NTPC LIMITED

PROJECT : SIPAT STPP STAGE-III (1X800 MW)

PACKAGE NAME : EPC PACKAGE
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“Salient Technical Features of the equipment/systems/services covered in the Bidding
Document No. CS-8003-001-2 are mentioned below. These Salient Technical Features are
mentioned only to facilitate the prospective bidders to prima-facie understand the
requirements under the tender and shall not in any way limit or alter the scope of work and
technical features/specification of equipment/ systems/ services covered in the Bidding
Documents. Detailed provisions in regard of scope of work and technical features/
specification of equipment/ systems/ services, contained in the Bidding Documents shall
be final and binding.”

A. BRIEF SCOPE OF WORK

The Brief scope of work for the subject EPC Package for SIPAT STPP Stage-III (1X800
MW) is as follows:
Design, Engineering, Manufacture, Supply, Construction, Erection, Testing &
Commissioning works for the EPC Package for SIPAT SUPER THERMAL POWER
PROJECT Stage-III (1 X 800 MW) on the basis of single point responsibility, completely
covering the following activities and services in respect of Steam Generator and
Auxiliaries, Electrostatic Precipitator, Flue Gas Desulphurization (FGD) System, Biomass
co-firing capability, Steam Turbine & Auxiliaries, Generator & Auxiliaries, Generator Bus
ducts and associated equipments, ECW system for TG & SG including station auxiliaries,
Condensate polishing plant (CPU), CST, CW system including equipment, Duct, IDCT &
CW channel and associated civil works, Raw Water system and associated Electrical &
civil works, Water treatment plant and associated civil works including Effluent quality
Monitoring System(EQMS), Ash Handling & disposal System, Coal and Biomass Handling
Plant, Limestone & Gypsum Handling Plant, Mill Reject Handling System, Compressed Air
System, Fire Detection & Protection System, Air Conditioning & Ventilation Systems,
Power cycle & Station Piping, Power Transformers, HT Switchgears for complete plant
facilities, Transformer Yard and associated controls & Instrumentation, LT indoor
Transformer, MV Bus-duct, DC Batteries, Battery chargers, DG sets, LT switchgear & LT
Bus Duct, Outdoor Transformers, Switchyard, HT & LT power cables, LT control cables,
Lightning Protection, DG sets for FGD, Lighting, Cabling, Earthing, all Control &
Instrumentation(C&I), Fireproof cable penetration sealing system, Pipe / Cable racks,
Solar PV plant on roof tops of buildings, Civil, Structural & Architectural works of Main
Power House, Common Control Room, Chimney with elevator, earthing mat/ grounding for
the Offsite areas, Miscellaneous Buildings and other civil works including Site Levelling,
Roads & Drains, underground facilities like drainage, sewerage, trenches, Packaged
sewerage treatment plant, Rain Water Harvesting, etc covered under the specifications:
(a) Basic Engineering of the plant including preparation of Plant Definition Manuals;
(b) Detailed design of all the equipment and equipment system(s) including civil,
structure steel & Architectural works included in bidder's scope.
(c) Providing engineering drawings, equipment sizing & performance data, instruction
manuals, as built drawings and other information;
(d) Compliance with statutory requirements and obtaining clearances from statutory
authorities, wherever required;

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 (e) Complete manufacturing including shop testing/type testing;
(f) The complete Civil, structural and architectural works
(g) Packing and transportation from the manufacturer’s works to the site including
logistic studies, insurance, customs clearance & port clearance, port charges, if any.
(h) Receipt, storage, preservation, handling and conservation of equipment at the site;
(i) Fabrication, pre-assembly, if any, erection, insurance, testing, commissioning and
completion of facilities including putting into satisfactory operation all the equipment
including successful completion of initial operation;
(j) Performance and guarantee tests along with initial operation;
(k) Supply of spares on FOR site basis;
(l) Reconciliation with Customs Authorities;
(m) Satisfactory conclusion of the Contract;
(n) Insurance and other requirements
(o) The plant shall be ZLD compliant

Detailed scope of work has been specified in the bidding documents.

B. SALIENT TECHNICAL FEATURES

1.00.00 Steam Generator

1.01.00 Type

The Steam Generator shall be of single pass (Tower type) or two pass type using either
spiral wall (inclined) or vertical plain / rifled type water wall tubing.

1.02.00 Other Features of Steam Generator Design

The Steam Generator shall be direct pulverized coal fired, top supported, single reheat,
radiant, dry bottom, with balance draft furnace and shall be suitable for outdoor
installation. The evaporator of Steam Generator shall be once-through type suitable for
variable pressure operation from subcritical to supercritical pressure range.

1.03.00 Rating of Steam Generator(s)

Steam Generator shall be designed to cater to duty requirements at Boiler Maximum

Continuous Rating (BMCR) specified below:

Capacity of Steam Steam Flow Temp. Pressure

Generator and Rated Kg/cm2(a)
(T/Hr) (Deg C)
Steam parameters:
i) At super-heater 102% of the The steam The steam
outlet turbine VWO temperature at pressure at
steam flow Superheater outlet superheater outlet
requirement. shall be atleast 3°C shall be atleast 9

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 higher than the rated kg/cm2 higher
main steam than the rated
temperature at HP main steam
turbine inlet. pressure at HP
turbine inlet
ii) At re-heater outlet - The steam ---
temperature at
reheater outlet shall
be atleast 3oC higher
than the rated reheat
steam temperature at
IP turbine inlet.
iii) Feed Water Temp. To be optimized by
at Economizer Inlet the bidder but not
less than 305oC

1.04.00 Limiting Parameters for Steam Generator Design

The Steam Generator design shall comply with the following limiting parameters with
`design coal’ firing, under stipulated ambient air condition i.e. 27 degree Celsius
temperature and 60 % relative humidity:
Flue gas temperature at air-heater outlet - 125oC (minimum)
(Corrected) at 100 % TMCR load
1.05.00 Operating Requirements

1. Minimum load without oil support 40% BMCR

for flame stabilization
2. Operation without HP heaters in Steam generator shall be capable of operation
service with HP heaters out of operation. The steam
generator heat output under HP heaters out
condition shall not be less than heat duty
required for generating rated power output or
design BMCR heat duty, whichever is lower.
Steam generator shall also be capable of
sustained operation with HP heaters out of
operation so as to generate rated power output
or output corresponding to design BMCR heat
duty, whichever is lower.
3. Steam generator control range The automatic control range of Steam
Generator shall be from 50% TMCR to 100%
BMCR. Under the above control range, the
steam temperatures at SH & RH outlets shall
be maintained at their rated values.
4. Mode of Steam Generator The Steam Generators shall be designed for
Operation variable pressure operation. Thermal design of
Steam Generator and the selection of materials
shall be suitable for variable pressure
operational modes.
5 Rate of loading / unloading

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 a) Ramp Rate (i) Minimum + 1% per minute (Below 50%
load to minimum boiler once through load)
(ii) Minimum + 3% per minute (50% to 100%
load)

1.06.00 Coal/Ash data

The primary fuel for the main steam generator shall be coal. LDO shall be used for initial
start-up, coal flame stabilization and low load operation of the steam generator while
firing coal.

2.00.00 Electrostatic Precipitator (ESP)

2.01.00 System Description:

The Electrostatic Precipitators shall be of outdoor type and installed on the cold end side
of regenerative air preheaters. The flue gas shall be drawn from air preheater outlets of
the balanced draft, pulverized coal fired Steam Generator and guided through
adequately sized duct work into the specified number of independent gas streams of
each ESP. Similarly, the flue gas after the Electrostatic Precipitators shall be led to the
suction of the induced draft fans.

2.02.00 Service Conditions

The Steam Generators are designed to burn pulverised coal. LDO shall be used during
startup and at low loads for warm up and flame stabilization of Steam Generator. The
ESP shall be designed to remove fly ash particles (to meet the stipulated ESP emission
levels) from the flue gas generated in the Steam Generator with pulverized coal firing.
Additionally, certain percentage of biomass firing is also envisaged in the Steam
Generator.

3.00.00 Flue Gas Desulphurization System:

3.01.00 Flue Gas Desulphurization (FGD) System and its auxiliaries shall be supplied for the
steam generator of 800 MW capacity. The FGD system shall be based on wet limestone
FGD technology and is intended to reduce the emissions of sulphur dioxide in flue gas
produced by coal being fired in boiler to the specified limits.

3.02.00 The FGD system shall have an absorber, limestone milling systems and gypsum
dewatering system for the unit.

4.00.00 Steam Turbine

4.01.00 Type
The steam turbine shall be tandem compound, single reheat, regenerative, condensing,
multi-cylinder design with separate HP, separate IP and two separate LP cylinders OR
combined casing for HP-IP and two separate LP cylinders directly coupled with
generator suitable for indoor installation.

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4.02.00 Rating
The steam turbine generator unit shall conform to the following design and duty
conditions:

1. Output under economic maximum : 800 MW

continuous rating (EMCR) (guaranteed
output load) at generator terminals
2. Turbine throttle steam pressure : 270 Kg/cm2 (abs)

3. Turbine throttle main steam temp. : 600 oC

4. Reheat steam temp. at turbine inlet : To be optimized by the bidder
between 600 and 610 deg.C
(both values inclusive) but not
less than 600 deg.C
5. Condenser pressure : 77 mm Hg (abs)
6. Turbine speed : 3000 rpm
7. Frequency variation range around rated : + 3% to - 5% (47.5 Hz to 51.5
frequency of 50 Hz Hz)

4.03.00 Other Features

(a.) Turbine shall be capable of operating continuously with valves wide open (V.W.O.) to
swallow at least 105% of EMCR steam flow to the turbine at rated main steam and
reheat steam parameters and also the corresponding output shall not be less than 105%
of rated load with 3% make up and 77 mm Hg (abs) condenser pressure.

(b.) The steam turbine shall have minimum eight uncontrolled extractions for regenerative
feed heating based on optimized cycle and shall be suitable for satisfactory operation
under tropical conditions.

5.00.00 Generator

5.01.00 Type

Three phase, horizontal mounted, indoor installed, two-pole, class-F winding insulation,
Stator water/ hydrogen cooled, cylindrical hydrogen/water cooled rotor type.

5.02.00 Rating

Generator and its excitation system shall have a capability at least matching the
declared maximum continuous rated output of the associated steam turbine (for the
designed secondary cooling water temperature) at all power factors between 0.85
lagging and 0.95 leading with +3% to -5% frequency variation, terminal voltage variation
of +/- 5% and combined voltage & frequency variation of 5%. It shall be ensured that
when the Generator is working at this capability and design cooling water temperature,
no part of the Generator shall attain a temperature in excess of the temperature limits
specified for class-B insulation as per IEC-60034.
5.03.00 Also the generator and its excitation system shall be capable of continuous stable
operation without any excessive temperature rise at the peak output of the associated
steam turbine under VWO & HP heater out condition, etc. as available for the designed
secondary cooling water temperature, at all power factors between 0.85 lagging and

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 0.95 leading with +3% to -5% frequency variation, terminal voltage variation of +/- 5%
and combined voltage & frequency variation of 5%. Temperature of different parts may
exceed those permissible for class-B insulation under such operating conditions, but
shall be lower than those permissible for class-F insulation as per IEC-60034.

5.04.00 Rated Parameters

1. Power Factor - 0.85 (lag)

2. Terminal voltage - In the 18 to 28 kV range
3. Frequency - 50 Hz
4. Speed - 3000 rpm
5. Short circuit ratio - Not less than 0.48 (without any
tolerance)

6.00.00 Coal and Biomass Handling System

Coal conveying system shall include interconnection conveying system from existing
stages, conveying, reclaiming from existing stockpile. Rated capacity of CHP shall be as
per the existing system capacity.
Biomass unloading, conveying and storage shall be for feeding upto the Bunkers after
blending with Coal.

7.00.00 Ash Handling System

Ash handling system consists of the following sub systems:

a) Bottom Ash, Economizer, APH, Duct Hopper ash Handling System

A wet ash conveying system for ash collected in the boiler furnaces, economizer
hoppers, economizer outlet duct hoppers (if applicable), air preheater hoppers and
duct hoppers (if applicable) including treatment system of Bottom ash hopper
overflow water. Dewatering Bins/Hydro Bins System for Bottom ash, Economizer
ash, Air preheater ash with Dewatering Bin system.

b) Dry Fly Ash Conveying system

Two alternatives for pneumatic conveying system (i.e. vacuum conveying system or
pressure conveying system) are specified for conveying of fly ash from ESP Hoppers in
dry form.

i) Vacuum Conveying System

It shall consist of liquid ring vacuum pumps, material handling valves, cast iron and
MS pipes, instrument air compressors etc.
OR
ii) Pressure Conveying System

It shall consist of screw compressors, air lock/pump tanks, ash intake & discharge
valves, CI & MS pipes, instrument air compressors etc.

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 c) Dry Fly Ash Transportation system

The dry fly ash from the buffer hoppers in the unit shall be transported to fly ash main
storage silos/intermediate silos or Classifier Silos. The user industries shall take the dry
fly ash from storage silos either in rail wagons, closed tankers or in open tankers.

d) Ash Disposal System

The unutilized fly ash and bottom ash shall be disposed to existing ash dyke in combined
(BA+FA) lean slurry form from Ash slurry pump house.

e) Ash classification and bagging system.

Fly ash from the ESP hoppers shall be led to the ash classifiers where fine ash shall be
segregated from coarse ash. The fine ash shall be stored in fly ash silo dedicated for ash
bagging plant. Unutilized coarse ash shall be disposed in slurry form to the existing ash
dyke.

8.00.00 MILL REJECT SYSTEM

The Mill Reject Handling System shall comprise Mechanical Conveying system. The
Rejects shall be stored in the storage silo. From the storage silo, the Mill Rejects shall be
disposed off in trucks. Metallic Belt conveyor/Chain Flight Conveyor along with drives,
accessories, supports etc for conveying the mill rejects from the mills for each row of
mills.

9.00.00 LIMESTONE AND GYPSUM HANDLING SYSTEM

Limestone unloading, conveying, Crushing and storage into Silos has been envisaged.
From Storage silos Crushed Limestone shall be fed into Day Silos.
Gypsum handling system shall consist of gypsum conveying upto the gypsum storage
shed.

10.00.00 WATER TREATMENT PLANT (WTP)

Water Treatment Plant (WTP) consisting of the following sub systems shall be provided
as per the scope of Technical Specification:
a) Pre-Treatment Plant
b) Chlorine Di-oxide Plant
c) Demineralizing plant
d) Liquid Effluent Treatment System
e) CSSP system
f) Drain Separation & ZLD

11.00.00 CW SYSTEM
Closed loop recirculating type CW system with CW Pumps, Induced Draft Cooling Tower
& CW Chemical Treatment; Equipment cooling water system for TG, SG & Station
auxiliaries etc. and Auxiliary Water Pumps (Raw water for PT & Ash, HVAC, FGD, AHP

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 wash, Service water, potable water etc.) shall be provided as specified in technical
specification.
12.00.00 CONDENSATE POLISHING PLANT
Condensate Polishing Plant (CPU) for the unit along with external regeneration facility
shall be provided as per the scope of Technical Specification.

13.00.00 FDPS & HVAC

Fire detection & protection system, Compressed air (instrument & service air) system,
A/C and ventilation system, shall be as per the scope of technical specification.

14.00.00 Electrical Systems

 Generator, Excitation System and its Auxiliary Systems

 Motors

 Generator Busducts, MV Busducts .

 Power Transformers, Auxiliary Oil Filled Transformers, Indoor Transformers

 MV Switchgears, LV Switchgears and LV Busducts, Numerical Relay Networking,

DC System, Battery and Battery Charger

 HT Power Cables, LT Power and Control Cables, Cabling, Earthing and Lightning
Protection, Station Lighting, DG Sets, VFD

 Construction Power facilities

 Switchyard Electrical and Control & Protection

 ESP, AHP & CHP Electricals

 Type Testing and Mandatory Spares as specified.

15.00.00 C & I Systems

All the systems/equipment being supplied under this package shall be monitored and
controlled from DDCMIS in this package
The control system, called Distributed Digital Control Monitoring & Information system
(DDCMIS) is envisaged to be procured under this package for control and operation of
 Integral control & protection of boiler including Burner Management System and
Boiler protection system.
 The integral control & protection of Steam Turbine Generator including Electro-
hydraulic control & Turbine Protection system.
 Modulating controls of the Steam Generator (SG) {Combustion Control- Fuel
Flow/Air Flow; Furnace Draft Control, FW flow control etc.}.
 Modulating controls of Feedwater & Condensate Cycle {Hotwell level control,
Deaerater Level control, Heater Level Control, etc.}.

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  Binary control of auxiliaries of Steam Generator (SG) {Forced draft (FD) fan, Induced
Draft (ID) Fan, Primary Air (PA) Fan etc.}.
 Advanced Process Control solution for Flexible Operation, Combustion Optimization
and Soot Blowing Optimization.
 Binary control of auxiliaries of Turbine Generator (TG) {Boiler Feed Pump (BFP),
Condensate Extraction Pump (CEP) etc.}.
 Electrical Breaker including synchronization circuits.
 Coal Handling Plant.
 Water System (PT Plant, DM Plant, Cooling Tower etc.).
 CW System.
 Air Conditioning and Ventilation systems.
 Ash Handling Plant.
 FGD System
 FOPH System

Human Machine Interface & Plant Information System (HMIPIS) is based on Large Video
Screen (LVS) displays supported by TFT monitor based Operator Work Stations (OWS).
These devices through customized user-friendly displays, soft alarm facia and pop-up
displays are used for giving fast pin-pointed faults/ status to the operator. Local ON/OFF
operation of equipments is envisaged through Graphical Interface Unit (GIU). The total
system is networked through a Station-Wide LAN for use of real time data of various plant
areas by other users like maintenance, planning, efficiency enhancement groups etc.

The sequence of events recording & alarm annunciation are also implemented as a part of
DDCMIS system. A GPS based master and slave clock system is to be provided for
uniform and synchronized timing signals throughout the entire station.

The power supply for the control system is based on 24V DC provided through
microprocessor based modular charger system and for the peripherals and other
subsystem through 230V Single Phase UPS.

Main Equipment related instruments like Flame Monitoring system, Coal Bunker Level
measurement system, gravimetric feeder control system, Acoustic Pyrometer, Acoustic
Steam Leak detection system, Furnace and Flame viewing system, Turbine stress control
/ evaluation system, Turbine supervisory and diagnostic system etc are also procured
through this package.

Field instruments like pressure, DP, flow & level transmitter, analyzers along with their
process connection & piping as well as measurement systems like vibration monitoring
system etc are also procured through this package.

Field bus based controls and devices are also envisaged in this package.

A plant-wide CCTV system based on IP technology is included in this package for

surveillance of plant equipment as an aid to the operation.

Apart from above, an on-line Steam & Water analysis system (SWAS), PA system,
Operator control desks, panels, shielded twisted pair cables as well as optical fiber cables

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 for system interconnection and all types of Instrumentation Cables are also included in this
package.

16.00.00 Rooftop SPV Plants

Solar Photo-voltaic plants to be supplied under the package shall be grid-connected rooftop
SPV plants including all auxiliaries. The SPV modules must conform to latest edition of IEC
61215 / IS 14286 for crystalline silicon Terrestrial PV Modules design qualification and type
approval. The modules must also conform to IEC 61730 part 1 & Part 2 or equivalent IS for
construction & testing requirements respectively. In addition, the modules must also conform
to IEC 62804 or equivalent IS for test methods for detection of Potential induced
degradation (PID).

17.00.00 Civil Works

The top layer is Silty clay/ Clayey silt with decomposed rock fragments of about 0.7m to
4.0m thickness below Natural ground level followed by highly weathered, fine grained,
fractured shale of thickness 0.7m to 6.8m. The core recovery varies from 18% to 25% and
RQD varies from 0% to 17%. This is underlain by highly to moderately, fine-grained,
fractured shale, The core recovery varies from 26% to 100% and RQD varies from 0% to
100%. Ground water level is encountered at a depth of about 0.0m to 6.2m below NGL at
the time of investigation and may fluctuate with seasonal variation.
The steel structures shall be pre-fabricated in factory and shall have bolted field
connections.

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