Shasta bio-fuels pvt ltd. - Environmental Clearance

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PRE-FEASIBILITY REPORT

For

SUBMISSION TO

MINISTRY OF ENVRONMENT FORESTS & CLIMATE CHANGE, NEW DELHI

Prepradd for

ROQUETTE RIDDHI SIDDHI PVT.LTD,

(Expansion of Cogeneration power plant from 6 MW to 18 MW)

AT

GOKAK (VILLAGE & TALUK),

BELAGAVI DISTRICT, KARNATAKA.

PREPARED BY

6-3-652 | Flat # 7-3 | Dhruvatara Apartments | Amrutha Estates | Erramanjil | Somajiguda | Hyderabad- 82 |

E mail: [email protected], pelcpl@ gmail.com |www.pioneerenvirolabs.com

|

PEOPLE WHO CARE FO

Accredited by ISO 9001: 2008 Certified

mailto:[email protected]

http://www.pioneerenvirolabs.com/

Roquette Riddhi Siddhi Pvt. Ltd., Prefeasibility report (Expansion of Cogeneration power plant from 6 MW to 18 MW)

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INDEX

S.No. ITEM PAGE NUMBER

1 EXECUTIVE SUMMARY 2

2 INTRODUCTION OF THE PROJECT /

BACKGROUND INFORMATION

3

3 PROJECT DESCRIPTION 8

4 SITE ANALYSIS 30

5 PLANNNING BRIEF 31

6 PROPOSED INFRASTRUCTURE 32

7 REHABILITATION & RESETTLEMENT (R & R)

PLAN

34

8 PROJECT SCHEDULE & COST ESTIMATES 35

9 ANALYSIS OF PROPOSAL (FINAL

RECOMMENDATIONS)

36


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1.0 EXECUTIVE SUMMARY

Project Expansion of cogeneration Power Plant from 6 MW to 18 MW

Project name Roquette Riddhi Siddhi Pvt. Ltd.,

Survey nos. of the site 250, 259, 260, 262, 263, 471 and 473

Location of the project Gokak (Village & Taluk), Belgavi District, Karnataka

Longitude & Latitude 160 10’05.49”N & 740 48’ 03.70”E

Technology Coal fired cogeneration Power Plant comprising of 100 TPH Boiler

& 12 MW back pressure Steam Turbine

Fuel Imported / Indian Coal

Source of water Ghataprabha River

Water requirement for expansion

project 720 KLD

Land envisaged The proposed power plant will be established in the existing

plant premises of 97 acres only.

Total Project Cost of 12 MW power

plant Rs. 6200.0 Lakhs

Project Implementation 18 months from the date of receipt of Environmental Clearance,

CTE from KSPCB & from the date of Financial closure.


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2.0 INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION

2.1 Identification of project and project proponent

Power is the important infrastructure facility and is critical for the development of the economy. For a

developing country like India, energy in the form of electricity is necessary and having its own

importance. As economy grows the demand of power increases at a faster pace. As on today the

demand of power is more than that of power generation. Further to say that it has been estimated by

the World Bank that the demand of power will increase nearly twice that at which the economy grows.

Power generation and its utilization in the form of electrical energy also reflects the living standard and

prosperity of the nation.

If we look into the history of the power generation which was in the hands of few private industries

before independence. After independence an act was framed in the year 1948 as Electricity Act 1948. As

per this Act, one of the major points is the power generation, transmission and distribution was

entrusted to the individual states and separate group has been formed in every state as State Electricity

Board apart from the private participation at that moment.

Later on in the mid seventies the government wanted to speed up the process of capacity addition as

the demand was immensely high. Thus the generation, transmission and distribution was entrusted to

NTPC, NHPC, PGCIL apart from the existing system of State Electricity Board and others.

A few years later in the year 1990, the act was amended for private participation in the power sector as

Independent Power Producers (IPP) in the area of generation, for further boost up to the capacity

addition process.

These all attempts of Government helped a lot in adding the capacity and improving the national

average of plant load factor and strengthening the distribution network and in many other areas. But,

still there is a gap observed between generation and its demand. For bridging this gap government’s

efforts are continuous and in this process in the year 2003 lot of reforms took place. This time

government wants to encourage more private participation in the energy sector so as to reduce the

demand vs. generation gap. This is the back drop for getting good response from private sector to set up

plant of various capacity adopting new technologies. With this kind of present power sector scenario for

accelerating the capacity addition process it is necessary that the entire sector like state/public/private

sector should participate actively.

Roquette Riddhi Siddhi Private Limited is India’s largest manufacturer of starch and starch derivatives.

The company has plants in Viramgam (Gujarat), Gokak (Karnataka), and Pantnagar (Uttaranchal). Its

products include corn starch powder, liquid and powdered glucose, modified starches, glucose D,

dextrose monohydrate, maltodextrine, high-maltose corn syrup, and dextrose syrup. These products


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cater to a number of industries such as food processing, pharmaceuticals, paper, textiles, adhesives,

inks, and paints.

Roquette Riddhi Siddhi Private Limited is a wholly owned subsidiary of Roquette Freres. Roquette Freres

(RF) is French Company. RF is the fifth-largest corn-processor and largest producer of polyols (sugar-free

sweeteners) globally. It is also a leading global producer of starch derivatives.

M/s Roquette Riddhi Siddhi Private Limited is registered under the Companies Act 1956 on 2013. The

promoters of Roquette Riddhi Siddhi Private Limited are working for manufacturing of starch based

products and also having a good background in project implementation. Now company proposed

expansion of starch plant and power will be required for the starch plant. 6 MW power plant is in

operation since year 2001. Now the company proposed to expand the power generation capacity from 6

MW to 18 MW (Installation of a 12 MW) in the existing plant premises only.

2.2 Need for the project and its importance to the country or region

Indian Power Sector – A Brief Snapshot

If you consider the Indian power sector, a very bleak picture emerges. If there have been any

achievements, they are definitely been very few and far between – and none of them worthy of any

mention. There are schemes galore – but they have largely remained on papers, and no effect has been

felt on the ground. Let us consider a few chief highlights of the Indian power sector, as it currently is -

Current installed power generation capacity – 150,000 MW (approximately).

Domination of public sector enterprises – National Thermal Power Corporation(NTPC), National

Hydroelectric Power Corporation (NHPC), Nuclear Power Corporation of India (NPCI) and Power

Grid Corporation of India.

Of this, 75% is constituted by thermal power(coal based and gas based), 21% by hydroelectricity

power, 3.5% by nuclear power and less than 0.5% by wind and solar power.

More than 50% of the power generation in India is coal based.

Gap between peak electricity demand and production – 12%

Though 80% of rural areas have been connected to electricity, less than 45% of rural households

have access to electricity.

Transmission and distribution losses – 35-45%.

A close look at the above figures reveals the bleakness of the Indian power sector. For example, let us

start from the last point – transmission and distribution losses. Rajiv Gandhi had once remarked about 5

paise out of 1 rupee reaching the intended beneficiaries. The situation is somewhat similar in the power

sector, where out of every 100 units produced, 33 are lost during transmission and distribution! Most of

this is due to power theft. The persistent gap in peak demand and supply levels of electricity has meant

frequent power outages, even in the so called metropolitan cities.


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Indian Power Sector – The Challenges

In typical fashion, the government has set up hugely ambitious targets for the past many years, and

failed miserably every time. The main reasons for this massive slippage are –

delays in technology procurements,

delays in awards of works,

delays in clearances and land acquisition,

delays in financial closure,

court cases,

law and order problems, and

lack of trained manpower.

Till 2012, the installed capacity is planned to increase by 78,000 MW – a steep target, especially

considering that the current installed capacity is only 150,000 MW. Another crucial factor is the really

huge finance that will be needed for this expansion – it is estimated that the targeted enhancement will

need an investment of RS 7,50,000 crores (more than USD 150 billion). With fiscal deficit already

approaching 10 % of GDP, it is anybody’s guess where this money will come from.

2.3 Demand – Supply Gap

The demand – supply position in the country with regard to electricity has been as follows during

March 2009 and during the Twelve months of the financial year 2008-09:

Mar 2009 Demand Supply Deficit

Energy 66,880 MU 59,980 MU (-) 10.3%

Peak Demand 108,572 MW 96,685 MW (-) 10.9%

April 08 to Mar. 09

Energy 774,324 MU 689,021 MU (-)11.0%

Peak Demand 109,809 MW 96,685 MW (-)12.0%

(Source: CEA)

It can be seen that the demand for power has been outstripping the supply. Substantial peak and energy

shortages prevail in the country. The shortfall in Energy during the twelve months of the current

financial year is 85303 MU and the shortfall in Peak Demand during the same period has been 13124

MW.

http://indianblogger.com/topics/finance/


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The region-wise power supply requirements by the year 2012 to 2022 as per the 17th Electric Power

Survey report is expected to be as follows:

Table – Seventeenth Electric Power Survey (EPS) Estimates

Region Energy Requirement (MU)

2007 to 2008 2011 to 2012 2016 to 2017 2021 to 2022

North 223928 294841 411513 556768

West 244481 294860 409805 550022

South 189312 253443 380068 511659

East 77221 111802 168942 258216

N-East 9326 13329 21143 36997

Islands 247 384 595 847

Total 744515 968659 1392066 1914509

Region Peak Electric load (MW)

2007 to 2008 2011 to 2012 2016 to 2017 2021 to 2022

North 35145 51987 71243 95308

West 37264 50406 68371 89441

South 29854 41982 62548 82900

East 12670 19852 29395 43992

N-East 1710 2739 4023 6551

Islands 57 88 136 151

Total 116700 167054 235716 318343

2.4 Imports V/s Indigenous generation

Without enough local suppliers, India turned to China to help bridge a peak power shortage of 12% seen

as an obstacle to matching its Asian neighbour's double digit economic growth.


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The zero duty on imports for equipment to build so-called Ultra Mega Power Projects (UMPPs), which

are larger and use more fuel efficient technologies, created a "perverse situation" that helped foreign

firms at the expense of Indian ones. Chinese power companies such as Dongfang Electric and Shanghai

Electric could accounfor 50% of India's capacity addition between 2012-17, said ShubhranshuPatnaik,

executive director, PricewaterhouseCoopers.

The sector's scope for growth is huge. India will soon become the world's largest buyer of power

equipment, Maira said. It will spend around USD 140 billion on power infrastructure in the five years to

2012, close to half from the private sector, according to the latest Planning Commission estimates.

India is world's 6th largest energy consumer, accounting for 3.4% of global energy consumption. Due to

India's economic rise, the demand for energy has grown at an average of 3.6% per annum over the past

30 years. In June 2010, the installed power generation capacity of India stood at 162,366 MW while the

per capita energy consumption stood at 612 kWH. The country's annual energy production increased

from about 190 billion kWH in 1986 to more than 680 billion kWH in 2006.[4] The Indian government has

set a modest target to add approximately 78,000 MW of installed generation capacity by 2012 which it

is likely to miss. The total demand for electricity in India is expected to cross 950,000 MW by 2030.

About 70% of the electricity consumed in India is generated by thermal power plants, 21% by

hydroelectric power plants and 4% by nuclear power plants. More than 50% of India's commercial

energy demand is met through the country's vast coal reserves. The country has also invested heavily in

recent years on renewable sources of energy such as wind energy. As of 2008, India's installed wind

power generation capacity stood at 9,655 MW. Additionally, India has committed massive amount of

funds for the construction of various nuclear reactors which would generate at least 30,000 MW. In July

2009, India unveiled a $19 billion plan to produce 20,000 MW of solar power by 2020.

http://en.wikipedia.org/wiki/Economy_of_India

http://en.wikipedia.org/wiki/Megawatts

http://en.wikipedia.org/wiki/KWH

http://en.wikipedia.org/wiki/Electricity_sector_in_India#cite_note-3

http://en.wikipedia.org/wiki/Thermal_power

http://en.wikipedia.org/wiki/Hydroelectricity

http://en.wikipedia.org/wiki/Nuclear_power_in_India

http://en.wikipedia.org/wiki/Coal

http://en.wikipedia.org/wiki/Wind_energy

http://en.wikipedia.org/wiki/Solar_power


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3.0 PROJECT DESCRIPTION

3.1 Type of the Project:

6 MW power plant( Biomass/coal) is in operation in the existing starch plant premises of Roquette

Riddhi Siddhi Pvt. Ltd. Now it has been proposed to expand the existing power generation from 6 MW to

18 MW.

3.2 Location of the project:

Already 6 MW cogeneration power plant is in operation since 2001 in the existing starch plant premises

at Gokak (Village & Taluk), Belgavi District, Karnataka. Location map, Topographical map showing the

location of the Plant site is furnished in Figure 1 & 2.

3.3 Details of the Alternate sites:

No alternative sites have been examined as the proposed Cogeneration plant will be established in the

existing starch plant premises. The existing plant has a valid Consent To Operate (CTO) from KSPCB.


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Figure: 1

Roquette Riddhi Siddhi Pvt. Ltd.,


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Figure : 2 Figure: 2

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3.4 Size or magnitude of the operation:

Roquette Riddhi Siddhi Pvt. Ltd. is operating 6 MW coal based Cogeneration power plant since year 2001

in the starch plant premises. Now it has been proposed to increase the power generation capacity from

6 MW to 18 MW in the same existing starch plant premises. Part of the power generated will be for

captive requirement and the balance to be exported to the grid.

3.5 Process Details (Power Generation Process):

The Power Generation utility uses most commonly encountered Rankine based thermodynamic cycle.

The facility generates electricity by producing steam in a steam generator and expanding the steam

through a turbine that is coupled to generator. The steam is then passed to process department and

around 50 % of the condensed water called condensate will be collected is again heated in the steam

generator.

The steam generator (Boiler) requires water and coal. The water system will have pretreatment and

demineralization plant. Pretreatment plant initially the water will be processed for removing the

sediments and then processed for de-mineralization. The demineralized water will be used in steam

generator to protect the boiler tube.

The coal handling system receive the coal inside the plant area by Road/Rail transportation system. The

coal handling system then stacks, reclaims, crushes and convey the same to the bunkers near the steam

generator. From coal bunkers the steam generator receives the coal for combustion. After combustion

in the furnace area the flue gas passes through the steam generator used for producing the steam at

required pressure, temperature and quantity. The flue gas after passing though Electro Static

Precipitator (ESP) where the fly ash in the flue gas gets precipitated and the flue gas then passes through

a stack of adequate height as per CPCB norms. The outlet particulate emission from the exhaust flue gas

will be limited to 30 mg/Nm3 as per latest MOEF&CC norms.

Thus the steam generated at high pressure and temperature comes to steam turbine for expansion.

Here the steam turbine converts the thermal energy to rotating mechanical energy. After the work done

in steam turbine it goes to process for drying (Recoverable), cooking by direct Injection (non

Recoverable) application. After Workdone in the Drying application, steam become condensed and will

be taken back to boiler as condensate. Apart from exhaust steam, number of steam extractions

provided in the steam turbine and the extracted steam will be supplied to the low and high pressure

feed water heaters for the liquid regenerative heating which improves the thermal cycle efficiency.

The generator which is coupled to the steam turbine converts the mechanical energy to electrical

energy. The electrical output will be 11 kV 3 phase 50 HZ. This electricity generated will be evacuated

through 33 kV switchyard and related transmission system to take care of entire plant demand and

sometimes will be exported to the grid. The total plant system is well supported by the electrical and


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control & instrumentation systems. Thus, it is helping the operators to direct the plant operation for

reliable and efficient production of electrical energy.

Main Plant Equipment:

a) Steam Generator:

The steam generator will be designed based on the coal composition to achieve a good furnace

management. The rating of the steam generator is:

Steam rate : 100 Tonnes/hr

Pressure : 110 ata

Temperature : 5400 + 50C

The boiler is of two pass, natural circulation type and this also contains economizer, super

heater and other rotating parts as its auxiliary. The units are designed for ease of maintenance

allowing operators to minimize the unit down time.

b) Steam Turbine:

The steam turbine will be of no. of stages depending upon the suitability of the requirement and

will have the parameters as below:

Steam Turbine Power Output : 12 MW

Steam Inlet Temperature : 5400 + 50C

Steam Inlet Pressure : 110 ata

Steam Quantity : 100 Tonnes/hr

The other parameters will be depending upon the type of turbine and will be specified on later

stage.

The turbine output is 11 kV, 3 phase 50 Hz.

The other auxiliaries of the turbine are HP & LP heaters, motor driven boiler feed pump,

extraction steam, deaerator like all other conventional type of steam turbines.

Coal Handling System:

The coal handling system receives the coal and then stacks, reclaims, crushes and conveys the same to

the coal bunker. The coal handling plant receives the coal to a maximum size of 200 mm and after

receiving, this coal goes to coal crusher house. Here, in the coal crusher the coal will be reduced from

200 mm size to 6 mm size before it goes for stacking. The coal from the stock yard will be transported to

crusher house and other places by way of a conveyor system. The conveyor system consists of fire

fighting system in the form of fire detection and fire extinguishers

Ash Handling System:

The fly ash in the flue gas will pass through Electro Static Precipitator. Here the flue gas will be ionized

and the fly ash will then be precipitated. The precipitated ash is collected in ESP hoppers. This ash will be

sent to either concrete/or MS Silos by vacuum and pressurized system. Thus the collected ash in Silo will


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be disposed to the cement or brick manufacturing units for their requirement. The entire fly ash disposal

will be in accordance with MOEF notification on fly ash utilization & its amendments thereof.

Water Treatment Plant:

The water received at site through a pipe line from the water source with the help of electrical motor

driven pumps. The source is identified as River Ghataprabha. The water is treated first for its sediments

in pre-treatment plant. Followed by clarifier, pressure sand filters & activated carbon filters. Thus, the

total treated water will be used as follows:

1. Boiler water after demineralization

2. Fire water

3. Service water

4. Equipment cooling water

5. Auxiliary cooling water

6. Coal sprinkling water

7. Potable water

The total water requirement for Entire Cogen plant will be 720 KLD. Depending upon the design criteria

and the quantity allocation by the state irrigation department reservoir will be constructed inside the

plant area for storage of the water. In any case priority will be given to conservation of water, reuse of

waste water, boiler blow down water, and other water will be put into reuse as far as possible.

The boiler make-up water will be treated in RO followed by DM plant for demineralization. The DM plant

will consist of cation resin beds, de-gasifier towers, anion resin beds and mixed bed exchangers. Acid

and alkali handling and storage system will be installed near the DM plant. The RO Reject and DM plant

regeneration water will be treated in neutralization pit followed by Evaporator. Thus, the DM water

produced in the plant will be stored in tanks for further use.

Ventilation & Air-Conditioning System

For good environment, for operation and maintenance of the plant as well as for proper functioning of

the equipment, controls and accessories, due consideration will be given for Ventilation and Air

Conditioning System.

Ventilation System:

The ventilation system envisaged for the plant will achieve the following:

i. Dust –free comfortable working environment.

ii. Scavenging out structural heat gain and heat load from various equipment, hot pipes, lighting

etc.

iii. Dilution of air.


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The following areas will be provided with suitable ventilation system, except for the Turbine building

which will be provided with evaporative cooling with washed air system all other areas will be with dry

ventilation system.

Turbine building

Air compressor room

AC plant room

DM plant MCC room

CW pump House

Miscellaneous room in power house building like cable spreader room, electrical switch gear

room, battery room, toilet, elevator machine room etc

Battery room in switch yard

DG Set Building

Workshop

The steam turbine hall in the power house building will be provided with air washer units and roof with

roof mounted axial fans of sufficient capacity to meet the minimum air change requirement and to limit

the temperature rise within the acceptable limits. All other building in the plant will be provided with

either roof mounted exhaust fans or wall mounted exhaust fans of sufficient capacity to ensure the

minimum number of air changes and temperature requirements. The cable spreader room electrical

switchgear room, all MCC rooms will be provided with positive ventilation.

Air Conditioning System:

Various control rooms in power station, housing a group of sophisticated and precision control panels

and desks call for controlled environment for proper functioning and for personnel comfort.

The following areas are proposed to be air conditioned:-

a. Control room, control equipment room/UPS room located in power house

b. Electrostatic precipitator control room

c. Coal handling system control room

d. Ash handling control room

e. DM plant control room

f. Office area, lecture rooms etc. In the service building

g. Switchyard control room

To cater to the above requirements the following systems are proposed:-

i. A central chilled water plant for the control rooms etc. comprising compressor, cooling towers,

chilled water circulating pumps, cooling water piping with valves, accessories, fittings etc, has

been envisaged. The chilled water produced will be circulated through the coils of air handling

units located near respective control room.


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ii. Expansion plant will be provided for ESP control room, CHP control rooms, DM plant control

room etc. Each direct expansion plant will be complete with condensing units, air handling units,

cooling tower, piping with valves, fittings etc.

iii. Water/air cooled packaged air conditioners will be provided adjacent to respective isolated

areas.

Compressed Air Systems:

This system will supply air to the plant in two forms. One is in dry form which is used as Instrument air

and another form is with or without drier and is used for service air.

The plant requires number of pneumatic valves for operating and these pneumatic valves required to be

operated with the dry instrument air. The minimum air pressure in the line is to be maintained around 6

kgs/cm2 for operating these valves. Hence based on these criteria the design of instrument air will be

finalised. The other important point is the valve operation. Stand by arrangements will be made

available.

Similarly the station service air requirement for normal cleaning, atomising air medium for warm up of

guns and igniters, motive power for burner drive mechanism etc will be met from separate plant air

compressors. This will be identical to the instrument air compressors and would run in same manner

with stand by support. The capacity of all the compressors selected is to be of same, so as to achieve

interchange ability of units and its parts.

Independent air receiver tanks will be provided for each compressor. Plant service air should have

suitable interconnection with the instrument air header for augmenting instrument air supply in case of

emergency for instrument air supply.

Fire Protection System:

For protection of the plant against fire, all yards and plant will be protected by any one or a combination

of the following systems:-

a. Hydrant system

b. Automatic High Velocity and Medium Velocity Sprinkler System

c. Automatic fixed foam system

d. Portable and mobile chemical extinguishers

The system will be designed as per the recommendation of Tariff Advisory Committee (TAC) of the

Insurance Association of India. Applicable Codes and Standards of National Fire Protection Association

(NFPA), USA, would also be followed.

In view of vulnerability to fire and its importance in the running of the power station, effective measures

are to be taken to tackle fire in the following susceptible areas:

h. The cable galleries &

ii. Coal handling areas, mainly coal conveyors, transfer points, crusher house and Tunnels.


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For containment of fire and preventing it from spreading in cable galleries, unit-wise fire barriers with

self-closing fire resistant doors will be provided. The ventilation systems, if provided in the cable

galleries, would be so interlocked with the fire alarm system that in the event of a fire the ventilation

system is automatically switched off. Also to avoid spreading of fire, all cable entries/openings in cable

galleries, tunnels, channels, floors, barriers etc, would be sealed with non-inflammable/fire resistant

sealing material.

Fire Hydrant System (Centrailised)

The source of water for the fire water pumps of the hydrant system, water spray and sprinkler system

etc, will be taken from dead storage of Raw water storage tank. Two (2) electric motor driven fire water

pumps with one (1) diesel engine driven pump as back-up for sprinkler system will be provided in the

fire water pump house. These pumps will start automatically in the event of pressure drop in the

header. In addition to these jockey pump sets hydro-pneumatic tanks, compressors, pipes and fittings as

required will be provided. The hydrant system will feed pressurized water to hydrant valves located

throughout the plant and also at strategic locations within the power house.

Automatic high velocity sprinkler protection system will be provided for cable galleries, cable

trenches/vaults, coal conveyors etc.

Automatic medium velocity sprinklers will be used for protection of burner zone of boiler front.

Automatic type water spray (emulsifier) protection system would be provided for the following

equipment:

Generator transformers

Unit auxiliary transformers

Station reserve transformers

Turbine oil storage tanks

Suitable fire detection system as necessary for all the above mentioned fire fighting system with

adequate supervisory circuitry will be provided.

. In addition to these, adequate number of portable and mobile (wheel mounted) chemical fire

extinguishers of foam, Water CO2 type and dry carbon dioxide type will be provided. Portable units

would be placed at strategic locations throughout the plant area. The extinguishers may be used during

the early stages of fire to prevent spreading.

Elevators, Cranes & Hoists:

Depending on the height of structure, the elevators will be designed and installed attached to boiler

structure and main TG hall.

One electrically operated overhead crane will be put in use in TG hall. The capacity of the crane will be

decided based on the design of steam turbine for using it during erection and operation and

maintenance.


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Conventional and special type of cranes required for maintenance of steam generator, auxiliary and

turbine generator auxiliary, condenser water box etc maintenance cranes/handling devices of suitable

capacities have been considered for all other pump houses and other places as per the requirement.

Apart from these mono trails and hoists will be used for lifting heavy motors and other equipments of

the power house which are not covered by EOT cranes. In some cases suitable rails shall be provided for

removal of internal parts such as heat exchanger and other.

Electrical Equipments

The design concept of electrical system as a whole is based on the requirements for the safe and reliable

performances of steam turbine generator sets and the inter connected electrical systems with provision

of easy maintenance and over hauling. The design principle and standards delineated herein is generally

in compliance latest IEC/IS standards and codes of practice already established in the country. Indian

Electricity Rules wherever applicable will be complied with.

Auxiliary Power System:

The power supply to unit auxiliaries will be given from the HT switchgear fed by the unit transformer or

Dedicated Diesel Generator of adequate capacity to black start the power plant and backup Emergency

power. The capacity of the unit transformer is selected on the basis that the unit auxiliary load and

common auxiliaries corresponding to the maximum continuous rating of the unit with due consideration

to the starting of largest motor, system fault level, available breaker capacity and voltage regulation

requirement. The station auxiliary loads will be fed from HT station switch gear located inside the power

house. All the drives of coal handling plant, switch yard located in the plant area required HT and LT

supply will be feed as per the capacity.

Batteries and Battery Charger Equipment

Dedicated Direct Current power supply for protective relays, Emergency Oil pumps, Distributed Control

System, Electronic Governors, Emergency Lighting will be made along with suitable charger having float

cum boost facility. Battery will be SMF / VRLA type.

System Neutral Grounding:

Generator neutral will be grounded through a neutral grounding transformer, the secondary of which

will be connected to a resistance.

33 kV systems neutral will be solidly grounded.

Other areas 415 V system grounding is envisaged as solidly earthed.

Generator Transformer:

The output of the generator is connected to the generator transformer with bus duct. The generator

transformer is basically designed based on the output of the turbine and the switch yard system design

and will be finalized accordingly.


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Generator Bus Duct:

The generator will be directly connected to the generator transformer through isolated phase bus duct.

The continuous current rating of the bus duct will be suitably selected to match with maximum output

of the generator. Necessary potential transformers, lightning arresters and surge absorbers will be

provided as required.

HT and LT Bus Duct:

The unit transformer will be connected to the HT unit switchgear by the HT phase segregated bus duct /

Cables. The secondaries of the LT transformers will be connected to the individuals LT power control

centres through LT bus ducts. The bus ducts will be non phase segregated type with aluminum

conductor in enclose. The continuous current rating of the bus ducts is selected considering the full load

secondary current of the transformer.

HT and LT Breakers:

The breakers will be provided as per international and national standards. All the breaker capabilities

are tied to the rated symmetrical breaking current, which is the value of current that the breaker is

required to interrupt at rated voltage and on standard operating duty.

Motor Control Centre and Power Control Centre:

Motor control centres and power control centres will be of sheet steel cubicle and fully draw out type

construction and located for dust proof. The MCC and PCC will consist of vertical sections and each

section having separate compartment for individual motors/drives/MCC feeders.

Power and Control Cables:

The HT power cables will have single and three core stranded aluminium conductor respectively, having

extruded conductor screen cross linked polyethylene insulation consist of semi conducting layers bare

copper screen and phase identification colour coding wrapped with filler core binder type, galvanised

steel wire armour and extruded flame retardant low smoke PVC overall sheath.

The LT cables are of 1, 2, 3 or 4 core normal stranded aluminium conductor having heat resistant PVC

insulation colour code wrapped with appropriate filler and core binder and enclosed in galvanised steel

wire armour and an extruded flame retardant low smoke over all PVC sheath.

All the control cables will be multi conductor, colour code with standard copper conductor of various

sizes as per the voltage and pre insulated.

Instrument cables will be of twisted multi-pair colour coded with stranded copper conductor of cross

section 1mm2, PVC insulation and PVC outer sheath.

The installation/laying of these cables are through trenches or above ground pipe racks etc depending

on the routing.

Other Electrical Systems:

Illumination system/General lightning


19

Normal cum emergency lightning

Emergency DC lightning

Plant DC system

Uninterruptable power supply system

Emergency DG set

Grounding and lightning protection

33 kV Switch Yard / HT Room:

33 kV switch yard /HT Room will be provided for enhancing the power generated and then transported

through 33 kV Cable Underground / overhead cable through Cable rack The generators are connected to

switch yard / HT Switch Board through generator transformers.

The switch yard will be outdoor air insulated type / Indoor type HT Switch Board. The switch yard will be

provided with necessary transformer, Current & voltage transformers, surge arrestors and protective

relays.

The control, monitoring and operation of the 33 kV switch yard / Indoor type HT Switch Board will be

through a dedicated operator interface station in the central control room of the power plant.

C & I Equipment and System:

Distributed control system

The instrument and control system will be provided with a Microprocessor based Distributed Control

System (DCS) and a few other analog instruments and control devices. It will perform the functions of

monitoring control, alarm, protection and interlock, diagnosing, accident treatment and maintenance

guidance of the unit to meet all requirements at various operational conditions.

The system will fulfill the following basic functions:

Monitor all major plant functions which are inputs to the DCS.

Provide the operator with a central, universal and instantaneous means to monitor the plant.

Collect and store data for trending of various plant functions. Keep track of various plant events

and record them for historical purposes.

Perform required basic calculations for performance monitoring and optimization.

Produce operating logs for record purposes and post trip review reports.

Provide sequence of events monitoring and reporting.

Perform self-checking and self diagnosis.

Provide capability to add, delete and modify points from the system from by means of

conventional mode.

According to plant operation process, the distributed digital control system will be divided into three

control levels: Unit control level, subsystem control level (function group) and drive control level.


20

The fundamental functions such as control, alarm, monitoring, interlock and protection will be

segregated, so that the failure of one does not result in the failure of the other function.

Alarm functions will be realized through CRT video alarms. A few conventional alarm windows are

provided for the most critical items.

Level of automation Monitoring and control of the unit will be centralized at CRTs and Keyboards. Unit

normal operation, emergency treatment and other operation conditions will be performed

automatically in the unit control room.

Failure at any station will not affect the normal operation of other stations or the communication

system. Error checking will be provided to ensure that accepted message is just the same as that was

sent.

Transmissions of signals between system not located on Plant Island (e.g. switchyard, coal handling, ash

disposal, etc) will be via optical data highways.

Information gathering from the PLC systems located around the plant for different process like

Switchyard, Desalination plant, Compressed air system Fire Protection system etc., has to be made via

the suitable communication protocol along with their corresponding physical media.

Redundancy and self-diagnosis will be provided for the control system and communication network. The

functions of the failed component will be transferred automatically, and bump lessly to the standby

processor. The CRT and the alarm printer will display the failure message.

The corresponding input and output circuits (digital input, digital output, analog input and analog

output) are to be housed in the I/O module. All input and output in I/O modules are mutually isolated.

Distributed digital Control System will be complete with all safety requirements/redundancy and the

following:

VDU Equipment and Printers

Colour CRT

Operators keyboard

Software

Plant Performance supervising

Historical Data Storage and retrieval

System Communication

System Engineering Station

Performance Monitoring Subsystem (PMS)

Alarm Annunciation System

Sequence of Events Recording System

The SCADA System for Switchyard.

Turbine Supervisory System


21

Operational philosophy:

The main plant systems like STG and auxiliaries will be operated through the Operator Console in Central

Control Room (CCR).

With the exception of auxiliary systems like Fuel handling, Desalination Plant, DM Plant, Compressed Air

Plant, chlorination and AC & Ventilation all drives will be remotely operable: from operators console in

the central control room.

The envisaged operation mode (Base load with normal fluctuations) will be governed by the C&I system.

Unit start up/shutdown process will be performed manually by setting breakpoints associated with the

initiation of functional groups, assisted by CRT operating guides.

Those auxiliary systems which are not necessary to be managed directly in unit control room will be

equipped with complete supervisory instrument and control equipment near the auxiliary system

equipment or in a local control room. These systems will be monitored and controlled by PLC’s.

Important supervising information will be sent to the DCS system.

All protection functions for plant as well as for individual equipments will run automatically without

manual interventions by the operators. Also manual operation will be feasible in case of failure of auto

system for control loops.

The control system will meet the requirement for unit start up and shutdown.

The transfer between automatic and manual modes of operation will be bump less in either direction.

The design of control system and related equipment will adhere to the principle of “safe operation” at

all system level. “Safe operation” means that loss of signal, loss of

Excitation of failure of any component will not cause a hazardous condition while at the same time

prevent occurrence of excessive false trips.

Control Philosophy

Mode of plant operation : Centralized

Type of control : Automatic

Mode of control system : Distributed digital control system

System controlled & monitored by DCS : Stream Generators and its auxiliaries.

Turbine generators and its auxiliaries.

Triple modular Redundant (TMR) or

Dual redundant fail safe system : BMS, T.G Protection (control & Aux)

Standalone control system with : a) Cooling water system

Critical signals Interfaced to DCS for b) Electrostatic precipitator

Monitoring purpose only c) Fire fighting system

d) Air compressor system

e) WTP and DM Plant


22

f) Air-Conditioning and ventilation

system.

Analyzers & Sampling System:

Analytical instrument will be provided for continuous monitoring of steam, condensate, feed water and

flue gas quality. A centralized analyzer room for steam/ condensate/ feed water sampling will be

provided at a suitable location. The room will house (i) Dry section comprising electronics / transmitters

for analyzers, (ii) Wet Section housing different steam processing equipment and measuring cells. This

concept would minimize the maintenance effort and assure trouble free operation of analyzers. The

electronic signal for Dry section will be hooked with DCS system.

Field Instruments:

Adequate number of local instruments will be provided to guide the local operator in his activities.

All electronic transmitters will have IP-65 enclosure, all local indicators will have IP-55 enclosure and all

pneumatic instruments will have IP-55 enclosure.

All local instruments will be mounted at a convenient height of about 1.5 meters above ground or

platform.

For pressure, flow, level and differential pressure measurement, electronic transmitter with and output

of 4-20 mA DC will be provided. All transmitters will be of SMART type.

For temperature measurement in the range of 0-3000 C Platinum resistance thermometer will be used

and in the range of 3000 C to 14000 C, thermocouple will be used. All T/C and RTD will be of duplex type.

All control valves will be provided with valve positioned, local position indicator, limit switches, hand

wheel, isolating and bypass valves. Wherever necessary, position transmitter for remote indication will

be provided.

Various switches for temperature, pressure and level as per requirement will be provided for alarms/

Trips.

Control of Electrical Equipment:

All interlocks, feedback signals and analog valves like voltage current, power etc., associated to one

switchgear element within the MCC will be processed in the DCS. The DCS will issue control command to

switchgear via interposing relays, which will be considered part of DCS.

Power Supply & Instrument Air Supply:

Power Supply System:

The C&I system will be supplied with a 240 VAC uninterrupted power supply.

Instrument Air Supply:

The C&I will be supplied with adequate instrument air supply from compressor, air dryer assembly.

Moisture and oil free instrument air at 8kg/cm2 and minus 400 C dew point will be used.


23

Civil Works:

General:

The type of foundation will depend upon the soil load bearing capacity and type. However, for all heavy

equipment foundations and building foundations foundation of suitable type and capacity will be

considered. For others Suitable of foundations can be considered. It is proposed to adopt steel framed

structure for the power house building. The floor slab will be cast-in-situ reinforced concrete. The

cladding shall be of Brick/solid/Hollow block work with architectural finishes. Steel doors, window and

rolling shutters, would be used for the plant building the floor finishes would be as required for the

various uses.

The roads in the plant area would be of adequate thickness and width as per requirement of different

areas. It is proposed to have WBM roads during construction stage and the same would be finished with

RCC completion stage. Adequate plant roads/culverts. Grading and drainage shall be provided.

The plant layout has been made in such a manner that adequate space is available for power block,

Boiler house, storage yards, etc.

Power Block Area:

The building will be multi span framed structures consisting of structural steel columns, beams and

trusses. Main power house structure will be based in longitudinal direction and moment resistant in

transverse direction. Main power building will comprise of turbo generator (AB) bay and multi level

heater (BC) bay. All platforms and floors will be supported on steel structures.

Bunker Bay:

Bunker bay block shall be single span multi storied framed structure consisting of structural steel beams,

columns and bunkers. The buildings will have floors at feeder location and tripper location. Bunker bay

building will be braced in longitudinal as well as transverse direction hoppers shall be made of stainless

steel. The bunker will be of mild steel.

Conveyor Galleries & Transfer Points:

Overhead conveyor galleries in the main plant (Boiler area) will be of structural steel frame with

cladding and roofing. Seal plate will be provided for full length. Transfer points and intermediate

supporting trestles will be made of braced steel framed structures. The staircase will be of external type.

Plant Buildings:

Roof of TG hall will be provided with colour coated metal deck sheet over which a RCC layer shall be laid.

Further skylight will be provided for natural light. Roof of other buildings deaerator, bunker building etc

will be provided with the metal deck sheet and /or RCC depending upon the clear height of the roof.

External cladding of all buildings will have combination of all brick works, metal cladding and structural

glazing.

Control room building will have brick wall on external face.


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Roof will be provided with electrometric membrane or other suitable water proofing treatment.

Windows will be of aluminium. Doors of control room and office area will be of aluminium frame with

glazing or particle board, wherever desired large glass panels with automatic door operation and in

reflective glass will be provided. All fire exits will be provided with fire proof doors.

Cable & Pipe Racks:

Structural steel trestles and galleries with provision of walkway will be provided for supporting over

head cables and pipes in the main plant and outlying areas. However, for blow ground routing. RCC

trench with removable pre-cast concrete covers/box culverts will be provided.

Pipes and cables supporting structure running along the boiler structure, mill and bunker buildings and

ESP structures etc will be supported from steel bracket fixed to the boiler/ESP/Mill and bunker building

structure.

Pipes and cable rack structures on C-row will be supported from steel brackets/from C-row

column/frames.

Other Buildings:

ESP control, DG set, air washer and other similar buildings located in power block shall be of framed

structures.

Coal Handling Plant:

There will be no increase in coal stacking quantity (3500 MT) with expansion and the same quantity of

coal will be stored. But no. of days of storage will come down from 15 days to 6 days. Conduit type coal

conveyers will be installed for coal transfer to prevent any fugitive dust.

The civil works for coal handling system including crusher house and reclaim hopper (RH) other items

will be provided. The reclaim hopper will be of RCC/Steel as per the system requirements.

The coal stockpile will be provided with drains all around (Strom water) and properly designed drainage

system to be considered for fuel stack yard area.

Transfer tower will be of structural steel framed structures supported on ECC pedestals. At ground level

it will be provided with RCC paving inside the structures and 1 m wide plinth protection all around.

Crusher house (CRH) structures to be completely in RCC. At ground level it will be provided with RCC

paving inside the structure and 1m wide plinth protection all around. Hand railing will be provided at all

floors. Staircase will be provided as per requirement.

The Stacker Re-claimers will be provided with drains all around (Strom water) and properly designed

drainage system to be considered for fuel re-claimer/stacker yard area. Re-claimer rail and belt will be

properly supported on RCC walls and footings. Fuel re-claimer cable platform will be of RCC duly filled

with sand bed as per the system requirement.

Crushed coal stockpile area, excavating or filling of earth up to the required level will be done.


25

Common monitoring basin pond will be in RCC construction as per BIS specifications and open to sky

with necessary piping, pump room, etc complete for other details refer to mechanical section this

document. Effluent will be pumped and conveyed by CI/RCC pipes of class NP2. The pipe will be buried

and minimum filling cover over the pipe shall be 1.2 m. Discharge point will be protected from the

erosion providing suitable concrete lining.

MCC building will be of RCC construction with plastered brick masonry cladding. The width of MCC

rooms will be 6 m and all round clearance of 2m from MCC will be provided.

Ash Handling System:

All pump houses and compressor house will have steel framing arrangement and metal cladding without

insulation. MCC/Switch gear room will be of RCC/Steel framed structure with brick/metal cladding.

Switch Yard:

In switch yard, tower and supporting structure will be of galvanized steel tower and other heavy

equipment will be supported on individual footing/Raft foundation/pile foundations depending upon

the final soil investigation report.

Switch yard control room will be of RCC framed structure and plastered brick/solid/hollow block

masonry.

Non-Plant Buildings:

The Existing administrative building shall be renovated and shall be centrally air conditioned. All internal

partitions shall and partially glazed in wooden frames.

Canteen, Dining room for senior executives shall be air conditioned.

Fire station building will be of RCC framed structure and side wall will be of brick/solid/hollow block

masonry.

Service building dormitory will be of RCC framed structure and plastered brick/solid/hollow block

masonry.

The watch towers at all corners of the plant boundary will have RCC elevated platform with roof.

The security shed building will be of RCC framed structure and side wall will be of

brick/solid/hollow/block masonry.

Construction Facilities:

Construction site office, storage area open and temporary workshop, garage, yard toilet etc are

proposed. Sufficient area will be earmarked for various contractors to build their own facilities.

Roads, Drainage & Compound wall:

Roads:

All roads in the plant area will be well designed bitumen/Concrete roads. The main roads from the plant

entry up to the main plant area 10 M wide with 1.5 m wide berm to accommodate large truck

movement. All other main road will be 6m wide with 1 m wide berm on either side.


26

Secondary road will be 4.0m wide with 1.0m berm. The crown of the roads will be minimum 200mm

above FGL. The final finished road will have of 1 in 60. Camber on top of water bound macadam surface

will be 1 in 40.

Paving:

Boiler and transformer areas will be paved with RCC slab 100mm thick in grade M15 and 230mm thick

rubble soling will be provided below the paving. Higher thickness as required will be provided in area of

vehicles movement.

Drainage:

Surface drainage will be designed based on the maximum rainfall intensity prevalent in the area over

last 10 years. Building will be provided with plinth protection all around, sloped towards side drains. The

side drains will be connected at the main drains on either side of the roads.

For pipe drains, concrete pipe class NP2 confirming to IS: 458 will be used. However for road crossing,

class NP3 pipe will be used. If sufficient clearance cannot be provided between the top of pipe and road

top, the pipe will be encased in PCC/RCC. For the process rain, catch pits will be provided at the source

location and they will be interconnected buried RCC/CI pipelines and connected to waste water

treatment plant.

Environmental Aspects:

To evaluate the effect of the proposed project on the surrounding environment, various factors such as

effect on population in the vicinity, type of land use, possible emissions from various sources would be

taken into consideration.

The major environmental considerations due to burning of this fossil fuel:

Particulate Matter from the stack

Gases like SOX, NOX, CO, Hg, etc from stack

Fugitive emissions.

Solid waste in the form of ash

Liquid effluents from DM plant, cooling tower blowdown , boiler blowdown, filter backwash,

etc.

Noise level generated due to steam generator and other rotary equipments during plant

operation.

Hazardous waste in the form of used batteries, waste oil.

Pollution Monitoring & Control Equipments:

All required latest environmental protection measures will be provided in the proposed expansion of the

power plant. Environmental management cell exists in the existing plant and same cell will look after the


27

various aspects of pollution under the Environmental Management Plan established during the Plant

Commissioning and Operation Phase.

The major environmental protection equipments/systems are:

Electro Static Precipitator: During the process of combustion of coal, ash will be liberated in the form of

particulate matter. In order to control the particulate matter from the flue gases coming out of the

boiler will be treated in Electro Static Precipitator (ESP) , where the flue gas will be ionised and the fly

ash particles will be precipitated on to the electrodes and after periodic rapping, the particles will get

collected in a hopper. The outlet particulate emission will be less than 30 mg/Nm3.The collected fly ash

will then be transported to Silos pneumatically for further disposal.

Control of SO2 emissions: Adequate stack height will be provided as per CPCB norms for effective

dispersion of sulphur dioxide emissions into the atmosphere. MS/RCC stack will be provided based on

the SO2 emission during the process of combustion of coal. The SO2 emission will be restricted to 100

mg/Nm3.

NOx Emissions : NOx emission will be restricted to 100 mg/Nm3.

Control of Fugitive Emissions: sources of fugitive emissions include unloading areas of coal, coal transfer

points, coal conveying, vehicular movement, etc.

Inorder to control the fugitive emissions the following measures will be provided.

IDENTIFIED SOURCE OF FUGITIVE

EMISSION

MITIGATION MEASURE

• Coal transportation • Covered trucks

• Unloading of coal • Dust suppression system

• Coal Handling Plant • Dust extraction system with bag filters

• Coal transfer points • Dust extraction system with bag filters

• Coal conveying • Conduit type conveyers to prevent

flying of any dust during conveying

• Ash handling & storage • Fly ash will be stored in silos.

• Vehicular movement • All internal roads will be made pucca.


28

Ash disposal: The maximum ash generation will be around 45.6 TPD for Imported Coal or 171.3 TPD for

Indian Coal. Of this quantity 20% is bottom ash and 80% is fly ash. The fly ash will be collected in dry

form in silos constructed of either concrete or of mild steel. For collecting the fly ash in these silos the

proposed plant will have vacuum and pressurizing system. The fly ash collected in silo in this process will

be disposed to cement industries/ brick manufacturers. Fly Ash generated will be carried pneumatically

into the silo, The Fly ash utilization will be in accordance with the MOEF notification of fly ash utilization.

Fly ash will be given to cement plants/brick making units. Bottom ash will be used as bed material, given

to brick making units.

Liquid effluent from water treatment plant & others: The liquid effluents mainly consist of CT

blowdown, Boiler blowdown, DM plant regeneration water, filter backwash, etc.

To control and reduce this, a neutralising pit will be provided in the plant, where the DM water effluents

and boiler water will join. In the pit the pH value will be maintained by adding chemicals, acid/alkalies.

The discharge of this neutralizing pit will join with the Plant Effluent and thereafter this will be used for

the dust suppression in coal handling plant, dust suppression on roads, ash conditioning and for

plantation. As river is close by we propose to construct Bund also to be created at the plant boundary

along side of the river to prevent any flood water entering the plant or any effluent entering from the

plant into the river.

Noise Level: The noise levels for all the equipment will be maintained as per the MOEF norms, OSHA

standards. The major area of noise is steam generator & turbine. Acoustic enclosure will be provided to

STG. Greenbelt will help in further attenuating the noise levels. Ambient Noise levels of less than 75 dBA

during day time and less than 70 dBA during night time will be maintained.

Green Belt: In the existing plant 34.8 acres of greenbelt has been developed within the plant premises.

3.6 Raw material required (Fuel requirement):

Following is fuel requirement for the proposed 12 MW thermal power plant:

S.No. Fuel GCV

(Kcals/kg)

Quantity

(TPD)

Source Method of

Transportation

1 Imported Coal

4140

(on ARB)

570 Indonesia By Sea route , Rail & by

road Covered trucks

(OR)

2 Indian Coal 3970

(on ARB)

581 SCCL,

Telangana

By Rail / Road with

covered trucks


29

3.7 Water requirement and its source:

Water required for the proposed 12 MW power plant will be met from Ghataprabha River. Total water

requirement for proposed 12 MW power plant will be 720 KLD.

3.8 Employment generation:

The proposed project creates employment to 200 people during construction and existing staff are

adequate for operation of the proposed expansion project.


30

4.0 SITE ANALYSIS

4.1 Connectivity:

Component Description

Road The existing plant is located adjacent to Gokak and falls road

Rail Gokak Road Station– 7.4 Kms.

Air port Belagavi – 38 Kms.

Sea Port (Vasco) Marmgoa Port – 135 kms.

4.2 Land use:

The present use of the land is Industrial.

4.3 Topography:

The topography of the land is more or less flat without undulations.

4.4 Existing land use pattern:

The following is existing land use of the plant site.

Land use Area in acres

Process plant 11.4

Raw material & Finished product storage 5.49

Offices & Amenity space 2.92

New Power plant 2.76

Greenbelt 34.8

Roads 7.65

Parking area 2.44

Open area 29.54

Total 97.0

4.5 Soil Classification:

The soil in the site is red soil.

4.6 Climatic data from secondary sources:

The climate of the district as a whole can be termed as semi-arid. The variation in the maximum

temperature during the year ranges from 270C to 35.7 0C and minimum from 13.90C to 20.60C. The

district experiences pleasant winters and hot dry summers. The hot season extends from March to May,

during which the daily maximum temperature often shoots up to 35.70C. .


31

5.0 PLANNNING BRIEF

5.1 Planning concept:

6 MW power plant is already in operation in the existing maize processing plant. The present proposal is

to increase the power generation capacity from 6 MW to 18 MW. The present proposal is for

establishment of 12 MW Cogeneration power plant. The power generated will be partly used for captive

use in Maize Processing plant and the remaining will be exported to the Grid.

5.2 Population Projection:

During construction Unskilled Man Power required for the proposed expansion Project will be sourced

from the local villages.

5.3 Land use planning:

The following is the land use planning of the proposed 12 MW power plant area:

S.No. Land use Area in Acres

1 Plant area : 0.96

2 Water Reservoir : 0.50

3 Internal roads : 1.20

4 Switch Yard : 0.10

Total : 2.76

Note: The above figures of the land use planning are approximately and will be projected exactly after

detailed engineering.

5.4 Amenities / Facilities:

Facilities like canteen, rest room and indoor games facilities are already exists in existing plant hence the

same will used for the expansion project also.


32

6.0 PROPOSED INFRASTRUCTURE

6.1 Industrial area:

The following are list of major plant and machinery that will be installed in the proposed Expansion

project:

a) Steam Generator

b) Steam Turbine

c) Coal Handling System

d) Ash Handling System

e) Water Treatment Plant

f) Ventilation & Air-Conditioning System

g) Compressed Air Systems

h) Fire Protection System

i) Elevators, Cranes & Hoists

j) Auxiliary Power System

k) Generator Transformer

l) Power and Control Cables

m) Switch Yard

n) Coal Handling Plant

o) Environmental Monitoring & Control Equipments

p) Ash Silo

6.2 Residential area (Non-Processing area):

Facilities like canteen, rest room and indoor games facilities have already been provided in the existing

Plant. No other additional facilities are proposed.

6.3 Greenbelt:

In the existing plant 34.8 acres of greenbelt has been developed within the plant premises.

6.4 Social Infrastructure:

Social infrastructure will be developed as per need based study in the villages.

6.5 Connectivity:

Component Description

Road The existing plant is located adjacent to Gokak and falls road


33

Rail Gokak Road Station– 7.40 Kms.

Air Port Belagavi –38 Kms.

Sea Port (Vasco) Marmgoa Port – 135 kms.

6.6 Drinking water management:

The workers at the plant during construction will be provided with water for their requirement and for

the construction activities. The construction labour will be provided with sufficient and suitable toilet

facilities to allow proper standards of hygiene. The existing facilities will be availed for this. And these

facilities shall be maintained properly to have least environmental impact. Drinking water required for

the workers will be sourced from mineral water plant from outside.

6.7 Sewage system:

Domestic waste water generated will be treated in septic tank followed by subsurface dispersion.

6.8 Industrial waste management:

The effluent generated will be cooling tower blowdown, Boiler blowdown, RO rejects, DM plant

regeneration waste water and sanitary waste water. D.M. Plant regeneration water will be treated in

neutralization tank.

Treated effluent will be utilized for dust suppression in CHP, ash conditioning and for greenbelt

development. No effluent will be discharged out of the plant premises. Zero liquid effluent discharge

system will be maintained.

6.9 Solid Waste management:

Major Solid waste generated from the proposed power plant will be fly ash and same will be given

nearby Cement manufacturing units/brick manufacturing units. Pneumatic ash handling system will be

provided. Ash will be stored in silo. Ash disposal will be in accordance with MOEF&CC norms.

6.10 Power requirement & supply / sources:

The generated power will be evacuated by 33 kV lines. To this extent the switch yard of 33 kV will be

located in the plant area and thereafter it will be transported through 33 kV lines to the nearest point of

Karnataka State Electricity Board Sub-station. Depending upon the situation the company will enter into

power purchase agreement either with SEB or third party.


34

7.0 REHABILITATION & RESETTLEMENT (R & R) PLAN

The present expansion proposal is proposed to be taken up in the existing maize processing plant

premises only. Hence no rehabilitation or resettlement plan is envisaged.


35

8.0 PROJECT SCHEDULE & COST ESTIMATES

The proposed expansion project will be implemented in 12 months from the date of getting the

Environmental Clearance and CTE from KSPCB. It is proposed to execute the project by engineering

procurement and construction basis either in two packages or single package i.e. BTG as one package

and BOP (Balance of plant) in another package. To ensure the quality control team of engineers in

respective disciplines will be deployed either by direct appointment or by deploying consultant

engineers. Necessary help will be extended to contractors/associates for initial mobilisation ad during

the project execution.

Testing & commissioning group including operation and maintenance will be deputed for pre-

commissioning checks and final commissioning of various plants. The project networks will be prepared

for project monitoring with the help of EPC agency and owner engineers. The following are cost of the

expansion project details.

S.No. PARTICULARS AMOUNT (Rs. In Lakhs)

1 Land : NIL

2 Land Development & Civil Works : 1000

3 Plant & Machinery : 5000

4 Preliminary & Pre-Operative Expenses : 200

5

Margin Money for Working Capital &

Contingency : NA

Total : 6200

MEANS OF FINANCE

1 PROMOTERS : 100%

2 TERM LOANS : NIL

Total : 100%


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9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

(i) Financial & social benefits with special emphasis on the benefits to the local people

including tribal population if any in the area.

This expansion project will provide indirect employment. The management will extend social benefits

like drinking water, health care measure, training for self-employment. Repair & maintenance of the

village roads, maintenance of school buildings, awarding scholarships for higher studies to the

meritorious backward class students and supply of free books & uniforms to the socially deprived class

of students. Thus, this expansion project is expected to yield a positive impact on the socio-economic

environment of the region.

SOCIO-ECONOMIC DEVELOPMENTAL ACTIVITIES UNDERTAKEN

The following CSR activities are taken up in the nearby villages from the year 2013 to 2016.

Our CSR activity – Education

SCHOOL NAME PLACE WORK BUDGET AMOUNT (IN LAKHS)

Govt. Kannada Higher Primary school

Maradimatt Midday meals shed & RO Plant 4.6

Govt. Kannada Lower Primary school

Sindikurbet Roof work & RO plant 4.6

Abdul Kalam Primary and college

Gokak RO plant 3.0

Govt. Kannada Higher Primary school

Lakshmi Badavani Roof work, Toilet and Drinking water tank

2.1

Govt. Kannada Lower Primary school

Neibouring school Flooring, Toilet renovation, 1.11

Govt. First Grade degree college

Gokak Plastering, Water proofing, Renovation of kitchen & Toilets

1.53

Total 17.3

Our CSR activity – Health

We had sponsored Rs.1.0 Lakh – Nutrient supplements to Paediatric TB Patients in and around Gokak

Town on 22/3/2016.

Our CSR activity – Other

Supplied 5 Surveillance cameras (Amount in Rs.4.5 Lakhs) to Gokak Police Department.


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