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New Generation
Super Efficient, Energy Conserving &
Eco-sustainable Solutions for WHR in
Cement Plants
1
www.tespl.com
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Group companies
Company Name Business
Transparent Energy Systems Pvt. Ltd.
www.tespl.com
Waste Heat Recovery
Systems
Transparent Technologies Pvt. Ltd.
www.ttpl.co.in
Industrial Dryers, Flue
Gas Desulphurization
Systems etc
Transparent Pollution Control Pvt. Ltd.
www.transpol.co.inAir Pollution Control
Decimin Control Systems Pvt Ltd
www.decimin.comNoise Abatement
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Innovative Solutions for Cement
Industries.
• Waste Heat Recovery Systems
• FGD Plants for SOx removal and Gypsum making
• Wet Fly Ash Drying Plants
• Waste Water Recycling Plants
• Bag Filter
• Coal Dryer
• New Generation Captive Power Plants
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• Pioneers in WHRS in cement plants.
• 11 WHRS Projects completed within 10 years – 2006-2016.
• More than 30 WHR Boilers installed in 11 projects
• Total installed capacity – 80 MW
• In-house R&D center with IP base of more than 40 patents
• Manufacturing facility with IBR, ASME and EN certifications
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Award from DSIR
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Award from SIEMENS
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WHR Schemes Implemented
• Steam Rankine Cycle Power Plant
• Organic Rankine Cycle Power Plant (ORC)
• Steam Rankine Cycle with Co-firing
• Heat Injection into Captive Power Plant
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Ultratech Cement Ltd., Tadipatri,
�Organic Rankine Cycle Power Plant
�Clinker Production – 2.5 Million TPA
�Source – Clinker Cooler
�Gross Power Generation – 4 MW
�Air cooled condensing
�Commissioned – March 2007
Note – WHR system supplied by TESPL to client & Organic Power Generator
sourced by client directly from ORC supplier
TESPL’s Experiences (cement WHR)
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The KCP Ltd., Macherla, AP
�Steam Rankine Cycle Power Plant
�Clinker Production – 0.5 Million TPA
�Source – Preheater and
Clinker
Cooler
�Gross Power Generation – 2.3 MW
�Water cooled condensing
�Commissioned – April 2007
TESPL’s Experiences (cement WHR)
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Shree Cement Ltd., Beawar, Rajastan
Project - I
� Steam Rankine Cycle Power Plant
� Clinker Production – 1 Million TPA
� Source – Preheater
� Gross power generation – 5 MW
� Water cooled condensing
� Commissioned – March 2008
TESPL’s Experiences (cement WHR)
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Shree Cement Ltd., Beawar, Rajastan
Project – II
�Steam Rankine Cycle Power Plant
� Clinker Production – Kiln – 1 : 1 Million TPA
Kiln – 2 : 1.5 Million TPA
� Source – Preheaters & Clinker Coolers
� Gross power
generation – 13.2 MW on waste heat from
cement plant
& 3.0 MW on heat from other
sources
Total 16.2 MW
� Air cooled condensing
� Status : Commissioned June 2010
TESPL’s Experiences (cement WHR)
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Ultratech Cement Ltd. Awarpur, MH
�Steam Rankine Cycle Power Plant
� Clinker Production – Kiln 1 – 1.30 Million TPA
Kiln 2 – 1.53 Million TPA
� Source – Preheaters and Clinker Coolers
� Gross power generation – 13.22 MW
� Air cooled condensing
� Status : commissioned on April 2014
TESPL’s Experiences (cement WHR)
13/6/2016
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HOLCIM Rozonik – Slovakia
�Organic Rankine Cycle Power Plant
�Clinker Production – 1 Million TPA
�Source – Preheater and Clinker Cooler
�Gross Power Generation – 5 MW
�Water cooled condensing
�Status : commissioned on Sept 2013
TESPL’s Experiences (cement WHR)
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Aditya Cement (Line III) – 6.5 MW
TESPL’s Experiences (cement WHR)
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Critical Review of Waste Heat
Recovery Projects
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Need for Review –
1. Unsustainable Prices
2. Cost overruns and delays in execution
3. Performance Variations
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Critical Review of WHR Power Projects
• Most of the BUYERS in past had procured
Captive Power Plant under EPC contracts.
• There was natural preference to order the
WHR Power plant on the same EPC basis.
• However the WHR power plants were much
more complex as compared to a CPP.
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Critical Review of WHR Power Projects
• Each WHR Power plant is tailor made and
has complexities –
� Integration with process
� Execution is a running plant
� Layouts undergo change during execution
� Uncertainties on various cost heads
� Unanticipated delays in execution
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Critical Review of WHR Power Projects
• Most of the over-eager bidders either
overlooked these complexities or were
too inexperienced to anticipate the
complexities.
• Such bidders offered the prices that did
not provide for any of these
complexities and uncertainties.
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Critical Review of WHR Power Projects
• The BUYER had a compulsive
preference for L1 bidder, with a belief
that –
“Once locked in legally enforceable fixed
price contract, the vendor has no
escape but to complete the project
whether affordable or not.”
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Critical Review of WHR Power Projects
• The BUYER’s compulsive preference for
L1 bidder, forced even experienced
bidders to make unsustainable
compromise on price to at least stay in
business.
• The BUYER could thus draw a
satisfaction of having made a
competitive procurement contract.
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Critical Review of WHR Power Projects
• The experienced players having long term
interest patiently tolerated cost over runs,
but completed the projects.
• The inexperienced players with no long term
vision abandoned the projects half way,
forcing BUYERS to complete the project by
themselves with heavy cost over run and
inordinate delays.
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Critical Review of WHR Power Projects
• The loss of projected savings due to
delayed projects proved to be much
higher than the satisfaction of
competitive procurement.
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Critical Review of WHR Power Projects
Performance Variations –
1. Variance in actual exhaust gas parameters
2. Absence of online measurement performance
monitoring instrumentation.
3. Absence of a Standardized Performance Test
Procedure
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Critical Review of WHR Power Projects
Fundamental decisions for next WHR
Power Projects for each BUYER –
• Is EPC Model of Procurement really most
beneficial?
• Does the policy of compulsive preference for
L1 Bidder needs a review?
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New Generation WHR Plants
• Improve the accuracy of cost estimation before entering into firm price contract
• Thorough planning for imely project completion.
• Provide facility for online measurement of all vital parameters.
•Evolve a Performance Test Procedure based on a universally accepted standard.
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New Generation WHR Projects in Cement Plants
27
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Prominent Features of New Generation WHR Projects in Cement Plants
28
13/6/2016
•Three Phase Execution Methodology
•Online Real time measurement & logging of Vital process parameters
•Innovative Mid Tap Control System.
•Steam Dryness improvement at Super-heater Inlet
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EPC Business Methodology for Successful Projects
Project is divided in Critical Phases of the project with milestones for both EPC / Managed EPC Contract
▪Phase -1 : System Optimization, Detailed Engineering, Accurate Project Cost Estimation,
▪Phase -2 : Actual Procurement
▪Phase -3 : Site Activities, Erection & Commissioning, Performance Trials
29
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Phase -1 Activities
•Work jointly with End User
•Conceptual Engineering & System Optimization
•Facility planning
•Performance test procedure
•Real time on line recording of all vital input-output
parameters at different locations in the system
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Phase -1 Activities
•G.A. Drawings / Layouts, P+I diagrams.
•Engineering Specifications / BOM / BOQ.
•Detailed engineering.
•BOM / BOQ / Material costs / Fabrication costs.
•Packing & forwarding transport.
•Unloading / shifting to foundation / site work / cabling /
insulation, piping, structural etc.
31
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Advantages of Phase-1
•Finally reach a stage in Phase-I where in Accurate Cost Estimation is possible for procurement process to be initiated.
•This eliminates surprises with reference to quantity & specifications of materials, their costs, project schedules etc.
•Performance Test Procedures are also prescribed. – No Disputes related to Input & Output parameters.
32
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Phase – 2 Procurement Activities
1. Waste Heat Recovery Boiler
2. Steam Turbine Generator Module
3. Air Cooled Condenser
4. Balance of Plant
5. Site Work (including Civil Work)
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Phase – 3 Activities
•Site Work Management
• Commissioning
• Performance trials
•Trouble shooting & Warrantee Services
• Post warrantee services
34
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Performance –Assurance and Monitoring
•Online Real-time Flue Gas Flow Measurement
•Online Real Time Dust Measurement System
•Dual Mid Tap Control System
•Steam Dryness improvement at Super-heater Inlet
35
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Measurement of Vital Parameters
•Online Real-time Flue Gas Flow Measurement
▪One of the most important parameter in Validation of WHR Project Performance.
▪Indirect method for Flue Gas Flow measurement is recommended by ASME-PTC-4.4 and it is universally accepted
▪The new generation WHR from TESPL will include a separate elaborate system to measure the online and real-time flue gas flow rates by indirect method.
36
13/6/2016
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Measurement of Vital Parameters
• Online Real Time Dust Measurement System
▪One of the most important parameter in Validation of WHR ProjectPerformance.
▪The Dust Content in Flue gas may affect WHR System Performance.
▪New generation WHR Project from TESPL will include online dust measurement system.
▪TESPL has applied for the Patent for online dust measurement system.
37
13/6/2016
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Innovative Mid Tap Control System
•Dual Mid Tap Control System▪Without Booster Fan▪With Booster Fan
•Using this control system consistency in Flue gas temperature at Boiler inlet can be achieved.
•TESPL has applied for the Patent for innovative Mid Tap Control System
38
13/6/2016
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Steam Dryness improvement at Super-heater Inlet
•Super efficient, Cyclonic type Drum Internals are provided to minimize droplets carried over in the saturated steam.
•Additional external cyclonic separator is provided at super-heater inlet to remove carried moisture / condensate at the super heater inlet.
•This reduces moisture load on super-heater, reduces scale formation in super-heater and also maintains the designed gas temperature profile in the WHRS.
39
13/6/2016
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New Generation WHR Projects
•Cost effective project implementation.
•Timely bound completion of project
• No variance in performance
• Online performance monitoring
NEXT
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Flue Gas Desulfurization (FGD)
Plant for Captive Power Plants
CII - WEbinar
byMr. Ajit Apte
Next
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Flue Gas Desulfurization (FGD)
•Removal of Sulfur Emissions
from Exhaust Gases
•Source of Sulfur Emissions –
Sulfur in fuel burns with coal
to form sulfur dioxide (SO2)
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Need of FGD Plants
• Use of Low Cost Fuels – Pet Coke, Imported Coal,
Lignite
• These fuels have high sulfur content (3 to 8%)
• High sulfur pyrites in limestone
• SO2 emissions from combustion of these fuel and
pyrites in the kiln
• Recent SO2 norms published by MOEF -
• FGD process – absorption of SO2 and generation of
bi products
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What is FGD?
• Exhaust gas is scrubbed with wet reagent
• SO2 reacts with the reagent to form by-
product
• By-product is separated and un-reacted
reagent is recycled.
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FGD Processes
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Processes Reagent used By-Product Formed
I. Wet FGD Processes
Limestone Gypsum Process Limestone Gypsum
Soda ash / Caustic Soda ProcessSoda Ash or Caustic
SodaSodium Bisulfite
Ammonia Process Ammonia Ammonium Sulfate
Seawater Process Seawater None
II. Semi-dry FGD Processes
Flash Absorption Process (FAP) Lime or Hydrated LimeCalcium Sulfite and
Sulfate
Spray Dryer Absorber (SDA)
ProcessLime or Hydrated Lime
Calcium Sulfite and
Sulfate
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Selection Criteria
•Cost and availability of reagent
•Revenue / Disposal of by-Product
•SO2 content in exhaust gas
•SO2 emissions regulations
•Utility consumption – Power and Water
•Type of user Industry
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Choice of FGD for Cement Plants
Wet Limestone Gypsum Process
• Limestone - Low cost & Easy Availability
• By-product – Gypsum for Captive Use
• Most effective for high sulfur fuels
including pet coke
• Output Emissions < 600 mg
• No solid waste generation & disposal
• Negligible Effluent Generation
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WET LIMESTONE GYPSUM PROCESS
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Chemical Reactions
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Wet FGD - Limestone Gypsum Process
1 CaCO3 (s) + SO2 (g) + ½ H2O (l) CaSO3. ½ H2O (s) + CO2 (g)
Limeston
e
Sulphur
Dioxide
Water Calcium Sulphite
Hemihydrate
Carbon
Dioxide
2 CaSO3. ½ H2O (s) + 3/2 H2O (l) + ½ O2 (g) CaSO4.2H2O (s)
Calcium Sulphite
Hemihydrate+ Water + Oxygen Gypsum
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Schematic Diagram
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FGD PLANT - LIVE CASE STUDY
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Key parameters
• Power Plant Capacity: 44 MW (22 MW x 2 nos)
• Fuel: Petroleum Coke with 7-8 % Sulphur
• Reagent Used: Low Purity Limestone (78%)
• By-product: Gypsum (Purity – 73%, 15%
Moisture)
• Status: Commissioned in Feb 2012
• Exhaust Gas Flow: 280000 m3 / hr
• Temperature: 140 Deg C
• Inlet SO2: 11420 mg / Nm3
• SO2 removal Efficiency: 92 %
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Key parameters
• Electricity Consumption: 950kW
• Lime Stone (78% purity) Consumption: 4300 kg / hr
• Water Consumption: 18 m3 / hr
• Gypsum Generation (73% purity on dry basis):
� On Wet Basis (12-15% moisture) : 7500 kg/hr
� On Dry Basis (approx) : 6500 kg/hr
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Installation Photographs
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Installation Photographs
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Installation Photographs
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FGD Economics for typical CPP
13/6/2016
Power Plant Capacity MW 27
Total Fuel Consumption TPH 15
Sulphur Content in Pet Coke (75 %) Wt% 7
Sulphur Content in Lignite (25 %) Wt% 3.0
SO2 in exhaust gas
kg / hr 1800
mg / Nm3 12077
ppm 4227
SO2 Removal Efficiency required to achieve
< 600 mg/Nm3% 95
Gypsum Generation on wet Basis (15 %
moisture )kg / hr 6600
Limestone Consumption ( 80 % Purity ) kg / hr 3674
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FGD Economics for Typical CPP
13/6/2016
Power Plant Capacity MW 27
Sulphur Content in Pet Coke (75 %) Wt% 7
Sulphur Content in Lignite (25 %) Wt% 3.0
Limestone Cost ( 300 Rs / ton ) Rs / hr 1102
Power Consumption kWh 1150
Power cost (3.0 Rs / kWh) Rs / hr 3450
Water Consumption m3 / hr 13
Water Cost (25 Rs/m3 ) Rs / hr 325
FGD Plant Running Cost Rs / hr 4877
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FGD Economics for Typical CPP
13/6/2016
Power Plant Capacity MW 27
Sulphur Content in Pet Coke (75 %) Wt% 7
Sulphur Content in Lignite (25 %) Wt% 3.0
FGD Gypsum Cost Rs / Ton 740
Equivalent Market Price for mineral
Gypsum ( 73% Purity )Rs / Ton 4000
Revenue Generation from FGD Gypsum
(benefit of pet coke against coal is to be
considered separately)
Rs / Ton 3260
Rs / Hr 21516
Lacs / Annum
(8000 hrs)1721.3
Investment Rs in Lacs 2700
Pay Back Period Years < 2
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Project Execution Project Execution
Methodologies for FGD plantsMethodologies for FGD plants
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FGD plant executionFGD plant execution
� Engineering
� Procurement
� Construction
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Schematic Diagram
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FGD Plant Site Activities
� FGD Tower manufacturing & erection
� Oxidation tank manufacturing & erection
� All ducting fabrication & erection
� All piping (Slurry circulation, Slurry transfer, filtrate
return etc)
� Anti corrosive lining on FGD tower & Oxidation tank
� Erection assembly, & testing of all bought out
components
� Wiring, Cabling & instruments fitting
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64
Proposed execution optionsProposed execution options
Option I- Engineering Services for FGD Plant (All
procurement to be done by CLIENT)
Option II- Engineering & Procurement Services
for FGD Plant (Procurement by TTPL, Payment
Directly by CLIENT to suppliers)
Option III- EPC (Turn Key - Engineering,
Procurement & Construction) excluding civil
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Option I- Engineering Services
� Basic Engg, P & I Diagrams, G.A. Drawings/ Layouts
� Specifications of equipments & Bought outs
� Specifications for Electrical components & wiring, All
input specifications & battery limits, Specifications of
anticorrosive lining
Phase II- Execution Services
� Detail engineering, manufacturing drawings,
assembly drawings, hook up drawings, electrical wiring
drawings, load data for civil design
Phase I- Design & Engg Services
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66
Option I- Engineering Services
� Support to client for procurement planning
� Participation in procurement process, summarization
of vendor offers, Due diligence and selection of vendors,
techno commercial discussion and negotiation
� Project Supervision and inspection services
� Overall project coordination
� Stage wise inspection, Inspection after installation
� Site work supervision, monitoring & controlling
Phase II- Execution Services Continued..
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Option I- Engineering Services
� Pre Commissioning & commissioning of individual
equipments
� Commissioning of the plant
� Provisional performance trials
� Final Performance trials
� Operation & Maintenance manual, training & handing
over
Phase III- Pre-Commissioning & Commissioning Services
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68
Option II- Engineering Services & Procurement
�In addition to engineering services provided on option
I, TTPL will also do actual ordering & co-ordination
� Fund provision for the project, payment to suppliers,
freight & insurance shall be arranged by client directly
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Option III- EPC (Excluding Civil)
� Engineering, Procurement & construction shall be
done by TTPL
� Entire civil work will have to be carried out by Client.
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70
Initial Investment with all 3 options
All Prices are Rs. in Lacs
Sr.
No.
Description Option I
(Engineering
Services)
Option II
(Engineering &
Procurement
Services)
Option III
(EPC)
Major
Bough
t Outs
Indian
Make
Major
Bough
t Outs
Chine
se
Make
Major
Bough
t Outs
Indian
Make
Major
Bough
t Outs
Chine
se
Make
Major
Bough
t Outs
Indian
Make
Major
Bough
t Outs
Chine
se
Make
1 Estimated Cost of Raw Material & Bought out
Components, Site
Activities
1320 1095 1320 1095 1320 1095
2 Cost of Services for TTPL 716 716 765 765 1360 1283
3 Total Project Cost 2036 1811 2085 1860 2680 2378
4 Cost of Civil Budget Estimate
70-90 70-90 70-9013/6/2016
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