extraction pump (CEP) with motors (1 working + 1 standby)

- Condensate piping from hot well through CEPs & ejector condensers and upto specified battery limits (i.e. upto outlet flange of by-pass line level control valve) complete with pipe supports, strainers, steam traps, drains, vents and isolation provisions.

- Dry air/vapor line within specified battery limit.

- Steam jet air ejector system complete with : Twin stage main (running) ejectors (1 working + 1 standby) Start up ejector with silencer Inter and after condensers Isolation valves on motive steam inlet and on individual ejector elements. Vent and drain valve Strainers Pressure and temperature gauges

Page 4 of 26

PART-B - ELECTRICAL AC Generator

AC Generator shall be complete with following accessories :

- Brushless exciter with PMG - Air coolers - AVR cum Excitation panel - Anti-condensation heaters - Twin bearings

Auxiliaries for Generator protection and control

- Generator control (Relay, Metering & Synchronizing) Panel

- Lightning arrestor, Surge capacitor and Potential transformer (LA, SC & PT) panel

- Neutral grounding resistor (NGR) Panel

- Battery and Battery Charger cum DC distribution panel. PART-C - CONTROL & INSTRUMENTATION Turbine Local gauge panel

Turbine local Gauge Panel shall house the pressure and temperature gauges for various operating parameters. Impulse piping with fittings shall be supplied loose for interconnection between field tap-off points and gauge panel. Various Transmitters (4-20 mA signals to PLC) and pressure switches (Digital Inputs to PLC) are mounted in this panel and signals are terminated at junction boxes on the panel for connectivity to PLC.

Condensing system

Condenser hot well level control system complete with : Control valves I-to-P converter Air filter regulators

- Dial type Pressure gauges for :

Motive steam to ejector Condensate to ejector Condensate from ejector First stage ejector condenser Condensate pump discharge

- Dial type temperature gauges for : Condensate after hotwell Condensate after inter/after condensers of ejectors Motive steam to ejector Cooling water inlet & outlet

Page 5 of 26

Condensate suction Condensate to ejector

- Pneumatic and impulse piping with fittings for interconnection within battery limits. Turbine Control cum PLC Panel (Non-redundant PLC)

Turbine control panel shall house the following :

- Electronic governor

- Vibration Monitor

- SCADA / PLC based turbine safety interlocks and trip logic

- Remote controls comprising of selector switches, ammeters, push buttons & indicating lamps for : AOP motor EOP motor Air blower motor CEP motors 1 & 2 Barring gear motor Vapour extractor motor

- Push buttons for turbine speed raise and lower

- Turbine remote trip/reset push buttons

- SCADA / PLC based temperature Monitoring for turbine and gearbox bearing temperature

- SCADA / PLC based alarm annunciations for Turbine fault monitoring The panel shall be complete with AC supply & DC supply on /off control switches, indicating lamps and space heater. Stand alone PC with SCADA will provided near the control panel.

Turbine Aux. MCC cum DC (EOP) starter panel

This Panel shall house: - DOL starters for:

• AOP motor

• Barring gear motor

• Air blower motor

• Vapour extractor motor

• CEP motors 1 & 2

- Feeder & control circuit for EOP motor.

Page 6 of 26

Local push button station

Local control stations with on/off push buttons for :

AOP motor EOP motor Air Blower motor Barring Gear motor Vapour extractor motor CEP motors 1 & 2

Generator

- Dial type pressure gauge for lube oil - 1 per bearing

- Dial type temperature gauges for : Bearing oil – 1 per bearing Hot air & cold air – 1 each per cooler

- Temperature sensors for : Winding temperature (embedded RTDs) – 2 per phase Bearing oil temperature (duplex RTD) – 1 per bearing Hot air & cold air – 1 each per cooler

- SCADA / PLC based Temperature monitoring of Generator winding and bearing oil temperature

Page 7 of 26

CHAPTER – 2

TECHNICAL SPECIFICATIONS PART – A MECHANICAL STEAM TURBINE

Design :

Type : Multistage, impulse, nozzle governed fully condensing type

Casing split : Horizontal Rotor type : Solidly forged & machined rotor with integral disks.

Shaft seal : Labyrinth No. of governing valves : Three (Inlet) Rated speed : 7545 RPM

Rated power : 6500 kW

Oil system :

- Oil :

Governing oil pressure : 5.5 Kg/Cm2g Lube oil pressure : 1.5 Kg/Cm2g Oil type : Servo prime ISO VG-46 / 57 / 68 Oil quantity for initial fill and flushing : 5000 Liters Oil reservoir capacity : 3000 Liters

Retention time : 5 minutes Material of oil reservoir : Carbon steel Material of oil piping from

Pumps to filters : Carbon steel Material of oil piping from

Filters to bearings : SS Material of oil piping from

Bearings to reservoir : Carbon steel - Main oil pump :

Type : Gear (positive displacement) Operating speed : 1800 rpm Capacity : 540 Liters/minute Driver : Gearbox low speed shaft Material of body : CI Material of end cover : CI Material of drive gear : EN 36 / EN 40

Page 8 of 26

- Auxiliary oil pump :

Type : Gear (positive displacement) Operating speed : 1800 rpm Capacity : 540 Liters/minute

Driver : AC motor (15 KW, 440 V, 3 Phase) Material of body : CI Material of end cover : CI Material of drive gear : EN 36 / EN 40

- Emergency oil pump : Type : Gear (positive displacement) Operating speed : 1440 rpm Capacity : 50 Liters/minute Driver : DC motor (1.5KW , 110 V) Material of body : CI Material of end cover : CI Material of drive gear : EN 36 / EN 40

- Oil cooler :

Design code : HEI / TEMA Type : Shell and tube / Plate type Oil inlet temperature : 60 0C Oil outlet temperature : 46 0C Tube material : Admiralty Brass / SS Plates Tube sheet material : Carbons steel Capacity : 540 Liters/minute Mounting : Saddle support

- Lube oil filter : Element type : Micro-felt Capacity : 540 Liters/minute Oil filtration Capacity : 10 – 15 microns Mounting : Foot - Oil Vapour Extractor : Type : Centrifugal Capacity : 400 m3/Hr Driver : AC Motor (0.375 KW, 440 V, 3 Phase) Mounting : Flange

Bearings :

- Journal Bearings Type : Tilting pad

Material : White metal with steel Babbitt

Page 9 of 26

- Thrust Bearings

Type : Tilting pad Material : White metal with steel Babbitt

Governing System :

- Governor:

Type : Electronic (Woodward 505) Inputs (critical) : 2 speeds from MPU-1 & 2 Control range : 0 to 110% of rated speed Control accuracy : +/- 2 RPM (steady state speed)

Speed droop : 3 to 6% (programmable) Power supply : 110 V DC Accessories : 2 Magnetic speed pick-ups (MPU)

1 electro-hydraulic actuator - Hydraulic Accumulator :

Type : Bladder Working fluid : Pre-charged Nitrogen Capacity : 20 Litres

- Governing oil filter : Element type : Micro-felt Oil flow Capacity : 35 Liters/minute Oil filtration Capacity : 10 – 15 microns

Safety devices :

- Over speed trip:

Type : Eccentric spring loaded oil dump valve

- Low lube oil pressure trip: Type : Spring loaded spool valve combined with LP trip

- Low control oil pressure trip:

Type : Spring loaded spool valve combined with LP trip

- High thrust wear trip: Type : Through vibration monitoring system/ Electronic thrust

position transmitter with alarm and switch

- High exhaust pressure trip: Type : Through pressure switch and solenoid trip

- Hand trip: Type : Block & dump valve in trip oil line

Page 10 of 26

Operation : Local hand lever

- Solenoid trip: Type : Solenoid operated block & dump valve Operation : De-energise to open & trip

GEARBOX

Design :

Type : Double helical , Single reduction Input |Output speed : 7545 / 1800 RPM S.F. : 1.5 AGMA

Accessory : Air breather Bearings :

- Journal Bearings

Type : Sleeve (offset halves) Material : White metal with steel Babbitt

- ThrustBearings

Type : Sleeve Material : White metal with steel Babbitt

COUPLINGS

- High Speed Coupling

Type : Flexible element

- Low Speed Coupling

Type : Flexible element with shear pins

ACCESSORIES - Barring gear :

Type : Auto engage & auto disengage

Driver : AC motor (11 kW, 440 V, 3 Phase)

- Gland vent condenser Design code : HEI / TEMA C Type : Shell and tube

Tube material : SA 249 TP 304 (¾” OD) Shell & end cover material : Carbon Steel Tube sheet material : Carbon Steel Accessory : Motor driven centrifugal air blower Driver for air blower : AC motor (0.375 kW, 440 V, 3 Phase)

Page 11 of 26

GENERAL : Material of construction for major turbine components - Steam casings & chest : BS 3100 Gr.B2 / BS 3100 Gr.A2 - Rotor shaft : 21CrMoV57 - Blades : FV-520B/ X22CrMoV121/X20Cr13/FV-624

/ FV-448E - Nozzle rings : AISI 410/AISI 304 - Shrouds : AISI 410 - Laby gland seals : BS 970 416 S21 - Diaphragms : IS 2002 / IS 2062 (Mild steel) - Steam strainer : SS

Material of construction for major gearbox components

- Casings : MS Fabricated / CI (BS-1452 Gr.20) - Pinion and integral shaft : 17CrNiMo6 Case carburised - Gear wheel : 17CrNiMo6 Case carburised - Gear wheel shaft : BS 970-080M40 Turbine connections :

For Number Size Rating Orientation

Inlet steam One 8” NB ANSI 900 # RF Side Exhaust steam One ← Special → Bottom

CONDENSING SYSTEM STEAM SURFACE CONDENSER

Design code : HEI (Thermal) TEMA (Tube sheet, cover plate & flange) Type : Shell and tube Capacity : To suit exhaust flow Construction : Divided water box Cleanliness factor : 0.85 Hotwell retention time : 3 minutes Tube fixing : Expanded joints Tube material : SA 249 TP 304 (¾” OD) Tube sheet material : Carbon Steel Water box & Shell material : Carbon Steel

STEAM JET AIR EJECTORS

Design code : HEI Suction medium : Air / Vapour

Page 12 of 26

System elements : Twin stage, 2 x 100% main ejectors Single stage, 1 x 100% start-up ejector 1 x 100% inter /after condensers Accessory : Integral steam strainers Time to reach 66% vacuum with start-up ejector : 20 minutes Material of nozzle : SA 479 TP 304 Material of shell & diffuser : SA 516 Gr. 70 / SA 105 Material of tubes : SA 249 TP 304 Material of tube sheet : Carbon Steel

Material of silencer : Carbon Steel CONDENSATE EXTRACTION PUMPS

Type : Centrifugal Mounting : Horizontal Suction pressure : Same as condenser pressure Discharge pressure : 80 MWC Operating speed : 2900 RPM Driver : AC motor (440 V, 3 Phase) Type of bearings : Anti-friction Type of seal : Mechanical Type of coupling : Flexible Type of lubrication : Oil Material of casing : CI Material of impeller : CF8M Material of shaft : C45 Material of shaft sleeve : AISI 316

RUPTURE DISC

Type : Diaphragm End connection : Flanged Material of diaphragm : SS Material of flanges : CS

EXPANSION BELLOW

Type : Round / Rectangular Design code : Universal type rectangular expansion joints Material of bellows element : SS-304 Material of liner : SS-304

Material of flanges : IS-2062 (Carbon steel)

Page 13 of 26

PART – B ELECTRICAL

AC GENERATOR

Design : Rated output : 6500 kW / 8125 kVA Rated voltage : 13.8 kV +/- 5% Rated frequency : 60 Hz + / - 3% Combined variation of voltage & frequency : + / - 5 % Rated p.f. : 0.80 (lag) No. of phases : 3 phase, 3 wire system No. of terminals : 3 for phase & 3 for neutral

Connection : Star Rated speed / No. of pole : 1800 rpm / 4 pole Ambient temperature : 40 Deg.C Excitation : Brushless with PMG Rotor : Cylindrical Cooling method : CACW Mounting : Horizontal Insulation : Class F (both rotor and stator) Temperature rise : Class B limits (both rotor and stator) Enclosure : IP-54 (Stator) & IP-23 (Exciter) Duty : Continuous and suitable for parallel operation Rotation : To suit driver output Terminal box : To suit HT cable connection

Bearings : Type : Sleeve Accessory : Temperature gauge

Lube oil system : Type : Forced feed

Source : Turbine lube oil system Air coolers :

Cooling method : CACW

Capacity : 2x 60%(or as per manufacturer’s standard) Cooler tube material : Admiralty brass

Mounting : Top

Anti condensation heaters: Type : Resistance heating Power supply : 230 V, Single phase

Page 14 of 26

Water leakage detector:

Location : Bottom of cooler Quantity : 1 No. per cooler

AVR CUM EXCITATION PANEL

Design:

Control type : Thyristor based Digital Control modes : 1 auto + 1 manual Voltage adj. Range : +/- 10% Regulation : +/- 0.5% Dead time : Less than 30 mS

Features :

- Compounding - Diode failure detector - Auto PF controller - Remote voltage control - Auto-Manual follow-up - Under frequency protection - Field flashing provision

AVR cum excitation panel shall be complete with generator voltmeter, field voltmeter, field

ammeter, PF meter, null meter, Auto/Manual selector switch, AC supply & DC supply on /off control switches, indicating lamps and space heater with thermostat.

GENERATOR CONTROL PANEL (RELAY, METERING & SYNCHRONISING) Generator control panel for generator protection shall house the following Numeric relay (with MODBUS RS-485 and/or Digital outputs for connectivity to PLC):

DESCRIPTION TAG NO. Voltage controlled over current protection relay 51 V

Stator earth fault protection relay 51 N

Differential protection relay 87

Over voltage protection relay 59

Timer for over voltage protection relay 2-59

Under voltage protection relay 27

Reverse active power protection relay 32 P

Under frequency protection relay 81 0

Over frequency protection relay 81 U

PT fuse failure sensing relays 60 A 60 B 60 C

Page 15 of 26

Loss of excitation (Field failure) protection relay 40 G

Auxiliary relays & timers for loss of excitation protection relay

40 X 27/40 G T1/40 G T2/40 G

Trip circuit supervision relay 95

Negative phase sequence protection relay 46

DC supply supervision relay 80

Generator master trip relay 86G

Turbine master trip relay 86T

- Meters System : 3 phase, 4 wire, unbalanced load

Digital Trivector meter : 1 No. (to indicate Current, Voltage, Power factor, Frequency, kVA, kW, kVAR, kWH & kVAH) (with MODBUS RS-485 port for connectivity to client’s PLC) Synchroscope : 1 No. Check synchronizing Relay : 1 No. Aux. relays for Synchronising scheme : 1 Set Auto Synchroniser : 1 No. (Woodward SPMD)

- Temperature monitoring for generator winding and bearing temperatures thru RTD inputs to

PLC.

- Alarm Annunciations for generator fault monitoring Thru Numeric relay (Digital inputs to PLC)

The panel shall be complete with synchronising selector switches, breaker control (T/N/C) switches, push buttons, AC supply & DC supply on /off control switches, indicating lamps and panel space heater with thermostat.

General : Type : Desk & free standing LA, SC & PT PANEL

LA, SC & PT panel shall house the following :

- Lightning arrestor Discharge current : 10 KA Quantity : 3 Nos. (1 per phase)

Page 16 of 26

- Surge capacitor

Capacitance per phase : 0.25 μF Quantity : 3 Nos. (1 per phase)

- Potential transformers

For Quantity Secondary output Class Burden

Protection 3 Nos. 110 V 3 P 100 VA Metering 3 Nos. 110 V 1 100 VA Excitation 1 No. 400 / 220 V 3 4000 VA

General : Type : Simplex, modular & free standing Terminal box : To suit HT cable connection

NEUTRAL GROUNDING RESISTOR PANEL

NGR panel shall house the following: - Resistor

Type : Naturally air cooled Rated current : 100 A Duty rating : 10 seconds Resistor grid type : Punched steel Temperature rise : 3750 C over ambient (max.) Mounting & fixing of Resistor units : Mounted on grid rods; fixed and assembled in tiers separated by porcelain insulators

- Neutral isolator

Operation : Motorised No. of poles : One Limit switches : 2 Nos. (for on / off positions)

- Earth connection

Type : Porcelain insulated 12 mm terminal studs Quantity : Two Nos.

- Current Transformers

For Quantity Secondary output Class Burden

Differential protection

3 Nos. 1 A PS N/A

Earth Fault Protection

1 No. 1 A 5 P 20 10 VA

Page 17 of 26

Neutral Current CT

1 No. 1 A 0.5 10 VA

General : Type : Simplex, dead front & free standing Terminal box : To suit HT cable connection Material of busbars : Copper BATTERY Type : Maintenance free, VRLA Capacity : 100 AH Rating : 110 V, DC Volt per cell : 2 V, DC No. of cells : 55 BATTERY CHARGER CUM DC DISTRIBUTION PANEL

Battery charger cum DC distribution panel shall house the following :

- Battery charger Quantity : One float & one float cum boost charger Input : 440 V, 1 phase, 60 Hz, AC supply Output : 15 A, 110 V DC (Float charger) 20 A, 110 V DC (Float cum boost charger) Voltage regulation : +/- 1% from no-load to full load Operation mode : Auto / Manual Charger panel shall be provided with alarm for following faults :

Float charger failed Float cum boost charger failed DC voltage high DC voltage low AC supply failed Batter earth fault

Charger panel shall house following meters : AC Voltmeter DC Voltmeter with selector for load/charger/battery DC Ammeter for load DC Ammeter for charger DC Ammeter for battery

Page 18 of 26

- DC distribution system

Panel shall be provided with feeders for : DC motor starter panel : 1 No. HT Breaker panel : 1 No. Generator control panel : 1 No. AVR cum excitation panel : 1 No. Turbine control panel : 1 No. Spare : 2 Nos.

General :

Type : Simplex, dead front & free standing AC MOTORS

Type : Induction Winding connection : Delta Duty : Continuous Enclosure : IP-55 Cooling : TEFC Insulation : Class “F” Power supply : 440 V, 3 Phase, 60 Hz Speed / No. of poles : To suit driven equipment

DC MOTOR

Type : Shunt field Duty : Continuous Enclosure : IP-55 Cooling : TEFC Insulation : Class “F” Power supply : 110 V Speed : 1440 RPM

Page 19 of 26

PART – C CONTROL & INSTRUMENTATION TURBINE LOCAL GAUGE PANEL

Turbine gauge panel shall house the following : - Pressure gauges for :

Inlet steam HP Wheel case

Exhaust steam Lube oil Control oil

- Temperature gauges for : Inlet steam Exhaust steam

- Pressure switches for : Turbine inlet steam pressure high alarm Turbine inlet steam pressure very high trip Lube oil pressure low alarm Lube oil pressure very low trip Control oil pressure low alarm Control oil pressure very low trip AOP auto cut-in & cut-out EOP auto cut-in & cut-out Condensate header pressure control & CEP auto-start interlock Condenser pressure high alarm (1 No.) Condenser pressure high trip (2 Nos.)

- Temperature switch for :

Turbine inlet steam temperature low alarm Turbine inlet steam temperature very low trip

- Level switch for Condenser hotwell level low alarm and CEP dry run interlock - Level indicator cum controller (for Condenser) - Pressure transmitters for : (for Connectivity to PLC)

- Turbine Inlet steam - Turbine wheel case

- Turbine Exhaust / condenser steam - Turbine Lube oil - Turbine Control oil

- Differential pressure transmitter for monitoring DP across lube oil filters - Main oil pump (MOP) discharge - Auxiliary oil pump (AOP) discharge

- Emergency oil pump (EOP) discharge

Page 20 of 26

- Motive steam to ejector - Condensate to ejector - Condensate from ejector - Condensate pump 1 (CEP1) discharge

- Condensate pump 1 (CEP2) discharge

- Temperature transmitters for : (for Connectivity to PLC) :

- Turbine Inlet steam - Turbine exhaust steam - Condensate after hotwell - Motive steam to ejector

- Level transmitter (for Condenser)

- RTDs for (for connectivity to PLC) : Turbine bearing oil Gearbox bearing oil Turbine oil cooler inlet Turbine oil cooler outlet Turbine oil cooler outlet

- Vibration Monitoring System for high-speed train (Turbine front bearing, turbine rear

bearing, turbine rotor axial shift, gear box high speed pinion shaft front bearing, gear box high speed pinion shaft rear bearing)

Note: The Transmitters (4-20 mA signals to PLC) and pressure switches (Digital input to PLC) are

mounted in this panel and signals are terminated at junction boxes on the panel for connectivity to PLC.

GENERAL : Type : Simplex, dead front & free standing TURBINE CONTROL CUM PLC PANEL

Turbine control panel shall house the following :

- Electronic governor (4-20 mA signals to PLC)

- Vibration Monitor (4-20 mA signals to PLC)

- SCADA / PLC based turbine safety interlocks and trip logic

- Remote controls comprising of selector switches, ammeters, push buttons & indicating lamps for :

AOP motor EOP motor CEP-1 & 2 motors Barring gear motor Air blower motor Vapour extractor motor

Page 21 of 26

- Push buttons for turbine speed raise and lower

- Turbine remote trip/reset push buttons

- SCADA / PLC based temperature Monitoring for turbine and gearbox bearing temperature

- SCADA / PLC based alarm annunciations for Turbine fault monitoring The panel shall be complete with AC supply & Dc supply on /off control switches, indicating lamps and space heater. Stand alone PC with SCADA will provided near the control panel.

Turbine Aux. MCC cum DC (EOP) starter panel

This panel shall house the following :

- Incoming feeder complete with MCCB unit, voltmeter, CT operated ammeter, indicating

lamps & bus bars

- DOL starter complete with switch-fuse unit, contactor, overload relay, CT operated ammeter, indicating lamps & pushbuttons for : AOP motor CEP-1 & 2 motors Barring gear motor Air blower motor Vapour extractor motor

- Incoming feeder complete with switch-fuse unit, voltmeter, ammeter and indicating lamps for

DC motor - 2 step resistance starter for EOP motor complete with switch-fuse unit, contactor, overload

relay, ammeter, indicating lamps & pushbuttons. GENERAL SPECIFICATIONS OF INSTRUMENTS

Pressure and temperature gauges

Dial : 150 mm circular Scale : 270 Deg. arc with black pointer Type : Bourdon (pressure gauge) Mercury in steel (temperature gauge)

Accuracy : +/- 1 % Over range protection : 125 % Accessories : Shatter proof safety glass

Pressure switch

Sensor type : Bellows Material of case : Die cast aluminium Material of bellows : SS-316

Page 22 of 26

Resistance temperature detectors :

Element type : PT-100, 3 wire Solenoid valve

Power supply : 110 V DC Operation : De-energise to open Type : 2 way, universal ports

Current to pneumatic converter

Supply : Air at 1.5 Kg/cm2.G Input : 4 – 20 mA Output : 0.2 to 1.0 Kg/cm2.G (air) Enclosure : Die-cast aluminum alloy body Accessory : Pressure gauges for supply & output

Air filter regulator

Filter element : 5 microns Element material : Sintered bronze Body material : Cast aluminium

Vibration monitoring system :

Type of detectors : Magnetic probes Type of display : Bargraph display (LCD) through panel mounted dual channel monitors

Accessories : Power supply module System Monitor

Proximitors and extension cables

Page 23 of 26

CHAPTER – 3

PERFORMANCE AND GUARANTEE DATA

Performance (Fully condensing) Parameter Turbine Inlet Steam Pressure (bara) 37 Turbine Inlet Steam Temperature (oC) 360 Turbine Inlet Steam Flow (kg/hr) 33,500 Turbine Exhaust Steam pressure (bara) 0.11 Turbine Exhaust Steam Temperature (oC) 47.7 Turbine Exhaust steam flow Approx (kg/hr) 33,500 Electrical Output at Generator terminals @ 13.8 kV, 60 Hz

6500

Page 24 of 26

CHAPTER – 4

UTILITIES

A. STEAM

CONSUMER / PURPOSE INTERMITTENT DEMAND

CONTINUOUS DEMAND

Turbine gland sealing system at 11 bara

250 Kg/Hr (during start-up)

N/A

Ejector system At 11 bara

350 kg/hr (during start-up)

300 Kg/hr

B. COOLING WATER Inlet pressure : 1.5 barg Inlet temperature : 33 Deg. C Temperature rise (ΔT) : 8 Deg. C

CONSUMER / PURPOSE CONTINUOUS DEMAND

Turbine oil cooler 60 M3/HrGland Vent Condenser 30 M3/HrGenerator air cooler 70 M3/Hr Surface Condenser 2305 M3/Hr

C. INSTRUMENTATION AIR For control purpose : 5 SCFM at 7.0 Kg/cm2g D. AC POWER Power supply : 440 V, 50 Hz, TP & N

CONSUMER INTERMITTENT DEMAND

CONTINUOUS DEMAND

AOP Motor 15 kW (during start-up & shut-down)

N/A

Vapour Extr. Motor N/A 0.375 KW Air blower motor N/A 0.375 kW Barring Gear Motor 11 kW (during shut-down) N/A CEP Motor N/A 15 kW

Note: All utility figures mentioned above are indicative only. The actual requirement shall

be furnished during detailed engineering.

Page 25 of 26

CHAPTER – 5

Q A PLAN

EQUIPMENT DESCRIPTION TESTS

Complete assembled turbine 1. Visual & dimensional checks

2. No-load run test & functional check on safety devices 3. Vibration check 4. Noise level check 5. Open inspection & dynamic rotor balancing (after no-

load run test) GVC with air blower 1. Visual & dimensional checks

2. Operational & functional tests Complete assembled generator 1. Visual & dimensional checks

2. OCC & SCC test 3. Over speed test 4. Vibration check 5. Noise level check 6. HV test 7. Measurement of winding resistance and insulation

resistance 8. Measurement of shaft voltage

NGR panel /AVR panel / Generator panel / Aux. MCC

1. Visual & dimensional checks 2. Operational & functional tests 3. HV test 4. Measurement of insulation resistances

Turbine Gauge Panel 1. Visual & dimensional checks 2. Range calibration

Instruments 1. Visual & dimensional checks 2. Operational & functional tests 3. Range calibration

NOTE : 1. Material test certificates from manufacturers shall be submitted for major

components of turbine and other bought-out items along with supply. 2. We have not envisaged any “customer hold point” in QAP and delivery & price

quoted are on the same basis.

Page 26 of 26

CHAPTER – 6

LIST OF TOOLS AND TACKLES

EQUIPMENT DESCRIPTION QUANTITY

TURBINE Overspeed trip cap removal bolt 1 No. Fixture for putting oil seals with cover 1 No. Allen keys 1/16” to ¾” 1 Set Circlip plier (internal & external) 6” 1 No. each Double end spanner ¼” x 5/16” 1 No. Double end spanner 3/8” x 7/16” 1 No. Double end spanner ½” x 9/16” 1 No. Double end spanner 5/8” x ¾ “ 1 No. Double end spanner 7/8” x 1” 1 No. Double end spanner 24/27 mm & 30/32 mm 1 No. each Double end spanner 1” x 1-1/8” 1 No. Single end spanner 1-¼ ” 1 No. Ring spanner 1” x 1-1/8” 1 No. Ring spanner 1 ½” x 1 ¾” 1 No. Ring spanner 24/27 mm & 30/32 mm 1 No. each Open end spanner 1-½ ” & 1-¾” 1 No. each Screw driver 6” & 12” 1 No. each Adjustable spanner 6” 1 No.

Date post:	10-Mar-2015
Category:	Documents
Upload:	michael-parohinog-gregas
View:	595 times
Download:	2 times

EPC Quotation-15th May 2011

Documents