ANNEXURE – I

EPC WORK

The scope of supply and service is Design, Engineering, Procurement, Construction, Erection,

Commissioning, and Testing including civil works for the power plant on EPC basis. Scope of

supply & services are as follows.

BROAD SCOPE OF SUPPLY

Mechanical

One (1) No. Boiler (48 TPH) TRAVELING GRATE type feeding system with all its

accessories & auxiliaries.

Complete feed water system for the boilers consisting of Deaerator complete with all

accessories and boiler feed pumps with drives including inter connecting piping, Control

and Regulating Valves.

Complete air handling draft system with fans, dampers and regulating vanes wherever

required.

Complete Fuel Handling System for Coal & Biomass (Soya Stalk + Soya Husk + Wheat

Husk & Gram Stalk).

One (1) No. of turbo generator set of rating 10 MW complete with all its accessories &

auxiliaries.

Complete Air Cooled condenser with Auxiliary cooling tower 300m3/hr, FRP type, and all

its accessories. 1W+1S.

EOT Crane (15T / 5T) for Turbine House with all its accessories with hoist one each for

15 T & 5T. Hoist shall be provided in ACC and ESP Trafo.

Complete water treatment system for boiler make up and auxiliary cooling tower make

up. With HP & LP dozing system.

One (1) No DM water storage tank with valves, fittings and instruments.

Pumps with all its accessories for the complete power plant.

Complete power plant piping system comprising of IBR & Non IBR systems.

All pressure reducing and de-superheating stations.

Air compressors, air drier and air receivers with all its accessories including

Interconnecting piping. One for Instruments/Service and One for Ash handling system.

Flue gas dust collecting equipment consisting of Electro Static Precipitator (outlet

emission 50 mg/Nm3) complete with interconnecting ducting and other accessories for

TRAVELING GRATE BOILER.

Complete thermal insulation and refractory for boiler, turbine, equipments, piping etc.

Complete chimney for TRAVELING GRATE BOILER.

First fill lubricants and chemicals for commissioning upto 10 lightups.

All the metallic parts which are site fabricated at plant site will be painted with one coat

of red oxide and two coats of synthetic Enamel / Epoxy paint.

Spares for two years operation and maintenance.

Special tools and tackle as per the list attached.

Complete services & Potable water distribution system with pumps and interconnecting

piping and Storage tank.

Complete Ash Handling System for TRAVELING GRATE BOILER with necessary

accessories shall be provided. The Dense phase ash handling system is used to

transmit the fly ash from TRAVELING GRATE BOILER to Ash silo.

Effluent Treatment plant (Membrane based technology type as per PCB), adequate

drainage system for all power plant equipment, piping up to drain gutter, with dewatering

pump.

All hangers, supports, anchors and other pipe fittings for the piping with in the battery

limits.

Fire protection system as per factory rules for Fuel storage and BTG Island.

Weigh Bridge (40 tons Pitless Type).

Electrical & Instrumentation

One (1) No of 10 MW, 11KV, 0.8 PF, 50Hz brushless exciter type Synchronous

generator along with metering and protection panel.

One no Auxiliary transformer 11KV/415V, 1600 kVA with standard fittings as per

standards.

11 KV HT breaker panel with necessary protection, metering and indication.

LTPCC and MCC which includes feeder protection and motor protection.

Lighting system complete, with outdoor mast lighting system. Applicable for two areas.

Near to Main plant buildings.

Complete plant / equipment earthing system with earth pit system. Separate earthing for

electronic system.

All AC & DC motors required for successful power plant operation

Complete lightening arrester system for Chimney, T.G Alternator and house.

Power, Control and Signal cables for interconnection of all equipment.

Cable tray, termination kits, ferrules and other accessories. All the cabling system shall

be above ground.

Cable and its accessories with bolts & nuts.

DC system complete with battery, battery chargers and DC distribution board.

Instrumentation and control system which includes interconnection with protection,

Interlocking, Sequential control system, Annunciation system and data Acquisition

system

DG Set – 2 x 500 KVA rating.

Power Evacuation system including one (1) No Power Transformer of capacity 12.5

MVA, 11/132 KV and 132 KV Switch Yard.

CIVIL

Power Plant/Station Building/Boiler/ ESP/ AHP control rooms.

Steam Turbine Generator building foundation, Chimney Foundations and all the

equipment foundations.

Control Room Building.

TRAVELLING GRATE Boiler up to firing floor.

Air cooled condenser up to operating floor.

Raw water pump house.

Raw Water Storage tank/Raw water reservoir with PCC lining. Above ground type.

MCC Rooms/ Plant control room/ Switchgear room.

Cable Gallery above ground will be designed for overall plant area.

Pipe Racks shall be above ground only.

Transformer Yard /Switch yard with control room.

Fuel Handling System

Biomass Storage facility

Weigh bridge.

Ash silo foundation will be RCC and Storage will be MS Tank.

Water treatment plant and D.M.water.

Weigh bridge room, Other Tanks & Vessels

Site leveling and grading to required Level not exceeding + or – 250mm.

Internal roads, along with drains all along the road.

Boundary wall, etc.

Construction of ETP Plant in case of Membrane based or Neutralizing pit.

Bachelor’s accommodation.

Note: The entire civil design is based on safe bearing capacity of 20 T/m2 at 3 Meter depth.

Piping

Piping Layout and Isometric Drawings for the following:

Low Pressure piping inside Plant boundary limits.

DM Water piping

Instrument & service air piping

Ash conveying piping

Fire fighting including hydrants and Piping.

Lube Oil System

Aux. Cooling Water System

Steam/Feed Water/Condensate System for Boilers

Review of Piping System which includes checking calculations for line sizing, strength &

stress analysis.

Procurement

1) Preparation of Technical specification for all the plant & equipments.

2) Floating of the technical specification for invitation of bids from the prospective Vendors.

3) Bids shall be invited by the EPC Contractor from prospective Vendors based on the

technical specification.

4) EPC Contractor shall obtain necessary clarifications, details, documents, diagrams from

the Suppliers for placement of orders.

5) A Techno-commercial discussion with the suppliers shall be arranged for finalization of

equipments.

6) EPC Contractor shall issue the final purchase order copies to the supplier

Erection & Commissioning

The activities includes

1) Prepare & review of Project Implementation schedule and subsequent monitoring.

2) Monitoring site activities, identifying likely delays and necessary corrective measures.

3) Review adequacy of Sub - Contractors resources in respect of Special Tools/ Equipment

for site work and adequacy of manpower.

4) Prepare monthly progress report based on the status of the project.

5) Review Monthly Progress Reports covering current construction status, deviations from

project implementation schedule and recommend remedial measures to be initiated.

6) Periodic follow up with suppliers for delivery of equipments.

7) Depute respective Engineers (Mechanical, Electrical & Civil) at site for construction,

erection & Commissioning of the plant

8) Co-ordinate with all sub-contractors / suppliers for smooth functioning of site activities.

PROCUREMENT & CONSTRUCTION CONTRACTOR along with OWNER will witness the

equipment guarantee tests which will be conducted by the respective equipment suppliers / sub

- contractors and coordinate for issue of acceptance certificates on satisfactory completion of

tests. Though it is clearly understood that in case the guarantees are not met, it will be

the responsibility of the contractors to adjust, repair or replace free of cost, the

equipment supplied by them and demonstrate the guaranteed performance.

Following works are also included in the scope of work of EPC contractor.

i. Site development as per Plot layout proposed.

ii. Leveling and compaction of plant area for civil construction. Contour plan and

trial pits for soil data.

iii. Security for the plant and equipments while construction upto commissioning.

iv. Water and power requirement for construction will be provided at one point inside

plant boundary will be provided by client, the same shall be distributed by

Contractor.

v. Colony for staff and workers engaged in EPC work.

vi. Removal/ disposal of excavated earth generated within the plant area,

vii. First filling of lubricants, chemicals and fuel for commissioning.

viii. Access area for temporary office, store, stock yard, fabrication area, labour

camps.

ix. Gate, compound wall with boundary fencing.

x. Non plant buildings like administrative building, canteen, security building, etc.

Labour and labour laws;- The contractor shall employ labour in sufficient numbers to maintain

rate of progress and of quality to ensure workmanship. The contractor shall provide transport,

housing, canteen, and payment of wages etc. thereof to the labors in accordance with relevant

statutory rules and regulations etc. All labors engaged by the contractor shall have no claim

against RIPL in respect of any right or benefit due to them in their employment.

Safety and Clearance.

The contractor shall take all necessary safety precautions and arrange PPE to prevent loss of

human lives, injuries, to personnel engaged by contractor before commencing of the work.

The contractor shall insure the workman engaged by contractor against all accidents. Otherwise

RIPL will arrange the same on contractors account for contractor manpower. In case of fatal or

disability injury accident to any person at the construction site, the victim and/or his/her

dependents shall be compensated by the contractor as per the statutory requirements.

Supply part for plant spares:-2 years O & M spares / 1 year mandatory spares shall be provided along with plant material. Spares listed below shall invariably be included.

Special Tools for Turbine

1. Rotor Lifting device.

2. Casing Lifting device.

3. Lifting device for diaphragm and diaphragm sleeve.

4. Bearing bush disassembly device.

Special Tools for Generator

1. Special tools (shoe plate etc.) for generator rotor threading in / threading out.

2. Lifting and rotating device for generator end cover.

Spares for Exciter

1. All necessary input / output cards – 2nos.

2. Diodes / Rectifiers – 2nos.

3. HRC Fuses – 10 nos.

Spares for Turbine

1. Spare shaft, impeller, mechanical seals, o rings for each type of Auxiliary oil pump

– each 1 nos.

2. Spare seat, gland packing etc. for all types of control values – each 1nos.

3. Lube. Oil filter element – each 1nos.

4. Spare tubes for ( 5% of installed quantity for each)

i. Generator cooler

ii. Oil Cooler

5. Generator bearing bush – 1 set.

6. Slip ring insulating sleeve – 1 set.

7. Turbine front bearing( Journal ) – One set

Boiler Spares

1. Different types of special material tubes, bends.

2. Anti erosion cover of different types and sizes.

3. Back plate, clamping color, lock plate hooks, claps nail etc.

4. Feed line valve spares for both low load and full load valve.

5. Essential spares for regulating / isolating valves and dampers.

6. Gauge glass spares – One set.

7. Repair kit for gauge glass – Two set.

8. Mechanical seal for BFP – One set.

9. IBR valves (class 1500) – 15 NB – 02 nos. , 25 NB – 02 nos, 40 NB – 02 nos.

Electrical Spares (Note* Subjected to OEM standard)

1. Assorted size of HRC fuses for power & control.

2. DC Fuses.

3. Auxiliary contactors of different size and capacity for power & control circuit.

4. Battery charger spares.

5. ESP spare electrode both +ve and –ve and hammers.

6. Shaft insulator – 01 nos.

7. Support insulator – 01 nos.

Instruments Spares

1. Impulse tube.

2. Compensating cable.

3. I/P converters.

4. Copper tube fittings.

5. Thermocouples/RTDs.

6. Pressure, Temperature and Flow Indicators.

ANNEXURE – II

Steam Generator Units

Steam Generators

The steam generating system for the power plant will consist of one (1) no. Soya Stalk/Husk,

Wheat Husk/ Gram Stalk biomass fired boilers of 48 TPH capacity and all the auxiliaries. The

boiler shall be of top supported traveling grate boiler, natural circulation, balanced draft, and

membrane wall radiant furnace design with two stage super heaters and inter stage

desuperheater designed for burning Soya Stalk / Soya husk / blend of 85% as the principal fuel

for Shajapur plant and balance 15% Indian coal grade F. The boiler will be suitable to operate

using 100% biomass or 100% coal during emergencies.

The steam generator design parameters shall be as follows:

I Maximum continuous rating (MCR)(T/hr) 48 for 10 MW

II Peak capacity of the boiler as a percentage of MCR capacity % 110 %

III Super-heater outlet pressure Ata 67 for 10 MW

IV Super-heater outlet temperature (°C) 445 ± 5

V Feed water inlet temperature (°C) 126

VI Excess air (%) Not more than 20

VII Boiler outlet flue gas temperature (°C) 140 (max.)

VIII Dust concentration at chimney (mg/Nm3) < 50 (max.)

The analysis of the fuel are furnished below

1) Coal- F grade

2) Soya Husk

SI. NO. PARTICULARS UNIT SOYA HUSK

(I) Ultimate Analysis:

1) Mineral Matter % 6.67

2) Carbon as C % 41.79

3) Hydrogen as H % 6.34

4) Nitrogen as N % 1.11

5) Sulphur as S % <0.01

6) Oxygen as O (Remainder) % 44.09

(II) Proximate Analysis:

1) Moisture % 8.63

2) Ash % 6.09

3) Voltaile Matter % 75.28

4) Fixed Carbon % 10.00

5) Gross Calorific Value

(on dry basis)Kcal/Kg 3360

3) Soya Stalk

Moisture,%

Ash,% Sulphur,% Bulk Density

(kg/m3)

Gross Calorific Value

(kcal/kg)

7.6 10.5 0.10 300 3830

SI. No. Elemental Oxides (%) SI. No Elemental Oxides (%)

1. Silicon Di-oxide 23.23 7. Sodium Oxide 1.87

2. Aluminium Oxide 6.35 8. Potassium Oxide 12.38

3. Calcium Oxide 26.31 9. Iron Oxide 2.67

4. Magnesium Oxide 19.00 10. Phosphorus Pentoxide 4.62

5. Chromium Oxide 0.1911. Sulphur Tri-oxide 3.09

6. Titanium Di-oxide 0.29

Ash Fusion

Temperature (ºC)

Initial DeformationTemperature

SofteningTemperature

Hemi-sphericalTemperature

FluidTemperature

1030 1080 1100 1120

Carbon,% Hydrogen,% Nitrogen,% Chlorine,% Oxygen,%

39.1 5.00 2.42 0.25 35.03

Pressure Parts

The complete system of boiler pressure parts, covering:

Steam and water drum

Boiler Bank Tubes

Furnace water wall.

Superheated system & system including headers and Down comer pipes, Risers, Blow

down & drains piping, HP dosing piping.

Desuperheating system

Economiser system

Together with all required headers, integral piping, interconnecting piping, valves, fittings,

supports, etc. will be provided.

The circulating system essentially comprising of the drums, water walls, furnace tubes, boiler

bank tubes, down comers and relief tubes shall be designed to provide an adequate circulation

ratio in the system. The down comers and the relief tubes shall be sized and routed to offer

minimum pressure drop and to aid the improvement in the circulation ratio. The sizing of the

circulation system components shall be adequate to ensure safe circulation ratios even under

peak loading conditions.

Steam & Water Drum

The boiler will be provided with one steam drum and one water drum of fusion welded type.

Both the drums will be provided with 2 nos. manhole doors to open inwards. Steam drum is

provided with cyclone and screen type separators as drum internals. The drum design pressure

shall have a minimum margin of 6% over drum operating pressure.

Suitable nozzles with flange of adequate thickness will be provided in the drum to mount the

valves and fittings. Provision for blowdown will be given in the steam & mud drum. The drums

are provided with semi ellipsoidal (2:1) dished ends.

Liberally sized downcomers and risers are provided. The thickness of the drum is arrived based

on the requirements as specified under IBR 1950 with latest amendment.

Furnace Water Wall System

The Furnace envelope shall be constructed of fully watercooled membrane/fin welded walls and

adequately supported. The design shall be such as to prevent distortion of steel work due to

thermal expansion. The construction shall be fully gas pressure tight and the furnace shall be

strengthened by providing buckstay and tie bar system. The furnace shall be adequately sized

for burning the Soya Stalk/Soya Husk having ash percentage of up to 10%. & Coal having ash

percentage of upto 40.0%.

Necessary supporting / suspension systems will be provided for the complete system for free

expansion of components when unit is in operation.

Adequate number of inlet and outlet headers, with the necessary stubs, commensurate with the

arrangement of the furnace shall be provided. Each of the headers shall have atleast two

numbers of handholes for inspection and cleaning. The downcomers, supply pipes and raisers

sizing shall be based on the circulation calculations.

The water wall panel fin thickness and width shall be such that the fin tip to base temperature

differential does not exceed 70 Deg C.

Superheater System

The superheater (SH) system shall be of two (2) stage design with inter-stage desuperheating

to achieve the rated steam temperature over 60% to 100% load range. The superheater shall be

of convection or a combination of convection and radiation type. The superheater pressure

drop, the inlet and outlet header sizing, arrangement and sizing of their respective inlet and take

off connections shall be so as to give minimum unbalance and the tube element material

selection shall be based on the actual metal temperature calculations.

Bank Tubes

The bank tubes are of seamless Carbon Steel construction. The bank design will be of inline

arrangement and the tube spacing shall enable easy removal of the tubes in case of any failure.

The bank tubes shall be expanded into both the top and the bottom drums and the tubes after

expansion shall be bell mouthed.

Adequate number of soot blowers will be provided to cover the maximum surface area of the

bank. The bank tubes are designed with a single pass arrangement.

Attemperator System

The attemperator system, to control the temperature of the final superheater outlet steam

temperature, will be provided in between the two stages of the superheaters. The interstage

attemperator shall be of the spray type, using the boiler feed water tapped off at the outlet of the

boiler feed water pumps, to control the final steam temperature between 60% to 100% MCR

load.

The desuperheater will be inter stage fixed orifice type. The desuperheating system will be

complete with all required spray valve, control valves, bypass regulating valves, piping and

supports etc.

Economiser

The Economiser will be located immediately downstream of the boiler bank. The design will be

of bare tube construction with inline, counter flow, and drainable arrangement. The economiser

shall be designed for an inlet feed water temperature of 126 Deg C. The economiser shall be

arranged such that there is space for the future addition of about 10% of the installed heating

surface area without disturbing the existing economiser coils.

Air Heater

The air heater will be arranged as the last heat recovery section downstream of the economiser.

The Air heater will be multitubular recuperative type with flue gas flowing inside the tubes and

the combustion air flowing over the tubes. Required access doors, platforms, walkways etc will

be provided as required.

The Low Temperature bank of the Air-preheater shall be designed to prevent corrosion and the

cold end material of the airheater tubes shall be Carbon Steel.

FUEL FEEDING SYSTEM & FIRING SYSTEM

The firing system will consist of a spreader stoker with continuous ash discharge travelling grate

with variable speed drive. The grate assembly will include the keys, air compartments, air seals,

tensioning mechanism, rails, lubrication system etc.

The fuels from the conveyor is brought into the storage silo. The fuel from the silo provided for

Bio-mass fuels falls through the drum feeder from where it is taken to screw feeder and then to

pneumatic distributor for uniform distribution.

DRAFT SYSTEM

The boiler will be equipped with 2 x 50% MCR FD fan, ID fan and SA fan. The fans (FD & ID

Fans) shall be coupled to the motor with variable frequency drive. The fan shall also be provided

with power cylinder operated dampers. Wear liners for ID fan on Impeller will be provided.

DUCTING SYSTEM

All ducts will be rectangular in cross section and will be of welded construction properly stiffened

and reinforced. All the air ducts will be fabricated from steel plates of minimum 4 mm thick and

all flue gas ducts shall be of minimum 5 mm thick. The duct plate material will conform to IS 226

/ IS 2062.

ASH SYSTEM

The ash from the fluidized bed, the Economiser / Air heater and the ESP shall be discharged

through dense phase system to the main ash silo, keeping the plant clean of ash.

BED ASH SYSTEM

The coarse grained fraction of fuel ash is not discharged from the fluidized bed but is retained

as bed ash at about 850°C. Bed ash extraction takes place through discharge pipes from the

fluidized bed bottom and conveyed through dense phase system to Ash Silo.

FLY ASH SYSTEM

Fly ash is collected below the economiser before entering the air heater as well as in

electrostatic Precipitator. Fly ash collected below economiser will be at a temperature of

approximately 300 deg C whereas the fly ash temperature in electrostatic precipitator will be at

140oC. Fly ash will be disposed off through a separate ash handling plant. Conveyed through

dense phase system to Ash Silo. The compressor shall be separately provided for Dense phase

system.

CHEMICAL DOSING SYSTEM

The boiler shall be provided with a common tri-sodium phosphate based High Pressure (HP)

dosing system and a hydrazine and ammonia based Low Pressure (LP) dosing system. The HP

dosing system shall add the chemical to the boiler water to take care of the ingress of the

hardness salts and to increase the boiler water pH. The LP dosing is done to the feed water

preferably at the outlet of the deaerator to scavenge the last traces of oxygen and to increase

the feed water pH. HP dosing system sizing shall be with one percent (1%) concentration of tri-

sodium-phosphate. The tank usable volume shall be on 24 hours basis. LP dosing system

sizing shall be with 0.1% concentration. The tank usable volume shall be on 24 hours basis.

Each dosing system shall include a stainless steel mixing tank with an electric motor driven

agitator. Each system shall have 2x100% capacity, motor driven positive displacement type

pumps, with wetted parts made of stainless steel with facility to vary the feed rate.

The HP and LP dosing systems shall be mounted on individual skids with their respective tank,

pumps along with all required piping, valves, fittings, supports etc. The complete piping for both

the HP and LP dosing system from the skid to the respective admission points to the boiler

water circuit shall be of type 304 stainless steel.

BLOW DOWN TANK

A single Blow down tank has been consider for continuous blow down and intermittent blow

down as suitable for boiler capacity. The tank shall be fabricated from carbon steel material.

ELECTROSTATIC PRECIPITATOR

The ESP will have three (3) working fields with collection efficiency of around 99.8%. The outlet

dust concentration from the ESP will be limited to 50mg/Nm3. Each ESP will be provided with

ash hoppers having capacity suitable for storing ash collected in at least one (1) shift operation

of the Boiler at 100% MCR. The Ash Hopper will be provided 2.5 M above the Ground Level.

SILENCERS

Silencers are to be provided for start up vent value and safety valves.

INSULATION

The entire water wall Panels, Economiser casing, Ducts & piping should be insulated by mineral

wool of proper thickness reinforced mattresses. There will be usage of PUF type insulation with

Clamp on provisions.

CLADDING

All the insulated area will be cladded by 24 SWG Aluminum sheet.

BOILER TRUSS

Boiler roof with sides will be covered by G.I. sheets upto Steam Drum.

INTER CONNECTION PLATFORM

Inter connection platform will be provided between TG Building and Boiler operating floor.

STEAM TURBINE

This project envisages one (1) no.10 MW Bleed- cum- condensing turbo-generator. The turbine

shall be designed for the operation with the inlet steam parameters at 64ata and 440±50C for

10MW and shall be with uncontrolled extraction steam.

a) The turbine shall be horizontal, single cylinder, Multi stage bleed-cum-condensing type for

10MW. All casings and stator blade carriers shall be horizontally split.

b) The uncontrolled extraction steam from the turbine shall be delivered to the deaerator.

All casings and stator blade carriers shall be horizontally split or otherwise and the design shall

be such as to permit examination of the bending without disturbing shaft alignment or causing

damage to the blades. The design of the casing and the supports shall be such as to permit free

thermal expansion in all directions. The casing shall also permit the inspection of the bearings

without dismantling of the casing. The extraction branches shall be located on the lower half of

the casing.

The low pressure casing shall have a bottom exhaust arrangement configuration and the

exhaust casing shall be suitable for connection to the air cooled condenser without air leakage

and suitable for maintaining the condenser vacuum. The turbine exhaust hood shall be provided

with exhaust water spray system to protect the turbine against excessive temperature due to

windage at no load and low load conditions. The spray system shall be provided with complete

spray nozzles, automatic spray control valve, interconnecting piping, all necessary controls,

instrumentation and fittings. The turbine shall have solidly forged and machined rotor with

integral disks. The rotor after fully machined and bladed shall be dynamic balanced accurately

in the shop and shall be given overspeed test under vacuum. None of the critical speeds of the

rotor shall fall within the range of 20% above and 20% below the normal running speed of the

rotor. The rotor shall be designed to withstand the maximum shock loading that may occur

during any power system disturbance.

Gland Sealing System

The glands shall preferably be of labyrinth type and sealed with steam. The gland packing shall

be of 13% chromium stainless steel. The labyrinths shall be of multi-section spring backed type

which would allow for any temporary deformation of the rotor shaft without overheating the rotor

due to friction. The gland sealing system design shall permit the examination of and

replacement, if necessary, of the glands without lifting the upper half of the turbine casing.

During the normal operation of the turbine the source of sealing steam will be from the turbine.

During the start up of the machine, steam shall be supplied externally for effecting the sealing.

Required gland steam condenser with 2x100% capacity AC motor driven exhausters shall be

provided. Suction fans shall have one operating fan and one standby fan. All piping and

components of shaft seal system shall be sized for 150 percent of the calculated new clearance

leakages.

Bearings

The turbine shall be provided with liberally rated hydrodynamic radial and thrust bearings. The

radial bearings shall be split for ease of assembly and of the sleeve or pad type, with steel shell

backed, babbitted replaceable pads. These bearings shall be equipped with anti rotation pins

and shall be positively secured in the axial direction. A liberal flow of lube oil under pressure

shall be supplied to all the bearings for lubrication and cooling.

All bearings shall be accessible without having to remove cylinder covers. The metal

temperatures of all the bearings shall be monitored by thermocouples with extension right into

the white metal layer. Provision shall be made for measuring the temperature of the oil leaving

the bearings.

Lubrication and Control Oil System

A pressure lubrication and control oil system shall be provided for the turbo generator unit to

supply oil at the required pressure to the steam turbine, gear box, generator and governing

system. The lubrication oil system shall supply oil to the turbine generator under all the load

conditions, including the turning gear operation. The oil system of the turbo-generator shall be

designed with adequate redundancy and emergency provisions such that a failure of a single

active component will not prevent the safe operation or a safe shutdown of the turbo-generator.

The Oil System shall include the following:

One hundred percent (100%) capacity centrifugal/gear type, main oil pump driven by the

turbine shaft/low speed gear shaft. A separate AC electric motor driven main oil pump is

also acceptable.

One (1) No. of one hundred (100%) capacity AC motor driven auxiliary oil pump of

centrifugal type, arranged to cut in automatically if the oil pressure falls to a preset value.

This pump shall also meet the requirements during the start up and shutdown.

One (1) DC motor driven, centrifugal type, emergency oil pump of adequate capacity to

provide adequate lubrication in the event of a failure of the AC motor driven pump(s).

This pump also shall cut in automatically at a pre set value of the oil pressure. The

minimum capacity of this pump shall be to ensure a safe shutdown of the turbo

generator.

Two 100% capacity (one working and one standby) water cooled oil coolers.

Two 100% duty oil filters arranged in such a way that it is possible to clean one oil filter

while the other is in service. The filters and the coolers shall be arranged with continuous

flow transfer valves with online changeover system.

Oil storage and settling tank with adequate reservoir capacity, strainers, level indicators

with float switches and alarm contacts, vent and oil mist eliminators and vapour exhaust

fans.

Flow and temperature indication for oil from every bearing.

Centrifugal oil purifier with drives, interconnecting piping and valves.

Emergency gravity lubricating oil system.

The auxiliary oil pumps and the emergency oil pumps shall be arranged to have flooded suction.

Oil Coolers

The oil coolers shall be water cooled with a duplex arrangement and changeover valves. The

coolers shall be of shell and tube type with removable tube bundle. The cooler shall be

constructed in accordance with TEMA class C. The provided surface area shall be adequate to

cool the oil with 32 Deg.C inlet cooling water temperature even with 10% of the tubes plugged.

The sizing of the coolers shall consider a tube side (water side) fouling factor of 0.0002 Hr. Sq.

M Deg.C./Kcal. The water velocity shall be not less than 1.5 M/sec. The coolers shall be

amenable for easy inspection and maintenance and cleaning of one cooler while the other one

is in service shall be possible.

The cooler tubes shall be of copper, and the body and the tube sheets shall be of carbon steel

conforming to IS 2062 or equivalent standards. The cooler on both the tube and the shell side

shall be designed for a pressure of 5 Kg/Sq.cm (g).

Filters

Full flow twin oil filters shall be used, for the lube oil, downstream of the coolers and shall be

piped in a parallel arrangement with a continuous flow transfer valve filter size shall be 10 - 15

microns nominal for the lube oil. Filter cartridges shall have a minimum collapsing differential

pressure of 3.5 kg/sq.m. The minimum design pressure for the filters shall be the maximum

discharge pressure of the oil pumps. Differential pressure gauge with alarm shall be provided

across the filters.

Oil Purifier

A centifugal type oil purifier shall be provided for the removal of water, sediments and other

oxidation products from the lube oil system on a continuous basis. The purifier shall be a

separate complete package, mounted on a skid, complete by itself with drive motor, piping,

heaters, valves and fittings. The capacity of the purifier shall be atleast two (2) percent of the

rate of normal flow through the reservoir. Feed to the purifier shall be from the drain end of the

reservoir and it’s operation shall be independent of the oil system with hose pipe.

Emergency Oil Tank

Emergency gravity lubricating system shall be provided to assure the lubrication at the time of

emergency due to the failure of the DC operated lube oil pump. This system shall draw lube oil

from a overhead tank, under gravity, and shall be designed to supply oil for the coasting down

period of the machine.

The overhead tank shall be SS lined and the complete piping shall be of SS 304 material. The

tank elevation shall be finalized based on the oil pressure requirements at the bearings. The

tank shall be suitably designed for at least one hour capacity.

Steam Turbine Governing System

The turbine governing system shall be electro-hydraulic designed for high accuracy, speed and

sensitivity of response. The governor shall ensure controlled acceleration of the turbo generator

and shall prevent overspeed without tripping the unit under any operating condition or in the

event of maximum load rejection. The governor shall have linear droop characteristics with a

suitable range for stable operation and shall have provision for adjusting the droop in fine steps.

The governing system shall have the following important functions:

Speed control

Overspeed control

Load control

Inlet steam pressure control

The governor shall be configured to incorporate the following controls while operating in parallel

with the grid.

a) Load set point shall remain unaffected for variation of frequency between 47.5 Hz and

52.5 Hz.

b) The turbine inlet steam pressure shall be maintained at the set value by controlling the

power export to the grid.

c) Turbine vibration monitoring system – is essentially required.

d) Speed Reducing Gear Unit: Should be provided between turbine shaft & Gen. Shaft. It

should be single reduction & double helical type & having factor of safety of at least 1.3.

Thermal Insulation and Lagging

The steam turbine and the other high temperature parts, including piping supplied, shall be

insulated with low conductivity inert material, where required, reinforced by stainless steel wire

net between applied layers. The insulation shall be so arranged that it can be removed for

access to the flange bolting, control valves and other parts that require periodic maintenance.

The insulation shall be designed, such that the outer surface temperature of the insulation does

not exceed 20 Deg.C above the ambient temperature.

PERFORMANCE PARAMETERS

The following gives the performance requirements for the turbo-generator:

Sl. No Description Parameters

1. Turbine Type Extractions cum Condensing

2. Inlet Steam Parameters

Pressure (Ata)

Temperature (0C)

Flow (Kg/Hr)

64 ata

440 ± 5 °C

45000

3. First Extraction Parameters

Pressure (Ata)

Temperature (0C)

Type Quantity Requirements

Minimum (Kg/Hr)

3.82

200+15

4730

4 . Air cooled Condenser Operating Pressure (Ata) 0.18

5. The economical steam rate required at

Percentage load (%)

80-100

6. Rating at the generator terminals (MW) 10

7. Power factor (lagging) 0.8

8. Generation Voltage (kV) 11

9. Ambient temperature for electrical equipment

design (0C)

50

10. Parallel operation with grid SEB

11. Grid Voltage (kV) 132

12. Duty Requirements 8000 Hours/year

13. Atmospheric Conditions Dusty

14. The maximum noise pressure level at 1.0 m

distance for any equipment from the equipment

surface shall be equal to or less than [db(A)]

85

15. The minimum continuous load at which the TG

is expected to operate as a percentage of the

MCR load (%)

House load.

16. System Frequency (Hz) (All components of the

turbogenerator system shall be designed to

operate in this frequency range

50 -/+ 5%

CONDENSATE SYSTEM (DRY SYSTEM)

Condenser shall be of Air cooled condenser, designed for operating with atmospheric air for condensing the exhaust steam from the steam turbine. Condensate from the condensate storage tank will be pumped by one of the two (2) 100% capacity condensate pumps for each circuit through a gland steam condenser, ejector condenser and to the Condensate storage tank in recirculation mode, Excess to deaerator.

The gland steam condenser condenses steam from the steam seals of the steam turbine. The gland condenser is a heat exchanger, which directs the condensate to condenser. The operating dumping capacity of the condensers will be 100% of the high pressure steam.

The condensate storage tank shall have sufficient margin to provide required suction head for reliable operation of the condensate extraction pumpsets during transient operation conditions.

Condensate Extraction Pumps

Two numbers for each circuit of hundred percent (100%) capacity condensate extraction pumps

to pump the condensate from the condensate storage tank shall be provided. The pump shall be

selected for a normal continuous flow rate equivalent to the maximum steam flow to the

condenser under all the operating conditions. The margin on the pump capacity and discharge

pressure shall be of minimum 15%, over and above the 100 percent capacity.

Both the pumps shall be driven by electric motors and the flow shall be controlled by discharge

throttling. The pumps shall be of vertical /horizontal type with mech. seal and shall be supplied

complete with all valves, inlet and discharge piping with manifolds. The pump shall be designed

to have adequate discharge head for supplying the condensate to the deaerator.

DEAERATOR AND CONDENSATE STORAGE TANK

One (1) Deaerator for each circuit of deaerating capacity equal to twenty percent (20%) higher

than the gross MCR steam generation capacity of the boiler with a deaerated water storage tank

of net useful capacity (normal water level to low water level) equivalent to twenty minutes (20

minutes) of MCR generation capacity of the boiler shall be provided. The material of the

deaerator, deaerated water storage tank is SA 515 Gr 70/ IS:2002 Gr 2.

The deaerator shall be of either spray-cum-tray type or spray type with counter flow of steam

and Water. The deaerator and the storage tank shall be complete with all the fittings and

mountings like vents, controlled vent, drains, gauge glasses, pressure indicators, relief valve,

steam and water inlet and outlet nozzles etc.

The complete deaerator pressure and level control systems with all the piping, fittings, valves,

control valves, instrumentation etc. shall be provided. Steam (from turbine extraction) shall be

supplied at the inlet of the pressure control station. The level control station shall be located at

the outlet of the condensate pumps, which pump the water from the feed water storage tank to

the deaerator. The condensate from the turbine air cooled condenser and the make up DM

water @ 32°C, shall be piped to this feed water storage tank. The tank shall be complete with all

the fittings and mountings like the vents, drains, inlet & outlet nozzles, gauge glasses etc.

The Condensate storage tank and the deaerator system shall be designed considering the

following condensate return and make-up water addition to the condensate storage tank :

Condensate from Air cooled - Condenser (approx.) for 10MW: 45 TPH @ 58.1°C

DM water from DM water tank for 10 MW: 3.3 TPH @ 32°C.

BOILER FEED WATER PUMPS

Two (2) Nos. of 100% capacity boiler feed water pumps, with one operating and the remaining

as standby, to supply feed water to the boiler. The feed water pump will take suction from the

deaerator. The pump shall be single suction, multi stage centrifugal type with drive motor of

suitable rating coupling common base frame, foundation bolts automatic recirculation valves etc.

Each feed pump shall be capable of meeting the peak generating capacity of the boiler with a

margin of 5%. The design margin on the head shall be 10% of its maximum discharge pressure

requirements for the continuous operation of the boiler. The pump shall be coupled to the motor

with variable frequency drive.

AIR COOLED CONDENSER

Technical features of Air Cooled Condenser

The finned tube bundles are fixed on a “roof" type structure with an angle of 60 °.

Such an Air-cooled condenser is made of cells each cell consists of:

– The structure supporting the cells and bundles; No. of cells should be atleast 03.

– The finned tube bundles;

– The main stream manifold feeding the bundles;

– The fan units with drive assembly and protection guards at the bottom of the A frame;

Gear box for fan should be with low oil level & vibration protection.

– The air inlet rings at an elevated level above the ground in order to provide a sufficient

air inlet area;

– Condensate extraction pump and Hotwell drain pumps;

– Wind wall for prevention of air recirculation.

Fin Tube Bundles

Finned tubes bundles are rigid, self supporting and designed for handling as a complete

assembly with lifting lugs.

The main components are:

– The finned tubes

– Tube sheet.

– C-frame

Tube bundles are made of extended surface fin tubes with 4 rows of circular carbon steel tubes

wounded with helical tension wrapped LL-shape (Overlapped) OR G Type Embedded fins.

Spatiality of LL- Overlpped Type Finned Tube & G Type Embedded fins.

LL - Fins are ideally suitable for application upto 160 Deg.C giving increased atmosphere

corrosion protection of the base tube .Fin foot is pre-formed into an LL-shape (overlapped LL)

and applied to base tube under tension.

G type - Fins are ideally suitable for application upto 160 Deg.C giving increased heat transfer

than any of the existing technology. As the Fins are embedded in the tube material wall they are

mechanically stronger than all other type of fins.

The LL-Overlapped fins are the cheaper alternative of more expensive than Extruded G grooved

Finned Tubes. Each bundle consists of two section i.e. primary and secondary sections. The

steam condenses mainly in primary section while flowing from top to bottom. The balance steam

condenses in secondary section while flowing from bottom to top. The non-condensable is

extracted from the top of the secondary section through air extraction line. The secondary

section works as dephlagmator for air extraction and thus it ensures proper extraction of air from

each bundle and ensures effective extraction.

The upper tubular plate of primary bundles is fixed to the steam manifold but can freely expand

to the bottom according to thermal expansion. Cleaning pump & arrangement should be

provided for on-line fins cleaning.

STEAM SUPPLY LINE

This consists of –

– Carbon steel exhaust steam duct with transition piece, hot well, balance line, expansion

bellows and a rupture disc, spring supports.

– The steam manifold, located on top of the air-cooled condenser is welded to the bundles

in order to prevent air leakage. The manifold can also expand freely with the help of

sliding pads. 02 Nos drain boot pump should be provided to remove condensate from

duct.

AUXILIARY COOLING TOWER

In the proposed plant the Auxiliary cooling tower envisaged to cool the water which is used to

cool the equipments like Alternator, Oil cooler, Boiler feed pump, ash vessels and the sample

cooler. The cooling water is circulated by Auxiliary cooling water circulating pump. ( 2 x 100 %

with drive motor, coupling, frame, foundation bolts, suction and discharge valves, NRVs.

STEAM EJECTOR UNIT:

Should be provided to maintain minimum 0.18 ata exhaust pressure in the condenser and

should consist of

(a) Hogger Ejector or start up Ejector

(b) 02 Nos. service Ejectors, one for service & other as standby

(c) Ejector condenser to condense service ejector steam in this condenser.

TECHNICAL FEATURES OF BALANCE OF PLANT (BOP)

MECHANICAL SYSTEMS

Fuel Handling System

a) Biomass - Soya Stalk/ Soya Husk/ Wheat Husk/Gram Stalk

The biomass handling system is designed based on the Indian biomass which requires high

Handling capacity. The biomass required for TRAVEL GRATE boiler is fed by means of

biomass handling system which contains ground hopper, screening unit etc. Requirement of

Soya biomass at MCR for the 10 MW power station shall be 11.2 TPH considering GCV as

3500 Kcal/Kg.

The raw biomass which is stored in yard is unloaded in the ground hopper by suitable movers

by drag belt conveyor, and will be fed into Boiler Bunker.

b) Coal

The Coal handling system is designed based on the Indian Coal which requires high handling

capacity. The Coal required for boiler is fed by means of Coal handling system which contains

ground hopper, crushing unit, and screening unit. Requirement of Coal at MCR for the 10 MW

power station shall be 12.27 TPH considering GCV as 3200 Kcal/Kg.

The ground hopper contains vibratory feeder and conveying belts. The Coal is transferred to

crushing unit through belt conveying system. The raw Coal is crushed by crushers to required

size. The sized Coal is transferred to screen house for screening. The conveyor will be suitable

for 16 hrs design and will be provided with metal detector, Pull cord switches, belt way switches,

& hood cover for conveyor both side walk way at each gantry.

Ash Handling System

The ash handling system envisaged in this project is to collect the ash from Boilers, ESP and

conveying it to the Ash silos. The ash is conveyed by means of compressed air. The ash

handling system complete with collecting vessels, conveying pipe lines, ash silos.

The Ash Handling system will be designed to meet the following condition:

a) Soya biomass

Soya biomass Consumption: 269 TPD

Ash content in Soya biomass : 10%

Total ash collection: 26.9 TPD

b) Wheat & Gram Stalk

Soya biomass Consumption: 269 TPD

Ash content in Soya biomass : 10%

Total ash collection: 26.9 TPD

c) Coal

Coal Consumption : 294 TPD

Ash content in coal: 38.63 %

Total ash collection: 65.53 TPD

In the TRAVEL GRATE boiler the ash collecting areas are Air preheater, Economiser zones. In

the ESP the fly ash is collected at field hoppers and it will be transferred to Ash silos. The ash

silo shall be equipped with bag filter, ash conditioner and rotary air lock feeder.

Water Treatment System

The water plays an important roll in the power plant. In the proposed project the raw water is

taken from the bore well which are located in various locations at the site. The raw water may

contain unwanted foreign matters, suspended solids, dissolved solids and pathogenic contents

so the raw water should be treated at RO/DM plant and fed to boiler and softener.

In RO/DM plant the raw water is treated at various stages to remove the contaminants in the

raw water. The RO/DM plant consists of CLARIFIER- SOFETNER-Multi grade filter, Softener,

Ultra filteration, chemical dosing systems, RO systems, mixed bed. The capacity of the DM

plant will be 7 M3/Hr 20 HRS OPERATION.

The raw water is fed to CLARIFIER- SOFETNER- Multi Grade Filter (MGF) to remove

suspended particles in the raw water. MGF & Softner shall be designed to supply eater to DM /

RO as well as to aux. cooling tower. The water from Multi Grade Filter will be passed through

the softener for removal of hardness. Minerals like calcium, Magnesium, will be removed in

softener with the exchange of sodium. The softener water is fed to cooling water make up

requirement and Ultra filtration unit for further treatment.

The filtered water is fed into the Ultra filtration system to remove colloidal contents like silica,

iron, Aluminium and manganese in water causing fouling, scaling and poor performance of the

plant. The treated water from ultra filtration unit is fed to Reverse Osmosis system in which a

synthetic semi-permeable membrane is used to separate water from dissolved solids by

applying reverse osmosis principle.

The water from the RO unit is further passed through the mixed bed unit wherein the total

dissolved is further removed with Cation and anion resin in the mixed form to achieve the

conductivity less the 1.0 ms/cm. this treated water will be used for boiler feed. The chemicals

like HCL, NAOCL and SMBS are dosed with the water at various stages to control ph of water,

and de-chlorination. The De mineralized water from RO/DM Plant is stored in DM water tank of

100CUM and the water is fed to Deaerator for Boiler make up and Boiler initial filling by DM

water transfer Pump. The water from softener unit is fed to Cooling Tower (or) Auxiliary Cooling

tower for cooling water make up.

Piping

The piping system will complete with Steam piping, Cooling water piping, Compressed air

piping, Raw water piping, Condensate piping, Feed piping, Ash conveying piping, DM water

piping, Service water and drinking water piping, and Fire hydrant piping.

The high pressure steam piping from boiler to turbine line. The steam from PRDS station is fed

to ejector; gland sealing and deaerator for initial heating purpose. The Bleed Line from Turbine

to Deaerator is low pressure pipings. The water from cooling tower will be circulated to cool the

equipments like alternator, oil cooler, boiler feed pump, sample cooler, and ash vessels through

cooling water pipe lines.

The atmospheric air is compressed by the compressor; the compressed air is used for

Instruments and other Service purposes. The instrument air is further treated with dryer to

remove moisture in compressed air and store it in a separate reservoir. The service air is stored

separately in another. reservoir. The instrument air is fed to instruments in various locations at

site by instrument air piping. The service air is fed to ash conveying vessels and other purposes

like cleaning through service air piping.

Cranes

To handle the main turbo – generator set and its auxiliaries housed in the TG Building, One (1)

EOT Crane with the capacity of 15 / 5 Tones will be provided. The crane will move to entire TG

floor to handle the equipment during maintenance. In addition hoist should be provided

wherever required.

Box girders shall be provided with end plates for sealing. Full depth diaphragms or stiffeners

shall be furnished at motor supports and below line shaft bearings. Short diaphragms shall be

furnished where required to transmit the trolley wheel loads to the web plates. All diaphragms

shall bear against the top cover plate. Rotating axle, equalizing end carriages shall be used to

distribute the load evenly between the wheels from each bridge girder. End carriage and crab

frames shall have built up structural steel members in welded construction to form a rigid box

structure and stress relieved as per accepted standards. Safety devices shall also be provided

to prevent the trucks from leaving the rails.

Bridge shall be driven by two (2) independent driving units comprising of AC electric motors with

IP 55 and TEFC, gear box and brakes and shall be placed (arranged parallel to longitudinal

shaft) one each near the end carriage on one side of the walkway platform. Each driving unit

shall be mounted on a specially designed rigid frame mounted on the bridge girder and

removable as a complete system. The trolley frame shall be built up from heavy steel sections

welded together to form a rigid one piece frame adequately braced to resist vertical, lateral and

torsional strain and support all loads without undue deflection.

The hoisting machinery shall consist a separate electric motor for each hoist with a separate self

contained, sturdy, automatic, self adjusting specified brakes or other approved type interposed

in the hoisting gear train as close to the source of power as possible.

Ventilation and Air conditioning System

For proper functioning of the equipment, controls and accessories as well as to provide the right

Environment for operation and maintenance of the plant, adequate Ventilation and Air-

conditioning system will be provided for the plant as described below. Main control room will be

air-conditioned. ESP controls will be located in the main air-conditioned control room. Roof

extractors and Wall mounted exhaust fans will be used in TG hall.

Battery room (dust proof construction fan & flame proof motor) will be ventilated by exhaust

fans. TG hall, A/c Plant room, Cable Gallery. Weigh bridge room.

FALSE SEALING will be provided in Main control room.

Chemical Laboratory

A central chemical laboratory is envisaged for the station. This will have necessary equipment

and facilities to test and analyze steam, water, etc. require ensuring satisfactory operation &

maintenance of steam generator.

Thermal Insulation

Insulation will be provided wherever necessary to contain heat loss from the equipment, piping

duct and to ensure protection to personnel. Insulation will be held by adequate cleats, wire nets,

jacket etc. to avoid loosening. Insulation thickness will be so selected that the covering jacket

surface temperature does not exceed the surrounding ambient temperature by more than 15

Deg C.

Turbine oil purification system

A turbine oil purification system will be provided for the unit consisting of centrifuge type oil

purifier, indirect oil heater, dirty & clean oil pumps and polishing filters. This will be required to

condition the turbine oil continuously on by pass mode, in order to remove water and other

impurities from the system to maintain the turbine oil at the optimum condition.

Chimney

The Steel chimney is envisaged with this Power Plant for Boiler. The flue gas from boiler

contains Sulphur content. If the sulphur is exhausted in the atmosphere it will cause severe

environmental problems. So the flue gas should be exhausted at safe height as per Pollution

control board norms. The STEEL Chimney shall be 48 Mtr heights and shall be provided

suitable for long life operation. Provision for installing Opacity meter shall be made available

with monkey ladder landing platforms & easy ladder upto sampling point.

Compressed Air System (Instrument/Service)

To cater for the plant compressed air requirements it is proposed to install Air compressor for

the instrumentation air system and plant service air system separately. The compressors shall

be 1W + 1S for each service. It is rotary, screw type non-lubricating type, complete with inter

cooler, after cooler. The compressor will be oil free type.

Heavy-duty dry type intake air filter, conveniently located for quick and easy replacement with

cyclonic separation and arrangement for pre filter separation.

The compressor shall be supplied with adequately designed air cooled radiation type oil cooler

and after cooler to take away the heat of compression from the oil. Copper finned tubes shall be

used for air cooled versions. The air receiver shall be vertical cylindrical welded construction

with elliptical / for spherical dished heads and Auto drain facility.

The compressed air drying unit shall be refrigerant type. It shall consist of close-loop refrigerant

circuit in which compressed fluid shall be chilled to a controlled temperature and so condensed

moisture could be separated out. To prevent freezing of condensed moisture on the refrigerant

coils, air/gas should be chilled to a minimum temperature of 2 to 3 Deg.C approximately. The

dryers shall be designed for automatic regulation with Auto draining and to adjust themselves to

varied load conditions. The regulation system shall consist of an expansion valve in the

refrigerant circuit to maintain the flow of refrigerant into the evaporator and Fan control switch to

start and stop the condenser fan motor to maintain near constant condenser pressure.

The dryers shall be provided with a control system for precise control indications and safety

features

Weighbridge

Weighbridges are large scales that are usually mounted permanently on a concrete foundation

weighing scales that are used to weigh entire vehicles and their contents. By weighing the

vehicle both empty and when loaded the load carried by the vehicle can be calculated. The

weigh bridge shall be of 40 Ton capacity Pit-less type. The weigh bridge room shall be air

conditioned.

ELECTRICAL System

All Electrical equipments shall conform to relevant IS/IEC standards and

recommendations of IEEE standards.

132/11kv Switchyard in power plant for power evacuation through 12.5 MVA

Transformer as per standard Aster design shall be providing to meet MPSEB

requirement. The transformer shall be provided with OLTC, with import & export

facility.

Fault level at 11 kV is 26.3 kA for three seconds and all bus bars shall be of AL bars.

Fault level at 415 V is 50 kA for one second.

Low voltage motors have class ‘F’ insulation with temperature rise limited to class ‘B’

offering high electrical and mechanical stability.

Motor Control panels comprises of Low voltage Switchgear such as Air circuit

breakers, Fuses.

Fuse-Switches, Contactors, Bimetal Overload Relays, Electronic Timers, Motor

Starters Pushbuttons and Miniature circuit breakers.

High Voltage switchgear shall be designed for rated voltage and rated power

frequency to withstand the short circuit current Breaker shall be Triple pole,

single/double break and high speed and Rack out draw type.

Vacuum/SF6 circuit breaker. The circuit breakers shall have three distinct and

separate positions on the cradle viz. Service, Test and Isolated with provision for

locking the breakers in any of these three positions.

Cables shall be suitable for laying in conduits trays or for direct above ground in both

wet and dry locations in cable gallery only. Entire plant shall be free of underground

cabling.

The breakers shall be Rack out draw type and provided with protection as per IP-55

standard.

110VDC system shall be provided with DCDB, Charger and SMF batteries. The DC

system for TG application and Electrical Switchyard shall be separate.

240 VAC UPS system shall have 60min backup.

APFC shall have PF improvement of to maintain the overall system PF @ 0.9 ranges.

Plant Electrical Systems

The Plant Electrical System is covering major equipment such as Generator, Unit Auxiliary

Transformer (UAT), Generator Transformer, Breaker panels, MCC, Switchyard, Earthing,

lighting and cables, as per approved SLD

Generator:

The rating of the Generator would be 10 MW at 11 KV. The Generator winding would be star

connected with phase and neutral terminals brought to an accessible position. The star point of

the Generator would be connected to earth through Neutral Grounding Resistor. Necessary

protection for various parameters shall be provided as required. Complete system shall be

provided with NGR panel, LAPT panel, Synchronizing panel, Generator protection panel (with

one numerical relay of AREVA/ABB/GE make GPR for Generator )

The Generator will be air cooled with Brushless Excitation. Generator would be provided with

class-F insulation and temperature rise will be limited to Class-B level to ensure longer life.

Following shall be the main parameters of the Generator.

MW rating : 10 MW

Voltage Rating : 11 KV

Rated power factor : 0.80 Lag

Related frequency : 50 Hz

Voltage Variation : ± 10%

Frequency Variation : ± 5%

Unit Auxiliary Transformer (11KV/415V, 1.6 MVA )

One Unit Auxiliary Transformer shall be provided to feed unit auxiliary loads. The Transformer

shall be designed to withstand electrical impulses and dynamic stresses. Solid Earthing shall be

provided in secondary winding of Transformer. Necessary protection for various parameters

shall be provided as required. (As per IP-55).

LTPCC and MCC:

LTPCC acts as a Power Distribution Board, which comprises of 4-pole draw out Air Circuit

Breaker in its incoming feeder and 3 poles ACB and MCCB in outgoing feeders. Necessary

protection such as Earth fault and Over Load Relay shall be provided in all incoming and

outgoing feeders. Motor Control panels comprises of Low voltage Switchgear such as AL

BUSBAR, Air Circuit Breakers, Fuses, Fuse Switches, Contactors, Bimetal Overload Relays,

Electronic Timers, Motor Starters ,Push Buttons, and Miniature Circuit Breakers. The various

auxiliaries will be supplied at the following nominal voltages depending upon their ratings and

functions:

(a) The 415V, 50Hz, 3-phase, 4-wire supply for auxiliaries will be obtained from 11kV/ 415V

Transformer through LTPCC. The 415V system will be Solidly Earthed.

(b) 230 V, 50Hz, 1- phase AC supply for lighting, Space Heaters, single phase Motors, etc.

11kV HT breaker panel:

The 11kV generated voltage from Generator is given to the Indoor HT breaker panel by XLPE

(UE) cables. The HT breaker offered is Vacuum Circuit Breaker. The parameter of VCB is given

below.

Circuit Breaker type: VCB

Short Circuit Current: 26.3 kA for 3 sec.

The Generator switchboard is housing four breaker panels, one for Generator, one for Auxiliary

Transformer, one for Power Transformer and one as spare. All the breakers are provided with

necessary protection and metering features. The breaker can be operated by manually or

motorized, with trip free Mechanism.

Cabling system:

The following types of cables will be used:

(a) For 11 kV system: 11 kV unearthed grade, stranded Aluminium Conductor, cross linked

polyethylene (XLPE) Insulated, PVC inner sheathed, Galvanized single steel wire

armored for three core, or Aluminium wire armored for single core and overall extruded

PVC sheathed cables.

(b) For Low Voltage System: Power cables of 1100 V grade, stranded Aluminium conductor,

PVC insulated, PVC inner sheathed, galvanized single steel wire armour for three core

or aluminium wire armour for single core and overall black PVC sheathed Cables

conforming to IS:1554.

(c) For Control Applications: 1100 V grade annealed high conductivity stranded copper

conductor, PVC insulated, PVC inner sheathed armour and PVC outer sheathed control

cables conforming to IS:1544.

(d) For Instrumentation Applications : Stranded high conductivity annealed tinned copper

conductor, PVC insulated, flexible, twisted pair /triplets, individually and overall shielded

(for low level analog signals) and only overall shielded for digital signals, PVC inner

sheathed, galvanized steel wire armour and overall PVC sheathed cables.

Safety Earthing System:

The plant safety Earthing consists of a buried grid provided to alternator, transformer and other

outdoor areas interconnected with Earthing grids provided in various plant buildings. The buried

Earthing grid will be connected to suitably located Earth Electrodes. All metallic conductive parts

in the plant buildings which risk accidental contact with a live conductor and cause damage to

Equipment and danger to life will be connected to Earthing grid inside the building through earth

leads. All equipment is generally earthed at two points for reliability. Main equipments should be

earthed with copper strip.

Separate earthing shall be provided for electronic instruments.

Plant Lighting System:

The Lighting system comprises of Lighting Distribution Board which distributes the supply to

Main Distribution Board at corresponding Location. The appropriate lighting equipment such as

sodium Vapour lamp, High bay lamp, etc will be provided based on the illumination requirement.

Control room lighting should be as per IS standard. Out side lighting will be provided with High

Mast Tower lighting in Two places.

Switchyard:

The power received from the grid is used for running the plant and the power produced by the

Turbo Generator is evacuated to the grid. The Switchyard is installed with SF6 circuit breakers,

Current Transformers, Potential Transformers, Isolators, Lightning Arrestors, etc., Power

Transformer of capacity 12.5 MVA, 132/11 KV is considered for this plant.

Instrumentation and Control System

The plant will be designed with Distributed Control System (DCS) to co-ordinate and control

Boiler, STG and Balance of Plant operation from control room. DM plant and Fuel-Handling

Systems shall be controlled from their respective local control panel. Important parameters and

status indications of these systems will be made available on the operator station in the control

room, Air compressors operation should be covered in DCS scope.

Distributed Microprocessor Based Instrumentation:

A Microprocessor-Based (DAS) BASED System is proposed to provide a comprehensive

integrated instrumentation and control system including the functions of Data Acquisition

System (DAS) to operate control and monitor the Steam Generator with its auxiliaries. Steam

Turbine Generator with its auxiliaries and utility systems with a hierarchically distributed

architecture in view of the following advantages:-

Increased reliability

Better availability

Higher system security

Increased flexibility

Modularity and expandability

Higher maintainability

Drift free control

Lower Power consumption

Lower Operating voltage

Improved man-machine communication with color graphics TFT based control stations

Increased data collection and storage capability

Faster response time

DCS Features:

The DCS will include the necessary system and application software to achieve control and

monitoring functions and data acquisition functions like logs, reports, trends, curves,

performance calculations and historical storage.

DCS incorporates the latest technology to provide functionally distributed architecture and

reduce the risk associated with the failure of any single control units. They provide hierarchical

system structure to facilitate the task of integration, co-ordination and operation of the plant

equipment / sub-systems.

DCS functions include:

(a) Data acquisition for measurement monitoring and control:

(b) Historical data logs (Automatic generation of 8 hour report & print)

(c) Trending

(d) Reporting

(e) Data conditioning and processing.

(f) Control functions such as:

1. Binary control (open loop control) – on/off logic and protection logic

2. Sequential Control.

3. Analog control – Closed loop control

4. Supervisory control and monitoring functions for plant utilities.

(g) Measurement & Monitoring functions

(h) Annunciation & Alarm reporting

The control system will be provided with 230 V AC UPS (with back up capacity of 60 minutes).

Uninterruptible Power Supply (UPS) will be provided to cater the 230 V AC, Single phase, 50Hz,

2 Wire power supply requirements of the DCS system. The closed loop controls, sequence

controls, protection and interlock system will work on +24 V DC voltages.

Control Philosophy:

The operation and monitoring of the complete plant will be from the control desk /panel located

in Control Room. The operator will perform the following operations from the control desk TFTs.

(a) Operation of pumps, Fans, Motors associated with the SG, TG, Coal Handling System,

Cooling Water System and their Auxiliaries.

(b) Operation of all control valves, dampers of the SG, TG and their auxiliaries.

(c) Carry out associated control operations with the aid of Plant overview, group display,

individual loop display etc.,

(d) Plant start-up, normal and shutdown operations will be from DCS. In case of DCS

Failure, hard-wired back-up operation is envisaged for a safe shutdown of the plant.

(e) For safety and reliability, dual redundant sensors will be provided for critical closed/open

loop controls. Redundant sensors will be provided with automatic signal selection and

rejection features in the DCS.

(f) Pre-alarms will be provided whenever necessary to avoid tripping of the equipment, to

increase the availability of the plant and to provide adequate information to the operator

regarding plant status.

Monitoring Instruments:

03 Nos. Monitors 21”, 1 NO. Dot Matrix Printer for reports.

(Two as operator station & one as operator cum Engg. station). Standard furniture for DCS

operation. They include electromagnetic type indicators, electronic indicators digital display

units, drum level Indicator, Ammeters, Voltmeters, Frequency Meters, Power Factor Meters and

Energy meter which are essential for starting, loading ,running and shutting down of the unit.

Local Instruments:

(a) Local instruments will be provided to enable local operators to supervise and monitor

equipment/ process.

(b) All transmitters for measurement and control will be electronic type of two wire systems

with 4-20 mA DC output-SMART versions

(c) All thermocouples will be duplex type and signal transmission through compensating

cables

(d) All temperature inputs for control will be taken to the system through temperature

transmitters.

(e) All RTD inputs will be directly wired to Temperature scanner.

CIVIL & STRUCTURAL WORKS

The main power plant building will be a RCC/ PEB framed structure with brick walls upto roof

level. The floor slabs at intermediate levels will be of RCC supported on RCC beams &

columns. The roof slabs covering and the MCC room portion of the buildings will be RCC

construction whereas the maintenance bay of the TG building will be of Steel roof construction.

The structure will be designed to cater for one (1) EOT Crane (15/5 Ton) to handle heaviest

load required in handling TG set. The doors and windows will be of metallic frame with glazing

to avail natural light. The auxiliary and ancillary buildings will generally be in RCC/Steel framed

structure, RCC roof slabs/sheets and brick walls. MCC/PCC room should be on intermediate

floor.

DESIGN LOADS

Design loads for all structures will be determined according to the criteria described below:-

i) Dead Loads

Dead loads will consist of the weights of the structure and all equipment of a permanent or

semi permanent nature including tanks, silos, bins, wall panels, partitions, roofing, piping,

drains, electrical trays, bus ducts and the contents of tanks measured at full capacity.

ii) Live Loads

Live loads will consist of uniform live loads and equipment live loads.

Floors and supporting members which are subject to heavy equipment live loads will be

designed on the basis of the weight of the equipment in addition to a uniform load of 500

kg/m2, or specifically defined live loads, whichever is greater.

Live loads will be used as follows:-

a) Ground Floors

Ground floor slabs will be designed for a minimum of 1,500 kg/m2 in all areas.

b) Suspended Floors

Suspended concrete floor slabs will be designed for a uniform load of 1000kg/m2,

except for the following:-

i. Control room areas : 1200 kg/m2.

ii. Storage areas : Mass of stored material, but not less than 1000kg/m2.

iii. Turbine generator : Determined by loads of laydown area major components, but

not less than 1,500 kg/m2. Suspended grating / chequered plate floors will be

designed for a loading of 500kg/m2 to the supporting members.

c) Roof Loads

All roof areas will be designed for wind loads as indicated in IS: 875 (Part-3). All roof

areas will be designed for imposed loads as per IS: 875 (Part-2) in addition to

calculated dead loads.

d) Impact Loads

Impact loads will be added to other loads for structural components supporting

reciprocating or rotating machines, elevators, hoists, cranes, or other equipment

creating dynamic forces. The impact loads will be as per IS: 875 (Part-2).

e) Pipe Hanger Loads

Pipe hanger loads for the major piping systems, such as the main steam, feed water

and extraction systems will be specifically determined and located.

f) Equipment Loads

Equipment loads will be as per Vendor drawings.

g) Access Walkways, Staircase, Handrails and Ladders

The walkways will be designed for the dead loads of the structure plus a

superimposed live load of 500 kg/m2 uniformly distributed, or a concentrated load of

150 kg at any point, whichever produces the most severe effect.

Stair treads will be designed for a distributed load of 225 kg/linear meter of tread

width or a concentrated load of 100 kg, whichever produces the most severe effect.

Handrail forces will be 100 kg applied outward at the center of the span and vertical

between posts.

Ladders will be designed to withstand a live load of 100 kg.

h) Wind Loads

Wind loads for all structures will be based on IS-875 (Part - 3).

i) Seismic Loads

The seismic risk zone for this site will be determined from the IS:1893-1984. Seismic

loading will be used in the design of structures only when they are greater than the

computed wind loads.

SPECIFICATION: - FOR CIVIL WORK EXECUTION

Boundary wall : -

Width : 9 inches

Height : 2 m from NGL

Column center : At every 3m

Column size : 6” X 9”

Above boundary wall 1 run of barbed wire will be provided on 45* 50 x 50 size angle

Plant road : -

6 mts wide

100 mm PCC

150 mm RCC

Weigh bridge room : -

Size – 3 mts X 3 mts

Two side Aluminium window and one aluminium door.

Security Room : -

Size : - 3 mts X 3 mts X 3 mts, Two side window and one door.

Watch Tower:- 1 x1 Mtr size platform at an elevation of 5 meters from ground level with asbestos sheet roof on tom.

Administration building :- Double story.

Ground floor – Office room -02 nos, Size - 3 mts X 3 mts X 3 mts with false sealing

Hall – 01 no., Size - 6 mts X 12 mts X 4 mts with Urinal and Toilet .

First floor –

A) Room 02 nos, Size : - 4 mts X 3 mts X 4 mts with attached Toilet and single window.

B) Dinning Hall – Size : - 6 mts X 4 mts X 4 mts, window at outside wall.

C) Kitchen : - Size : - 3 mts X 3 mts X 4 mts

Slab for cooking at 1 mt level. Exhaust fan provision, sink and arrangement for water purifier.

Plant Store : -

A) A)Room - Size : - 4 mts X 3 mts X 4 mts, 02 Nos side window (glass)

B) B)Hall : - Size : - 6 mts X 3 mts X 3 mts, Fixed steel window – Two side.

Testing lab : -

Size : - 6 mts X 4 mts X 4 mts . Working slab at 1mt level at two sides. Aluminium window and door false sealing.

Work-shop:- 15 mtr x 12 mtr size floor with roof at 5 mtr height and suitably covered sides with wide opening for entrance and door.

Site Office:- 15 mtr x 20 mtr size shed with asbestos roofing and false ceiling and covered with brick walls to accommodate site staff of both company and contractor.

TG BUILDING : -

A) AT 3.5 Mts LEVEL – MCC / PCC / BREAKER ROOM – 6 Mts X 18 Mts.

B) AT 6.5 Mts LEVEL – TG HALL – 12 Mts X 18 Mts

– CONTROL ROOM – 6 Mts X 15 Mts

– OFFICE – 02 NOS – 3 Mts X 3 Mts (Glass partition)

C) AT 10.5 Mts LEVEL – Deaerator foundation beam and PRDS System.

D) AT 14 Mts LEVEL – EOT crane rail.

Rain water harvesting system shall be provided in all the buildings with pits. Suitable area for truck parking shall be developed and provided. Bachelor’s accommodation shall be provided for at least 20 nos.

EXTERIOR ARCHITECTURE

Doors, Windows / Ventilators

Door, Window and Ventilator frames will be made of extruded aluminum, steel, or other tried

and proven material which is resistant to the corrosive environment. All windows will be fully

flashed and sealed for weather tightness.

Equipment Access Doors

Large access exterior doors of vertical lift Rolling shutter type with weather seals and wind locks

will be provided.

Roofs

RCC slabs with proper waterproofing will be provided for main TG building and other critical

building. Galvanized steel sheets will be provided on the roof of other buildings with water

proofing treatments; adequate slopes and roof drainage indicating rainwater down comers.

Lighting

Lighting fittings and fixtures will be provided for proper illumination in all buildings as per good

Engineering practice. Outdoor area shall be provided with Mast lighting tower.

Auxiliary buildings

The Power Station with provision for expansion is proposed to be installed in the space

earmarked. Land is partly level and therefore no major cutting & filling has been envisaged. Soil

is top over hard clay & rocks. The soil bearing capacity will be determined after conducting

detailed soil investigation. The precise plant formation level will be finalized after contour survey

of the area high flood level and according to the site.

The general criteria for various designs will be as follows:

– All RCC structures will be designed as per IS:456 and all structural steel structures as

per IS 800 and IS 875 and IS 1893 pertaining to wind and earthquake forces.

– Mud mat concrete for all foundations shall be of grade M-10 and shall be minimum 75

mm thickness.

– Dust load on roofs for any structure will be assumed as 100 kg/m2 in addition to live

load.

– A surcharge of 1500 kg/m2 at graded level will be assumed for design of all foundations

and structures.

– Wherever external staircases provided for the buildings etc., the same will be extended

up to the roof. In case of non-provision of external staircases, a cage ladder will be

provided as an access to the roof.

MISCELLANEOUS CIVIL WORKS

All Precast cover slabs for trenches will be provided with MS edge protection angles on all sides

with epoxy painted (minimum size of angle 50 x 50 x 6 mm). Trench edges will be provided with

suitable protection.Civil foundation will take into consideration soil bearing capacity, water table

and equipment loading data.

Concrete quality for various works shall be :-

– M30 TG chimney and any other special foundation

– M20 Station building columns foundation, boiler structural foundations, transformer yard,

beams, slabs, pedestals, columns, floors and ancillary building, Air cooled condenser

structure etc.

– M20 Grade slab and other miscellaneous items

– M10 Sub-grade filling, mud/mat plinth protection etc.

Suitable Compound Wall with barbed wire fencing, wherever required, will be provided around

the power plant for safety and protection of the installation.

The ash dump will be identified and located in the close proximity of power station and

connected with a road for dumping dry ash from silos in truck. Internal roads have been planned

as per the layout for power plant block. The roads shall have drain on one side and street

lighting poles on other side.

Compound wall with fencing shall be providing based on plot layout . Security points with

outpost shall be provided. The civil work in Ash handling system includes construction of Steel

silos fly ash. Plant raw water storage tank having two compartments to facilitate maintenance,

raw water pump house for conveying water further to DM plant etc.

PILE FOUNDATION * Not Required as per SBC data provided by Owner, In case Pile

foundation is required the additional cost shall be discussed and mutually arrived.

PAINTING:

Final painting of steel structure which are site fabricated should be done by single coat of red

oxide and two coats of synthetic enamel/epoxy paint shall be in scope of EPC contractor.

ANNEXURE – III

TERMINAL POINTS

Raw water tank inlet.

Ground hopper inlet for biomass/ coal.

Up to ash silo outlet.

Drains up to drain pit.

Flue gas at the outlet of the chimney.

Power evacuation up to power plant substation gantry inside boundary limits.

Construction power shall be provided at one point inside plant area.

Construction water shall be provided at one point inside plant area.

EXCLUSIONS

Procurement of land and cost thereof.

Transmission line and bay, statutory fees thereof.

Raw water & fuel analysis and the corresponding documents shall be provided by owner

to EPC contractor for detailed engineering.

Preparation of environment impact assessment report and related government

authorization.

Security for the plant except within the battery limits.

Operation and maintenance of the plant.

Water and power required for construction of the plant as per battery limit.

Fuel storage and its handling beyond the battery limits.

IDC, PRE-op expenses, contingencies, financial services & co-ordination with financial

institutions.

Route survey for raw water supply, transmission line , etc.

Legal advice on the work except related to EPC contract.

Getting no objection from electricity board for generation of surplus power and exporting

same to grid.

Construction of bore well for construction as well as continuous water supply.

Obtaining clearances and fees thereof from MOEF / Pollution control board / SEB /

Elect. Inspector.

Obtaining permission from ground water authority.

Obtaining clearance for wheeling power from the source to destination.

Raw water intake canal ( or ) pipe line to water reservoir in the power plant.

Future expansion of buildings / foundations.

Any pipe, cabling, instrumentation beyond battery limits.

SERVICES AND UTILITIES TO BE PROVIDED BY THE OWNER

Space for operating & main staff during construction and commissioning.

Power required for construction at free of cost.

Power for start up at free of cost.

Water required during construction & commissioning at free of cost.

Project land free of any legal issues.

All or any kind of liaising work related to or what so ever liaising or statuary

requirements.

ANNEXURE – IV

GENERAL TERMS AND CONDITIONS FOR ENGINEERING, SUPPLY, ERECTION & COMMISSIONING AND HANDING - OVER OF THE PLANT.

INTRODUCTION

The purpose of this document is to state the conditions that will be diligently followed by the

EPC contractor for Engineering and Supplies for “10 MW nameplate capacity plant”

supplement with associated auxiliaries for operation as a station with grid connectivity.

THE CONTRACT

The contract or the contract agreement ( the terms are interchangeable in this context

unless otherwise specified ) means the agreement that will be entered into between the

EPC contractor and the Owner for execution of works that includes the Commercial

conditions of contract, Technical specifications, Letter of award and acceptance, the

documents referred to and schedules and drawings annexed to the agreement and those

addendums, revisions and change orders agreed to by both parties with express

understanding of their inclusion in the agreement as and when such occasion arises at a

subsequent date. This part, commercial condition of contract for engineering and supplies

(hereinafter contract through out this section unless otherwise mentioned ) shall deal with

engineering, design, drawing and supply of equipment, machineries, components and things

that will form the plant at the site.

Contractor

The contractor means the EPC contractor whose offer was adjudged the most suitable and

acceptable by the owner for award of contract and whose Letter of acceptance was received

for entering into the contract. It includes the legal successors of the contractor but not any

assignee.

Sub Contractor

Sub- contractor means the person, firm or company to whom any part of the contract is sub-

let by the contractor as per contract or with the written consent of the owner. The contractor

remains responsible and liable to all acts of the sub contractor in the same way as it is

responsible for its own employees and agents. The term includes Vendor, Sub Vendor and

Supplier for this contract who are named in the tender for specific works

NOTICE

All notices to be given under this contract shall be in writing and in the English language. All

certificates, notices or written instructions to be given by each party, owner and the

contractor shall be delivered by hand with acknowledgement, or sent by registered post or

by speed post and the acknowledgement be collected for records. Notices given by

registered post with acknowledgement shall be deemed to have been received on the date

of acknowledgement. In case of service of notice by telex, email, facsimile, a hard copy duly

signed by the server of notice must reach the receiving party at the address given as under.

In all cases electronic communications shall be deemed as Notice, should the receiver duly

gives the acknowledgement for it. Otherwise the day of receipt of the hard copy by

registered post duly acknowledged shall be considered as day of receipt by the receiving

party. Notices shall be effective when received by the recipient.

If to Owner (It will be copied to the Owner’s Engineer):

Attention :

Designation :

Address :

E-mail :

If to Contractor (It will be copied to Contractor’s Rep at Site):

Attention :

Designation :

Address :

Fax :

E-mail :

CONFIDENTIALITY AND NONDISCLOSURE

Confidential Information

The owner shall furnish to the contractor information which shall be proprietary in nature and

sensitive in character to the extent that it may affect the owner’s development of the project

in hand and other ongoing business if disclosed or passed to others. The contractor shall

also be preparing documents based on the information of the owner and its principals and in

house expertise which if disclosed to others, may jeopardize the development of the owner’s

project. All these are “Confidential Information”. The owner and the contractor expressly

agree that either party shall not use the confidential information for any purpose other than

the contract.

Limited Disclosure

The contractor expressly agrees that it will ensure that its employees, officers and directors

will, take all precautions and measures to ensure that its sub- contractors, vendors,

suppliers and others will, hold in confidence the technology, processes and its drawings,

designs and other related documents and all information, documentation, data, know-how

disclosed to it by the owner and / or prepared specifically for the owner based on the

supplied information for the plant and will not disclose to any third party or use any part

thereof without the owner’s prior written approval. The contractor also undertakes to

disclose confidential information only to those of its employees, sub-contractors and vendors

who are engaged in the work on a need to know basis.

Disclosure As Required under Circumstances

Confidential Information may be disclosed to (i) a Governmental body pursuant to legal

requirements and (ii) to lenders and bankers whose duties reasonably require such

disclosure and such parties shall first have agreed not to disclose the relevant confidential

information to any other person for any purposes whatsoever.

Information Available

The restrictions shall not apply, or shall cease to apply, to any part of proprietary

information, specifically developed or acquired information for the setting up of this Plant or

trade secrets relating to owner’s business that

i) is in the public domain ; or

ii) was otherwise in the rightful possession of the contractor without any obligation to keep

such information confidential, at or prior to the time of the disclosure; or

iii) was obtained by the contractor in good faith from a third party entitled to disclosure it.

Disclosure required by Law

If the contractor is required by Law to disclose certain information in the document or

information supplied to it by the owner relating to the plant for execution of this contract, the

contractor must promptly give notice to and consult with the owner about the disclosure; and

use its reasonable endeavors to minimize any such disclosure.

Survival

The confidentiality contained herein shall survive the termination or expiry of this agreement.

Communication

All communications between owner and contractor shall be in English and the copies shall

be marked to owner’s engineer and contractor’s site in charge respectively.

REPRESENTATIONS AND WARRANTIES

Either party is not in default under any agreement to which it is party or by which it or its

property shall be bound, or in any material default of any obligation, which could have a

material adverse effect on the ability of the parties to perform their respective obligations

under this contract.

The parties shall execute and deliver all further documents and instruments, and provide

such further assistance that may be necessary or desirable in the reasonable opinion of

other party to carry out the provisions of this agreement or to effectuate the purpose or

intent of this contract.

Representation by the EPC Contractor

The contractor represents to the owner as an experienced EPC contractor with wide

exposure in such contract execution and has successfully completed plants of comparable

size in the past and has technical, commercial and financial resources with adequate in

house expertise and supporting manpower for undertaking the assignment.

The contractor guarantees and give warranty that the supplies shall conform to the

specifications ; all supplies be new, unused and shall be manufactured and produced from

materials of appropriate quality and meet the purpose, duty and operational requirements for

which they have been supplied throughout their life cycle exhibiting no defects, flaws, faults

and failures in use. The best available technology shall be utilized and latest industry

practices shall be followed for all supplies and their duties in operation.

The contractor undertakes to repair, rectify, replace as a part of its obligation the

machineries, components and equipments that are found to be faulty in design, poor in

workmanship, deficient in material of construction or such other which affect the operation,

safety or deliverance in any manner.

The contractor represents that all documents including invoices, billings, waivers,

certifications, releases, and reports submitted to owner, government agencies or bodies

constituted under law per this contract shall truly reflect the facts about the activities and

transactions to which they pertain and contain no material misstatements or omissions.

Contractor further represents that all of such documents and reports shall be complete and

accurate and understands that owner and other recipients will rely on those documents and

reports though acceptance of such reports and documents does not constitute the

agreement of owner with their contents.

CONTRACTOR’S DUTIES & OBLIGATIONS

WORK SCOPE

Works scope means the complete works to be undertaken by the contractor under the

contract including engineering, design, drawings, supplies of machineries, equipments,

components, assemblies to form the plant equipment at site meeting the specifications and

terms given in this document. It is inclusive of such engineering drawings and supplies

which are not specified in the documents or the contract but need to be done and supplied

for completion of the works in the contract.

Design Criteria

The contractor shall be responsible for the design of the plant and its detailed engineering

including auxiliaries, systems and all things within the battery limit barring exclusions,

agreed and acceptable to the owner, which are not in the work scope of the contractor. The

contractor has to ensure that the design conforms to and in line with the specifications given

in the document and the orders are placed on sub-contractors and the equipments and

machineries such as Boiler and Turbo generators, etc need to be designed conforming to

criteria laid down for it by corresponding regulatory/statutory body and need to be approved

by the inspectorate at Central / State level. Similarly for all such equipments, machineries

and components the contractor has to meet the design criteria and seek necessary

permission from the constituted bodies as required by law. The contractor shall promptly

communicate its plan, action and response from the government and other empowered

bodies for such permissions to the owner.

Engineering Documents

The contractor has to give the owner sets of engineering documents in the form of

Drawings, Manuals, Inspection Certificates, Test Repots and such others for the purpose of

furnishing information, ordering of components and equipments and dispatch to site etc.

These are to be furnished in as much detail as practicable as they form the basis for owner

to take a decision and should the information be not sufficient, the owner will ask for more

and detailed information. Design drawings will constitute a large portion of all documents

and shall need owner’s approval prior to ordering. Approval and acceptance of documents

or rejection / conditional approval giving reasons for modification, changes, incorporation /

deletion of items or any other shall be done by the owner within reasonable time and the

contractor shall be communicated action and return of documents with remarks wherever

applicable. The contractor shall furnish the schedule of supply of engineering documents

taking care to give sufficient slack time for their perusal and approval / instruction for further

action.

Technical Standards & Codes

The design, drawings, engineering documents need to conform to the technical standards

and codes applicable to them and acceptable to the owner and the authorities in the state of

location of the plant and India , dependent upon their respective regulatory bodies for

approvals, consents and no objections, need to be sought for the setting up of the plant. The

contractor shall plan out and furnish alongside each equipment / component the standards

and codes applicable to it and the equivalent followed in India and acceptable to concerned

authorities. The contractor shall initiate steps at appropriate time, observing the procedure

for filing application, furnishing information and data and making representations and

attending meetings for obtaining permissions in time. The contractor is deemed to be fully

aware of the statutory bodies, regulations, approval procedures and documentation required

for installation of different equipments and machineries forming the plant.

DRAWINGS

Submission of Drawings

The contractor shall submit all drawings, samples, patterns, models in numbers and form as

given in the schedule in the program for owner’s approval in writing. They will include all

such drawings under the engineering and supplies to the owner. The drawings shall be

drawn at a scale that make the drawings legible conforming to ISO/DIN standard and

dimensioned in the metric system and supplied in standard sizes. The contractor may use

some of non standard drawings for proprietary, patented and special drawings with prior

intimation to and permission by the owner.

Approval of Drawings

All drawings shall be submitted to the owner for approval. Those which need no approval,

the owner shall acknowledge and then it will be deemed to be approved. All approvals shall

be made on the drawing itself and the reasons for disapproval, conditional approval,

wherever applicable, shall be explained in sufficient detail in the covering letter with

reference to the drawing and be returned back to the contractor within a reasonable time. All

such drawings that need to be modified or corrected shall be done promptly and re-

submitted for approval. Delay due to disapproval of drawings shall be entirely to contractor’s

account. The contractor shall furnish to the owner three copies (1 original + 2 copies+1CD)

of each drawing for approvals.

Contractor’s Responsibility

The approval of drawings by the owner is in principle agreement to the basic concepts and

conformity to the contract requirements in general. It doesn’t dilute the contractor’s

responsibility in any manner. The contractor continues to be responsible for the

consequences of errors, discrepancies, omissions, disregard to site situations or oversight

of inaccuracies with regard to corresponding drawings for dovetailing and these shall be

considered to be contractor’s negligence and all consequences thereof shall be entirely to

contractor’s account. The contractor shall enjoy no relief for delay, remedial action or cost

incurred for alteration caused by its own mistake in preparation of drawings.

Use of Owner’s Drawings

The contractor will receive from the owner information including but not limited to the

drawings, specifications, technical data, design guidelines and clarifications during the

course of award and execution of this contract and the contractor shall develop

documentation based upon the information supplied as a part of performance under this

contract. All these receipts and developed documents shall be returned by the contractor on

completion of this contract and remains the property of the owner. Records of

communication and retention of documentation relating to proof of discharge of duties by the

contractor which shall be retained by the contractor shall be treated under confidentiality and

non-disclosure and survive for the period after completion of the contract and termination.

Drawings of Machines and Equipments

The contractor shall supply all the drawings which it prepared or obtained from suppliers

which will be required for the purpose of dismantling, assembly, maintenance, spares

ordering, troubleshooting or for such other purpose in future. The owner shall not demand

the drawings relating to manufacturing practices for the machines or those which are

proprietary in nature and can be reasonably assumed to be of no use for the machine or

equipment user.

Final Drawings

The contractor shall compile the whole set of drawings which truly represent the

machineries and equipments supplied and as built at site after the changes and

modifications they have undergone. The final plant layout and all other drawings on

completion shall be prepared and be furnished to the owner under the package “As Built

Drawings”.

Inspection and Testing

Test Observation

The contractor expressly offers and vests on the owner the right to access all information

relating to plant and machineries at its possession, inspect machines, equipments and

materials of construction at different stages of manufacture in contractor, sub-contractor and

supplier’s premises and examine and observe the tests. The contractor shall furnish the list

of scheduled tests well in advance to the owner for its preparedness to be present at the

place of testing on the appointed dates. The owner may communicate in writing to the

contractor to go ahead with the test(s) where its representative’s presence is waived for the

particular test(s). In such cases the contractor shall send the Inspection Report and Test

Results along with its observations promptly to the owner. Presence and deemed presence

of the owner in no way relieves the contractor from any of its obligations under this contract.

Testing, Retesting, Rejection and Acceptance

All tests irrespective of whether it is carried out at contractor or supplier’s premises, at the

approved laboratories as per contract or agreed between the owner and the contractor in

writing, the costs for all tests and re-tests not as part of OEM standards by client shall be

borne by the client in full. In case of failure to comply with the requirements as laid down for

testing and acceptance of the equipments and materials, retesting date shall be decided

between the owner and the contractor. The contractor has to submit to the owner a failure

investigation report giving reasons of failure and steps taken by it for eliminating recurrence

possibilities. All expenses for travel, accommodation etc. for the owner’s representative to

observe the retests shall be borne by the client .

Dispatch Advice

The observation of tests by the owner is a part of QA/QC program and shall be followed

scrupulously in all cases except where a waiver has been given by the owner. No material

or equipment shall be acceptable without proper inspection and acceptance of test results

by the owner prior to dispatch to site. The owner has to issue the dispatch advice based on

its inspection or deemed inspection (waiver) before any material is dispatched to site.

Material and items dispatched without dispatch advice shall be treated as rejected and shall

not be allowed to be warehoused at site.

Packing, Marking, Shipment and Receipt at Site

The contractor shall instruct its suppliers and vendors and take adequate care and

precaution in packaging of the materials and things for dispatch to site. Dependent on the

characteristics such as size, contour, material of construction, function and usage they are

to be packed to avoid any damage during loading, movement and unloading. The imports

are to be in seaworthy packing in containers and domestic supplies shall be able to

withstand transport by train or trucks. All materials are likely to be subject to multiple

handling, multi modal transportation, and storage could be in open during transit thus

exposed to heat, rainwater and site atmosphere. All the packages shall be clearly marked

for easy identification and must carry “Packing List” giving details such as order number,

name of the machine and components, pieces therein, part number, tag number, reference

drawing for the material, nature of the material (hazardous, toxic, inflammable), direction for

storage vertically and if any special care is to be taken during storage, opening of the boxes

and cases. The owner shall be informed well in advance and be intimated relevant

particulars of the consigned material. The contractor shall be fully responsible for all material

receipts including unloading, storage, inspection, completeness of materials as per

consignment and packing list, pilferage/ damage reporting if any. The ownership of all

materials at site is vested with the owner.

Manufacturing Defects and Workmanship

The contractor is responsible for design, engineering and supply of the machineries,

equipments and components for the plant and thereby it takes all steps to ensure that all its

supplies are free from manufacturing defects, conform to quality, workmanship, and

functional duties during the lifecycle. If any component or part of the machine or the plant is

found defective at any time before “take over” or deficient in operational deliverance than it

is meant for, so detected during commissioning, the contractor has to repair or replace the

component, machine or the system as the case may be at its cost and care.

Program

The contractor shall prepare and submit the program to the owner for approval,

immediately after receipt of LOI. The program duly approved with agreed changes and

modifications within the time stated in the contract shall be submitted to the owner as a part

of the Letter of Acceptance by the contractor. The time schedules are to be clearly worked

out to fit into the program for engineering and supply of the items at site. The contractor

shall carry out all home office work diligently for design of the plant and backend tie ups for

timely supply of machineries and equipments queuing them in a logical manner. The

contractor has to ensure that the design is fully integrated and compatible amongst various

supplies and properly dovetailed for operational modes and report generation and meet the

requirements laid down by the owner in technical specifications in bid documents. The

contractor’s program shall give a detailed time schedule for design works in the program

enlisting sub-contractor/vendor’s name against each item that is outsourced. The program

shall demarcate and describe all parallel and sequential activities, schedules of start and

finish and overall project activities within the completion date. The program shall

incorporate the indicative features given as under. The central idea of formulating the

program is to identify all the activities as accurately as practical at the stage of award of the

contract, highlight the critical path to prepare well in advance for avoidance of delays in

completion of the works and have a monitoring and remedial mechanism in place to ensure

that the progress is maintained at the estimated pace and unforeseen events could be

accommodated without affecting the overall schedule.

The contractor shall prepare and submit PERT chart and shall update it every

fortnightly so as to monitor the progress of work.

Sequence of Works

The following activities are the indicative list of main activities to be included in the

program, and each shall have a number of sub activities to be elaborated by the contractor

in the critical path network: -

a) Plant design criteria, detailed engineering, preparation of design, specifications,

documents and datasheets for manufacturing, ordering and procurement.

b) Progressive submission of drawings for approval in the sequence as shall be

required to be used.

c) Placement of orders with sub-contractors and suppliers, particularly for Boilers,

Upper and lower drums, Pressure and non pressure parts, Turbine generators and

their Auxiliaries.

d) Inspection, testing and acceptance of all imported and indigenous, various

machineries and equipments.

e) Submission of technical information, P & ID data, calculations, various drawings,

manuals, manufacturer / supplier drawings to the owner.

f) Owner’s approval and generation of dispatch advice of machineries, equipments

and materials for shipping of site.

g) Site receipt of machineries, equipments and components in groups as they will be

assembled / erected / integrated.

Project Milestones and Monitoring

The contractor shall prepare and submit pert chart including all the activities and

shall upgrade it every fortnightly for monitoring the day to day progress of the work.

The program submitted by the contractor and approved by the owner shall have distinct

milestones to achieve which are to be monitored on agreed periodicity basis to make up for

the small delays if any. The monitoring process is to be internalized such that activities lend

themselves for full attention and immediate measures for their completion and the overall

monitoring process quickly pinpoints to bottlenecks in terms of lack of resources, co-

ordination, impractical time estimation and the like which could be adequately reinforced to

match the schedules time. Should the contractor anticipate a delay in completing any

activity with or without impact on milestones for whatever reasons, it need to communicate

to the owner in writing as soon as it realizes such events and open a dialogue for

containment or reducing its impact on the schedules.

Cash Flow

The contractor has to prepare and submit a chart showing the major activities on a

timescale with milestones and the attributes that fulfill achievement of the milestones in

each case for drawdown, that is payments for the works as laid down in payment schedule

of the contract. The cash flow shall conform to the program items and milestones of works

progress. Such requirements for payment could be verification of engineering works done

or receipt of materials at site duly certified by the owner’s engineer, receipt of invoice from

the contractor and physical verification, proof of placement of orders on suppliers and

vendors, submission of bank guarantee for the amount and in the format if required for the

particular trench of payment and such others. Fulfillment of all of these requirements is

necessary for disbursements of each trench of payment as laid down in the contract.

Legal Obligations

The contract shall be drawn with express understanding and full compliance to the

prevailing law of India and the provisions thereof, acts and statutory requirements and

compliance to them as may be required for the execution of the contract. The contractor

shall do all works as permitted by law and shall seek consents, permissions, approvals, no-

objection certificates, licenses or other instruments as may be required for carrying out the

obligations under this contract, which may involve imported supply of capital goods and

materials and design services carried outside the country. The contractor shall declare

them to the authorities wherever required and pay fee to the Central and State

Governments and /or the legally constituted bodies as the case may be for performance of

the contract. The contractor shall make itself fully conversant with these requirements as

applicable to power plants having equipments and machineries which are to be designed

to meet the standards laid down by corresponding bodies and have to seek permission and

use permitted equipments for generation of electricity. All the information and drawings

shall be submitted to government departments / statutory / regulatory bodies and prior

permission shall be taken as needed before manufacture / installation / operation as the

case may be. Should there be any violation, deliberate or due to lack of knowledge and

understanding of the statutes, regulations and law, the contractor shall be solely

responsible for actions that might be taken by the bodies including penalty, imprisonment,

stoppage of work or any other and delay or any adverse impact it could have on the

project. Should the owner as principal employer be held responsible the eyes of law, the

contractor shall be made responsible and shall compensate for all things, expenses and

project related losses under this contract?

Ownership of Supplies and Plant

The ownership of all goods shipped to the site after receipt of approved dispatch advice

from the owner shall be vested with the owner on ex-works dispatch. The plant supplies

received at site and stored in warehouse shall be in the care and possession of the

contractor for the limited purpose and shall be within the ownership of the owner.

DELIVERABLES & DELAYS

Commencement of Work

The Contractor shall start the works under this contact on receipt of Letter of Award with

Advance payment as per payment terms . The owner shall ensure that all conditions

precedent is fulfilled and the contractor is communicated to enable him to start work on

receipt of LOA. The contractor’s deliverables shall be in terms of design drawings and

machineries and materials at site. All works relating to them must start and be completed in

a structured manner as given in the timescales of the program..

Time for Completion

The Time for completion under this contract shall mean that the drawings are supplied and

the materials and things be made available at site in time as per the program. Keeping in

view the whole of the works, the contractor shall so execute the works that no delay is

caused in commencement of works under other related contracts due to delay in

completion of any of the activities in this contract. The completion time is 18 months from

the date of receipt of first advance. The Contractor’s completion of its Works shall be

considered delayed if the date of the commissioning events goes beyond the

predetermined date calculated from the commencement date, unless otherwise time

extensions provisions are applicable. The completion time shall be strictly adhered to the

supply schedules in the agreed sequence that will enable erection in an orderly way, first

arrivals being required and used first by the erector. Delay in erection and commissioning

shall be attributed to supply delays and shall be subject to Penalty Clauses by the owner

under such conditions which may be enforceable.

Time Extension

Extraneous Circumstances

The time of completion can be extended for extraneous circumstances beyond the control

of both the parties provided both take cognizance of it and mutually agree to extend the

period by certain number of days and record the same with due regard to change in pricing

and shift in schedules.

The same to be agreed to in writings by both parties.

Impact of Variation

The owner have the right to add, delete, alter, modify and thereby direct the contractor for

material changes in the contract, which shall be carried out under “Variations”. The

variations shall have impact on time and cost on the contract in force. The contractor shall

assess them and submit the “Variation Note” with full details justifying additional time and

cost requirement (unless this could be done during slack period and not impacting the

critical path in the network). The owner shall issue change order with amended PO for

additional price and permit additional / reduced time for completion dependent upon nature

of work and thus the time extension shall not be construed as “Delay under this Contract”.

Delays and Penalties

Delay in Completion

The contractor’s program clearly sets out the schedules and thus any delays, lapses or

failure to any of the actions shall be considered as delay. In order to correlate the delay

with the events of consequence, that is to say the commissioning of the plant if delayed,

the contractor has to pay a penalty as detailed out under penalty clauses in this document.

This is independent of the penalties applicable on account of delay under other contracts

for the facility. This does not mean in any manner that the contractor shall get any relief

whatsoever for failure of delays for its supply of deliverables as set out in the program. The

contractor is deemed to have made itself fully aware of the processes and time demands

for approvals and consents for various items that will be supplied for the plant and transport

logistics and transit times for machineries to reach the site. These are consciously

considered in the program and any stretched periods on these accounts shall not be

considered to have caused delay in completion.

TERMINATION

In case there are reasons for the owner to believe that the contractor is not carrying out the

obligations the way it is intended during the award and may cause delay in completion,

poor performance of the plant, the plant may not meet the acceptance criteria for “Take

Over” or unforeseen situations arise during the contract period which shall not permit the

contractor in discharge of its duties and obligations under this contract. In such situations

the owner may initiate steps for correction or termination of the contract.

Effect of termination

The owner shall utilize the services of owner’s engineer and external experts to assess the

value for completion of works comprising of balance of engineering and supplies under this

contract after terminating the contract. The balance scope of work may be awarded to

another contractor after the owner terminates the contract and the works may be

completed. The owner is entitled to utilize the documents, equipment supplies and any

other prepared, furnished, supplied by the contractor under this contract. The contractor’s

equipments shall be returned on as is where is basis on or after scheduled “Date of

Completion”.

Payments on Termination

The owner shall not be liable to make any payments to the contractor on termination. The

costs of design, supply, completion, rectification of defects, replacement of defective

components and all other costs incurred and to be incurred by the owner for completion of

works of the plant are to be assessed and reasonably established by an agency competent

to do this task. Should the contract value as assessed and penalties as applicable be

higher than originally estimated for completion of the project the owner shall be entitled to

recover additional cost under the scope of this contract. In case of Bankruptcy and

Insolvency, the owner shall serve notice to the receiver or administrator or to the person

responsible and designated for the claims.

PERFORMANCE GUARANTEE

Performance Guarantee Test

The contractor is obliged to demonstrate that its design and supplies of the plant meet the

various enlisted output and consumption guarantees for the plant, machinery and

equipment and are in compliance with the terms of performance and shall operate to

deliver the power output as guaranteed and meet the operational parameters as

guaranteed during the prescribed test detailed out in Technical Specifications under the

supervision of Operational and maintenance provided by client . The test shall be carried

out after the plant is commissioned and entered the stable operation regime. The

contractor shall notify to the owner three weeks in advance or earlier, its intention for

conducting the test starting on a specific day. The test shall be carried out in presence of

the owner in accordance with the procedures and under specified operating conditions and

all measurements and observations shall be noted jointly by the representatives of the

owner and the contractor. The contractor shall be in full control and command of the plant

during the test period. The inputs parameters as committed by client for fuel and water

shall be strictly adhered . The client shall also provide the operation and maintenance staff

during the performance test.

Postponement and Cessation of the Test

The owner may defer the date of test on reasonable grounds and fix a new date

acceptable to the contractor for carrying out the test. The owner is entitled to intervene and

order stoppage before completion of the test, if it considers that the test may jeopardize

safety of operating personnel or cause damage to the plant or so directed by the

transmission utility for other reasons.

Repeat Tests

The contractor can ask for and be permitted by the owner for re-testing after the cessation

of earlier test or failure to meet the guaranteed level of power output and parameters, one

or more of them. The contractor shall be able to justify why the guaranteed values could

not be attained during the last attempt and what refinements and adjustments have been

made to achieve them this time. The contractor shall be allowed to carry out not more than

ten tests / three retests excluding incomplete tests which could be solely attributed to

owner or external circumstances and not later than one year from the commissioning date.

Rejection of the Plant

Criteria for Rejection

If the contractor fails to achieve all the guaranteed values during the test or repetition

thereof, totaling on three different retest occasions, it will be deemed to have failed in the

“Performance Guarantee Test” and the set of values in the best of the tests as acceptable

to the owner and contractor shall be recorded as the values for the test and accordingly

penalty clauses be applicable and penalty money shall be recovered. This provision shall

be applicable as per the contract terms only if the plant does not get rejected due to non

compliance of other conditions or the value(s) of parameter(s) shoot beyond the

acceptable limits making the plant liable to rejection by the owner. The criteria for rejection

of the plant are to be read as individual conditions and as a set of conditions taking into

consideration all parameters in the overall context.

The plant shall be operable at full load or at a plant load level acceptable to the owner for a

continuous period not less than 15 days or fully stable 72 hours with adequate fuel

storages prior to undertaking the tests and during the reliability run all equipments and

systems of the plant exhibit their robustness, capacity, accuracy, reliability and functional

deliverance in a continuous operation without failures and deficiencies irrespective of the

extraneous factors and external conditions.

1. During the Performance Test the Plant Capacity at full load is less than 95 per cent

of the guaranteed output value.

2. The Gross Plant Heat Rate exceeds 5 per cent of the Guaranteed Value.

3. Auxiliary Power Consumption for the Plant exceed 10 Per cent of the value

guaranteed.

4. TG Vibration exceeding the permissible limit.

5. Noise Decibels exceeding the permissible levels as mutually agreed.

6. Particulate Emission higher than allowed by Pollution Control Board of the State or

any other statutory Body responsible for it.

7. Stack emission of NOx & Sox beyond permissible limits.

8. Any other restrictions and limits to be complied with for any other parameters as

stipulated in technical specification and / or were in force at the time of Tender

Submission.

Notice of Rejection

Should the contractor fail to establish the Guaranteed Values during the Performance

Testing (the value or value going beyond the acceptable limits) and other values relating to

machine vibrations, noise level containment, environmental compliance etc.(indicating

values not acceptable to the owner as per the contract ) after the contractor has availed

the opportunities the number of times as owner is obliged to permit within the period as per

contract to conduct tests and observe other values during stabilization regime, the owner

reserves the right to notify the contractor rejecting the entire plant or a part of it as

reasonably justified. The rejection so done have deeper implications namely (i) the plant

not being allowed by the authorities for commercial operation if certain norms such as

environmental compliance are not met (ii) the operational norms such as “Heat rate” going

beyond the acceptable band renders the plant commercially unviable for power generation

and sale.

Remedial Measures & Adjustments

The owner retains the right to reject the entire plant and take remedial measures of its own

thru another contractor, and the previous contractor shall have the obligation to pay all

costs incurred for it and the delay caused by it for failing to meet the guaranteed values

within the acceptable band. The owner retains the option to open the dialogue after service

of notice and ask the contractor to submit a proposal detailing out the remedial measures

in a time bound program within the scheduled warranty period for adjustments,

replacements, changes, modifications, retrofits and measures that could bring the

parameters within the tolerance range. Acceptance of the proposal of the contractor does

not release it from any of its duties and responsibilities under the contract. During the

period of rectification and adjustment no payment shall be due and all costs are to be

borne by the contractor for the remedy. The liquidated damages for late completion and

any other penalty as laid down shall be applicable. On completion of the rectification and

modifications the contractor shall be required to undertake performance test and prove that

all the

parameters are within acceptable limit and should there be any shortfall penalty for that

portion shall apply. All other obligations of the contractor as laid down in the document after

performance testing shall follow in full force. In case of failure this time around after all

efforts, the entire plant shall stand rejected and the contractor has to replace it as per the

revised program acceptable to the owner.

Owner’s Option to Operate

The owner has the right and option to operate the plant with temporary measures that

might enable it to get permission of the authorities in case the statutory requirements are

not met during the test. For other conditions in terms of shortfalls from the guaranteed

values and faulty or deficient equipment installations, the owner may decide to operate the

plant as it is while the contractor undertakes remedial measures and replacements. Such

provisional operation regime doesn’t dilute the responsibilities and duties, obligations and

penalties in any manner and it has to undertake the works as per the contract as if such

operation does have no impact on any aspect of the contract. This overrides the Clause

12.2 and doesn’t mean the take-over of the plant, pending “Performance Guarantee Test”.

TAKE OVER OF THE PLANT

Contract Conditions Fulfilled

The contractor may notify to the owner for “Take-over” of the plant provided the mechanical

completion of the plant has been done, all defective and deficient parts and components

have been replaced, performance test has been successfully done and no outstanding

work is pending and the plant is on normal running mode in the operation regime and the

contractor has fulfilled all its obligations. The owner has to examine all aspects of the

contract works and satisfy itself that all works including outstanding works have been done

to its satisfaction and nothing is pending and accordingly arrange for take over which shall

not be unreasonably delayed.

Taking Over Certificate

Upon issue of the certificate, the owner acknowledges and certifies that all obligations on

the date of issue of certificate have been satisfactorily discharged by the contractor and it is

taking over the risk of operational regime, other than those coming under warranty and

latent defects. Only in the exceptional case of failure of performance test, the owner can

operate the plant without taking over as described in clause 12.4

DEFECT LIABILITY

Warranty Period

The period shall be for duration of fifteen (15) months from the date of respective supply

starting from that date for a period of twelve (12) months from date of commissioning of the

plant by the contractor, whichever is later. The warranty period shall mean the period when

the contractor is obliged to make good the defects at its care and cost.

Making Good the Defects

Upon mechanical completion and successful commissioning of the plant, the contractor

guarantees that the plant is complete in all respects as per contract and ensures sound

functioning of all systems and stable, trouble free operation of the plant. Should there be

any defect or deficiency in any part, component, machinery, equipment, system of the

plant, the contractor shall be responsible for taking appropriate remedial measure like

replacement, repair, modification, correction or any other during the “Defect Liability or

Warranty Period”.

Owner’s doing the Needful

If the omission or defects are not attended to and appropriately rectified by the contractor

within reasonable time and in owner’s opinion with prior written notice to contractor and

receiving the acceptance of same from contractor that it affects the operation of the plant or

poses potential threat to life and safety of the personnel, it can undertake the work thru

another contractor at the risk and cost of the previous contractor. The money could be

recovered from the bills or bank guarantee, if not paid directly within 30 days from

presentation of invoice to the contractor.

Latent Defect Liability

The Latent Defect Liability Period shall be the period of 60 months counted from the take-

over of the plant by the owner. If any defect or failure mode due to fatigue or sub standard

material unfit for the kind of application in operation is detected or diagnosed within this

period, it shall be made good by the contractor by repair, replacement or any other method,

provided that such defects would not have been detected in short period of operation or

disclosed by reasonable examination during warranty period. Such defects and problems

could also arise from faults in design, negligence during manufacture and disregard during

shop inspection and testing.

FORCE MAJEURE

Force Majeure shall mean any event or circumstance or combination of events or

circumstances set out below that materially and adversely affects the contractor in the

performance of its obligations in accordance with the terms of this contract, but only if and

to the extent that such events and circumstances are not within the contractor’s reasonable

control, and/or the effects of which it could not have prevented through prudent business

practices or, through reasonable skill and care, including through the expenditure of

reasonable sums of money.

DISPUTE RESOLUTION / ARBITRATION

Dispute

Should there be a dispute on any matter, the owner and the contractor shall make their

best efforts to resolve between themselves failing which the parties can resolve in

accordance with the provisions of Arbitration and Reconciliation Act 1996. The seat of

arbitration shall be at Kolkata and the governing law shall be that of Republic of India.

Language

The language of the arbitration shall be English.

CONTRACTOR’S DUTIES & OBLIGATIONS

WORKSCOPE

Work scope means the complete works to be undertaken by the contractor in this contract

including unpacking and destuffing of material and equipment cases and boxes, checking

as per packing list, safe warehousing in an orderly manner, transport / lifting and putting in

place the machines/equipment in a safe manner, (strictly following the manufacturer /

supplier’s instructions and field construction manual and drawings), assembling, firmly

putting supports/foundation bolts etc., interconnecting to other systems. On mechanical

completion the plant is to be tested section by section and the startup be taken up and the

plant is to be successfully commissioned for continuous run. It is inclusive of such

engineering drawings and supplies which are not specified in the documents or the

contract but need to be done, to be used or to be supplied for performance ad discharge of

duties and obligations under this contract.

STANDARD OF PERFORMANCE

The contractor shall be responsible for the execution of that part of the plant and its

detailed engineering under this contract that relate to Erection, Testing and Commissioning

including allied minor constructions, steel fabrications, assemblies, and things within the

battery limit barring exclusions, which are not in the works cope of the contractor. The

contractor has to ensure that the erections, constructions and abdications conform to and

in line with the specifications given in the document and the orders are placed on sub-

contractors and vendors who have been named for such work are to be pre-approved by

the owner prior to placement of orders.

The contractor shall exercise care, skill and diligence and utilize its experience and

expertise to perform to the highest standards of industry benchmark. It acknowledges that

the equipments and machineries that will be used at site shall conform to their use for the

purpose and handled by skilled people and those licensed to handle them, if so applicable.

Similarly for all such equipments, machineries and components the contractor has to meet

the criteria and seek necessary permission from the constituted bodies if so required by

law.

ACCESS AND FACILITY AT SITE

The owner shall give the contractor unobstructed and non exclusive access to site. The

owner shall assist to the extent that whatever declarations and endorsements are to be

made, it will do so when requested within reasonable time without incurring high costs for

the purpose. The responsibility for complying with government requirements is in the scope

of the contractor. It will arrange for permissions and approvals for carrying out works at

site. This will include accommodation of its minimum number of personnel at site, use of

cranes /hoists, lifting machines etc., steel fabrication and welding machines, workshop with

facilities for doing a host of jobs, storage of materials and wherever required, seek and

have in possession permissions and approvals for the ongoing work requirements. The

work shall be executed in the manner set out in the specifications and as required by

relevant rules and regulations.

TECHNICAL STANDARDS & CODES

The field drawings and documents need to conform to the technical standards and codes

applicable to them and acceptable to the owner and the authorities in the State of Madhya

Pradesh and India, .dependent upon the respective statutory regulatory bodies who have

the jurisdiction on them and competent authority to give approvals, consents and no

objections, need to be sought for the setting up of the plant. The contractor shall initiate

steps at appropriate time, observing the procedure for filing application, furnishing

information and data and making representations and attending meetings when called, for

obtaining permissions in time. The contractor is deemed to be fully aware of the statutory

bodies, regulations, approval procedures and documentation required for installation of

different equipments and machineries forming the plant.

FINAL PLANT DRAWING

The contractor shall compile the whole set of drawings which truly represent the layout and

erections at site after the changes and modifications they have undergone respecting the

site conditions and amends made during the course of work. The final plant layout and all

other drawings under the contract on completion shall be prepared and be furnished to the

owner under the package “As Built Drawings”.

The contractor shall submit three copies (1 original + 2 copies+1CD) Drawings” to the

Owner.

PROGRAMME

The contractor shall prepare and submit the Master Program to the owner for approval,

immediately after receipt of LOI. The program duly approved with agreed changes and

modifications within the time stated in the contract shall be submitted to the owner as a part

of the Letter of Acceptance by the contractor. The time schedules are to be clearly worked

out to fit into the program for completion of Erection, Interconnection, Mechanical

Completion of all sections and systems, Testing section by section and rectification, Startup

and Commissioning of the Plant to its rated capacity. The owner shall not be involved nor

the contractor has the right to bind the owner in any contractual obligations or discharge of

duties arising out of contractor’s transactions for performance of the contract. The central

idea of formulating the program is to identify all activities as accurately as practical at the

stage of award of the contract and tie it up with other activities outside the scope of this

contract. The sequencing of the activities and organizing parallel activities shall highlight the

critical path to prepare well in advance for avoidance of delays in completion of the works

and enable to evolve a monitoring and remedial mechanism in place to ensure that the

progress is maintained at the estimated pace and unforeseen events (change orders) could

be accommodated without affecting the overall schedule. Various schedules are to be

drawn up and be submitted to the owner for approval keeping in view the logistics and

timelines to complete the set of activities and works per below mentioned schedules.

Mobilization

Manpower Loading Schedules

Sub Contracting Schedule

Erection Schedule

Section wise Test Schedule

Plant Start up Schedule

Commissioning

Cash Flow.

DOCUMENTATION & REPORTING

The contractor shall prepare, keep and report on all important matters including the

following: -

Keep accurate and detailed written records of the of the progress of works at site during all

stages of erection and submit periodic written progress reports as frequently as decided by

Owner/OE which shall include information concerning the completion of percentage of work,

planned vs. actual work carried out and work planned for the next period in a format to be

prepared by the contractor and approved by the owner.

Maintain a daily log of all erection works in detail including activities like destuffing, moving

to site, putting on to foundation, interconnecting with other machines and systems for

monitor progress of Works.

Take video photos on a regular basis as an authentic record of physical progress and they

be included in relevant reports. All photos, negatives and videos are deemed owner’s

property and covered under confidentiality.

All changes, notices from Owner/OE, inventories, working personnel attendance records etc

must be updated on daily basis and be available with supervisor of the site office for

inspection by Owner/OE at all times.

ERECTION WORKS PROGRESS AND MONITORING

The erection works progress review and monitoring is to be organized by the contractor and

Owner/OE shall attend it and the objective shall be to take remedial measures for

maintaining and accelerating speed and do the troubleshooting. The contractor has to do

the following:-

Organize and attend monthly review meetings to assess progress during the month in

construction activities and review problem areas.

Identify possible problems and delays that may arise in immediate future to appraise the

Owner/OE for contemplating timely action.

Review the material receipts, inventories, preparation for meeting next week / month’s

planned work in a systematic and planned way to take action.

Implementation and effectiveness of current QC/QA Plan and measures to reinforce it.

The contractor has to give access to Owner/OE to visit and observe all onsite works in

progress and compliance with relevant rules and regulations and any action that is required

to be taken per observation of the owner shall be complied without delay.

The contractor has to take action on all changes /variations on receiving written advice from

the Owner/OE, whether the valuation has been done or not and appraise plan and progress

thereon to the Owner/OE.

The owner shall give feedback on the status of invoices, monies disbursed and Bi Monthly

Reports of the contractor.

An overview shall be made regarding availability of the drawings and documents to the

owner and contractor, one to the other as per this contract; observations and comments on

housekeeping, material receipt and warehousing, workmen safety and security, traffic

intensity, preparedness for meeting emergencies at site etc.

The ownership of all goods shipped to the site, warehoused, erected, in transit shall be in

the care of the contractor for the limited purpose and shall be within the ownership of the

owner.

WORKMEN AT SITE

Compliance

The contractor shall fulfill all conditions involving employment of labor at site including

compliance with laws, acts and local requirements. All the records and permissions are

available at site for inspection and verification.

Wages and Conditions

The contractor shall pay rates of wages and observe conditions of labor which are as good

as general levels of wages and conditions in the area of site for similar work. In case the

Minimum Wages Act is applicable, the contractor shall pay a level higher than as required.

Personnel Safety

The personnel working at site must use safety appliances and observe safe working

conditions at all times.

Site Accommodation

Housing shall be provided by the contractor at site to those minimum number of staff and

labour whose presence round the clock is considered necessary for emergencies or for

proper deployment for continuation of work. It is contractor’s responsibility for construction of

temporary accommodation and amenities on the Site without violating any rules, acts or

conditions imposed by local government.

Health and Safety

The contractor shall take due precautions at its own cost and ensure that adequate

measures are in place for first aid, ambulance, doctor on call at all times throughout the term

of this contract. Suitable arrangements are made for the prevention of epidemic and for all

necessary welfare and hygiene requirements.

Site Facilities

The contractor shall make adequate and suitable arrangements at Site for drinking water,

washing and bathing place, latrines and urinals, disposal of excreta, rest shelters, crèches,

canteen etc and maintain desirable cleanliness and hygiene at the Site.

Disorderly Conduct

The contractor shall take all reasonable precautions to prevent any unlawful or disorderly

conduct by or amongst staff and labor. Should such things be observed or reported to the

Owner/OE, the persons indulging in quarrelling, disturbing others or pose threat to

preservation of peace, they shall be made to vacate the premises by the contractor.

Reporting of Accidents

The contractor shall report to the owner details of accidents as soon as possible after the

occurrence and take immediate measures for treatment without loss of time.

DEFINITION OF TERMS

OWNER - refers to M/s. RAJSHREE POWER

EPC CONTRACTOR - refers to M/s. ASTER TELESERVICES PVT. LTD.

OWNER’S REPRESENTATIVES

The Owner shall nominate an Officer to represent him for the purpose of this project and will

notify the EPC Contractor accordingly.