IN-DEPTH STUDY & PREPARATION OF TEFR FOR INSTALLATION OF GAS TURBINE AT RCF THAL FOR ENERGY REDUCTION

Transcription

1 IN-DEPTH STUDY & PREPARATION OF TEFR FOR INSTALLATION OF GAS TURBINE AT RCF THAL FOR ENERGY REDUCTION PREPARED FOR RASHTRIYA CHEMICALS & FERTILIZERS LTD., MUMBAI द व र प र ष त प र ज क ट स एण ड ड वऱऩम ट इण ण डय लऱलमट ड (भ रत सरक र क उऩक रम) ऩ.ड.आई.एऱ. भवन, ए-14, स क टटर-1, न एड (ण जऱ ग तमब द ध नगर) उ.प र. Job No. FS August 2014

2 TABLE OF CONTENTS Chap. No. Title Executive Summary 1.0 Introduction 2.0 Scope of Work 3.0 Existing Steam and Power System 4.0 Modification of Steam and Power System 5.0 Electrical Philosophy 6.0 Plant Operation under Different Scenarios 7.0 Environment Impact Assessment 8.0 Project implementation Plan & Time Schedule 9.0 Benefits and Savings 10.0 Project Cost & Economics 11.0 Conclusion & Recommendation Annexures Financial Statements (F.S.) Drawings

3 LIST OF ANNEXURE Sl. No. Title Annexure No. 1.0 Feeder List: Complete Replacement of Existing 11 kv Switchboard at CPP 2.0 Feeder List: Additional 11 kv Switchboard at CPP in addition to Existing 11 kv Switchboard at CPP 3.0 Feeder List: New 11 kv Switchboard Near Ammonia Substation I II III 4.0 Steam Balance of Ammonia Plants IV 5.0 Power Balance of the Complex V

4 LIST OF FINANCIAL STATEMENTS Sl. No. Item F.S. No. 1.0 Saving/Benefit after Changeover Capital Cost Estimate Pay Back Period Internal Rate of Return Sensitivity Analysis 05

5 LIST OF DRAWINGS Sl. No Title Drawing No. 1.0 Base Case - Reference Operation FS Option-1 Normal Operation FS A 3.0 Option-2 Normal Operation FS B 4.0 Option-3 Normal Operation FS C 5.0 Option-4 Normal Operation FS D 6.0 Option-5 Normal Operation FS E 7.0 Single Line Diagram -Option-I FS A 8.0 Single Line Diagram -Option-II FS B

6 EXECUTIVE SUMMARY 0.1 RCF Thal complex comprised of two trains of ammonia plant of 1750 MTPD capacity each i.e. Combined capacity of 3500 MTPD and three trains of urea plant of combined capacity of 6060 MTPD along with all necessary utilities and infrastructure facilities. The Thal Complex started its commercial production of urea in Subsequently, DMF Group of Chemical Plants was added to the manufacturing facilities, which made the Thal Unit as an integrated Chemical Complex. RCF has since gone for de-bottlenecking of Thal I & II and enhanced the urea capacity from 1.7 million MTPA to about 2 million MTPA. Revamping of Thal ammonia-urea plants was completed in the year After completion of revamp, the daily average ammonia and urea specific energies are ranging between 8.15 to 8.20 and 5.76 to 5.79 Gcal/MT respectively. Considering higher specific energy consumption of ammonia and urea plants as compared to latest plants, RCF intends to further reduce the specific energy consumption of ammonia / urea plants at Thal by way of replacing some of the steam turbine driven equipments of ammonia plants with motor driven. RCF desires to enhance efficiency of power production by installing Gas turbine/turbines of required capacity. For this purpose, RCF intended to carry out feasibility study for installation of GTG with HRSG and replacement of some of steam turbines, if necessary, with motor. 0.2 The basic objective of the study is to reduce the specific energy consumption of ammonia-urea plants of RCF, Thal complex by installing a new GTG (Gas Turbine Generator) and HRSG (Heat Recovery Steam Generator) of optimum capacity. The detailed scope of work has been presented in Chapter 2.0 of the report. 0.3 The existing ammonia-urea complex was designed in such a way that major moving machineries were steam turbine driven; as it was prevalent at that time. For the production of ammonia and urea, the major energy consumption centre is feed and fuel to ammonia plant and minor energy through steam and power consumed in the plant complex. For production of steam and power to this complex, it was originally based on coal as well as natural gas as fuel for steam and power generation. 0-1

7 The details of existing steam and power configurations are presented in Chapter 3.0 of the report. 0.4 With a view to reduce the overall energy of the complex, it is proposed that steam and power system have to be modified in such a way that both steam and power shall be adequate to run the main plants and auxiliaries un-interrupted. It is proposed to change the existing steam turbine driven machineries to motor driven. As per existing available data of RCF Thal, PDIL analysed the configuration by replacing the existing steam turbine driven machineries which are using HP, MP and LP steam to motor drives for Ammonia plant and auxiliaries to the maximum possible extent. The details of existing as well as proposed modification thereof are given in Chapter -4.0 of the report. 0.5 In the present report, PDIL also covers study of the existing Electrical Systems of Ammonia Plants and CPP with respect to change in load in Ammonia Plants and installation of new GTGs. The study broadly includes checking adequacy of electrical equipment/facilities which are likely to cater the load of equipment (fan, pump, compressor) presently being driven by steam turbines and now proposed to be replaced by driver motors. The equipment are detailed in chapter -5.0 of the report. 0.6 The Plant operation under different scenarios are optioned in Chapter 6.0 of the report. 0.7 The impact of proposed changeover scheme on land, air, water, noise and socioeconomic environment has been studied and it is concluded that as such there will be no adverse impact on the environment due to proposed scheme. The details have been presented in Chapter -7.0 of the report. 0.8 For the proposed modification, there shall be two types of activities. The major activity shall be related to installation of GTG and HRSG which is completely new set of facilities to be executed in the adjacent of existing CPP area. The other installations are related to in-plant modifications/replacement. The new set of facilities shall be installed separately by following the appropriate procedure. These new equipment and portions of the equipment, which shall be needed to modify for the new duty shall be procured and kept ready at site. In the proposed revamp scheme, some of the steam turbines, specifically Ammonia Refrigeration 0-2

8 Compressor III turbine, shall be replaced by motors. Though the motors will be procured and kept ready at site but its installation requires opportune time after plant shutdown of the particular equipment i.e steam turbine. The steps will be like- dismantling of existing turbine, preparation of suitable civil foundation for motor, setting of civil foundation etc. All these steps may require around one month s time. The installation of motor in place of ARC III turbine is planned in such a way that loss of urea production is minimum to the extent possible. One month prior to beginning of normal shutdown, ARC III turbine will be taken offline and above steps will be followed. By doing so, ammonia - urea plants will be in operation but at lower load. The final erection and hooking up will be done during the annual turn around period, which is expected to last for days. Hence one month partial production loss has been envisaged for dismantling of existing turbine, preparation of suitable civil foundation for motor and setting of civil foundation. It is envisaged that major time shall be required in execution of GTG and HRSG without affecting the operation of ammonia and urea. The total time schedule for completion of project, especially GTG and HRSG would be about 24 months after receipt of approval from concerned authorities. The zero date will commence after completion of all the pre-project activities. 0.9 For the existing case (Base Case, Drg. No. FS ), the natural gas consumption for steam generation is given below: Sl. No. Item NG (NCV kcal/sm 3 ) Consumption Sm 3 /hr 1. Auxiliary Boiler in Ammonia Plant Steam Generation in SGP Total After implementation of changeover scheme (Option-I, Drg No FS A), the natural gas consumption for generation of power (in GTG), steam generation in HRSG and SGP for are as follows: Sl. No. Item NG (NCV kcal/sm 3 ) Consumption Sm 3 /hr 1. GTG (Power) HRSG (Steam)

9 3. SGP Total From above tables, it shows that there is substantial saving in consumption of natural gas after changeover i.e Sm 3 /hr. The details have been presented in Chapter -9.0 of the report The project cost estimates for the facilities installed as described in chapter 4.0 for the proposed changeover scheme has been worked out to Rs Crores. This estimate also includes production loss during change over. An approximate break-up of the project cost estimates is given in Table-0.1 and details are presented in FS 02. Sl.no Particulars / Items A Erected Cost Table Project Cost Estimates (Rs Lakhs) Cost 1.0 Gas Turbine Generator (2 32 MW ISO) HRSG (2 100 MTPH) 4000 B Supplies 1.0 All motors and its accessories Pipes valves & Fittings Electrical & Instrumentation 1342 Total Supplies 2369 C Incidentals on (B) Excise 12.36% 293 Sales 2% 53 Inland 3% 71 1% 28 D Erection 245 E Civil Works including extension of buildings 175 F Design Engineering & Procurement 830 G Contingency (5%) 1598 H Revenue Loss on account of forced shutdown 1020 Total Cost

10 The IRR and Pay Back Period of change over scheme are estimated as 17.80% and 4.57 years respectively. Sensitivity analysis has been done with respect to change in project capital cost, Energy (NG) price and amount of savings in energy. The effect of these variations on IRR and Payback have been worked out and presented at F.S-05. The details of project economics have been presented in Chapter of the report Considering the results of study, wherein IRR and pay back is attractive with NG price of US$ 4.2/MMBtu, PDIL strongly recommends for early implementation of the proposed modifications. 0-5

11 1.0 INTRODUCTION 1.1 Rashtriya Chemicals & Fertilizers limited (RCF) is a public sector undertaking involved in the manufacture and marketing of nitrogenous, phosphatic and potassic fertilizers as well as a variety of industrial chemical products. The company was carved out of the erstwhile Fertilizer Corporation of India Ltd. at the time of the reorganisation in The company has presently two manufacturing units, one at Trombay and the other Thal, both located in the state of Maharashtra. 1.2 Thal unit is one of the first Fertilizer Complex established to utilise the Bombay High Off-shore Natural Gas. The Thal complex of RCF is spread over an area of about 850 acres of industrial land provided by government of Maharashtra. RCF Thal complex comprised of two trains of ammonia plant of 1750 MTPD capacity each i.e. Combined capacity of 3500 MTPD and three trains of urea plant of combined capacity of 6060 MTPD along with all necessary utilities and infrastructure facilities. The Thal Complex started its commercial production of urea in Subsequently, DMF Group of Chemical Plants was added to the manufacturing facilities, which made the Thal Unit as an integrated Chemical Complex. RCF has since gone for de-bottlenecking of Thal I & II and enhanced the urea capacity from 1.7 million MTPA to about 2 million MTPA. Revamping of Thal ammonia-urea plants was completed in the year After completion of revamp, the daily average ammonia and urea specific energies are ranging between 8.15 to 8.20 and 5.76 to 5.79 Gcal/MT respectively. 1.3 Considering higher specific energy consumption of ammonia and urea plants as compared to latest plants, RCF intends to further reduce the specific energy consumption of ammonia / urea plants at Thal by way of replacing some of the steam turbine driven equipments of ammonia plants with motor driven. The switch over from steam turbine to motor is possible only after modification of the existing steam and power system to a considerable extent. The present requirement of power for the complex is about 28 MW which is met through Steam Turbine Generator (STG) of 30 (2 15) MW capacity. The required steam for this STG is supplied from the existing gas fired steam generation plant. This steam and power system is also inefficient with respect to energy which ultimately is loaded on ammonia and urea plants. Considering these factors, RCF desires to enhance efficiency of power production by installing Gas turbine/turbines of required capacity. 1-1

12 For this purpose, RCF intends to carry out feasibility study for installation of GTG with HRSG and replacement of some of steam turbines, if necessary, with motor. 1.4 Projects & Development India Limited (PDIL), a premier consultancy and engineering organization in India, have been retained as Consultant by RCF for carrying out a in-depth study and preparation of Techno-Economic Feasibility Report (TEFR) for installation of GTG with HRSG and replacement of some of steam turbines with motors for reducing the specific energy consumption of ammonia and urea plants. 1.5 With the above background, PDIL team of engineers visited the Thal unit of RCF and examined the related existing facilities. The team also discussed with the RCF s operating personnel and collected requisite information for developing base line data for analysis and working out techno economic feasibility. 1.6 The present report has been prepared on the above background and details of techno-financial results are presented in the subsequent chapters of the report. 1-2

13 2.0 SCOPE OF STUDY The basic objective of the study is to reduce the specific energy consumption of ammonia-urea plants of RCF, Thal complex by installing a new GTG (Gas Turbine Generator) and HRSG (Heat Recovery Steam Generator) of optimum capacity. To meet the objective of the study, PDIL has to carry out in-depth study and prepare Techno Economic Feasibility Report for installation of GTG with HRSG and switching over from steam turbine driven equipment to motor drive equipment in ammonia plants and utility facilities. More specifically, the following shall cover the following areas. Existing power generation capacity and existing power consumption for the factory. Existing steam network, consumption centres and steam balance of Ammonia Plant and Steam Generation Plant (SGP). Existing Steam driven system required to be converted to motor driven system in Ammonia Plant & SGP. Steam balance of Factory, SGP and Ammonia plant after conversion to motor driven system. Find out the utilisation of excess steam after stopping 2 nos. of auxiliary boilers or requirement of additional steam from HRSG of GT set, as the case may be. Gas Turbine power generation capacity to be installed to meet the present factory and additional demand of Ammonia Plant, Steam Generation Plant and Argon Plant. Steam generation capacity from the HRSG of the installed GTs. Energy calculation for the existing and changed over system. Configuration of Gas Turbine (capacity and number) for achieving minimum specific energy consumption. Reliability of the proposed system with GT to take care of typical emergency situations. Estimated investment for the proposed changed over system of GT and HRSG including changes required in existing electrical system. 2-1

14 Economics of the new system i.e. saving in energy vs investment in various scenarios of power and gas price. Pay-back period and Internal Rate of Return (IRR) analysis with different gas prices. Sensitivity analysis: w.r.t. gas price, power cost, foreign exchange rate, capital cost, generation capacity etc. Sufficiency of proposed system for steam and power for various scenarios such as cold start-up of both Ammonia plants, cold start-up of one Ammonia Plant (other one in operation), cold start-up of two Urea plants along with one Ammonia plant, and Black start. Space requirement for new equipments. 2-2

15 3.0 EXISTING STEAM & POWER SYSTEM 3.1 The Thal urea manufacturing complex has two ammonia plants of total capacity 3500 MTPD capacity and three urea plants of total capacity 6060 MTPD. To service the main plants at Thal offsite & utility facilities are adequate. While installing these facilities, at Thal, the technology adopted for the manufacture of ammonia and urea was latest of the time. 3.2 The existing ammonia-urea complex was designed in such a way that major moving machineries were steam turbine driven; as it was prevalent at that time. For the production of ammonia and urea, the major energy consumption centre is feed and fuel to ammonia plant and minor energy through steam and power consumed in the plant complex. For production of steam and power to this complex, it was originally based on coal as well as natural gas as fuel for steam and power generation. Accordingly, 3 (coal + NG) fired boilers were installed. However the coal handling system was dismantled after a period of around two years and the boilers were converted to only gas firing ones. Existing steam and power configurations are as follows (please refer Drg. No.: FS also): Steam Generation/Consumption System of the Complex The steam production of the complex is from three sources. One is from waste heat of Ammonia plant, second from auxiliary boiler installed within ammonia plants and third from direct natural gas firing in Steam Generation plant (SGP). The details of total steam production/generation are as follows: Sl. No. Item Capacity (MT/hr) Generation/ Consumption (MT/hr) A Steam generation from waste heat of Ammonia Plant (105 ata, C) 1. RG / CG Boiler Syn Loop Boiler Auxiliary Boiler (in Ammonia plant) SGP Plant (Offsite) Sub-total (A)

16 Sl. No. Item Capacity (MT/hr) Generation/ Consumption (MT/hr) B Steam Consumption at 100 ata, C 1. Ammonia Syn Gas Compressor Amm. Refrg. Compr -III PRDS + Quench Urea Plant Captive Power Plant BFW Pump (SGP) Chemical Group Plants - 30 Sub-Total (B) Power Generation/Consumption System of the Complex The existing power generation of the complex by STG is from the HP steam generated from direct firing of natural gas in the SGP. The break-up of source of power generation and consumption is given below: Sl. No. Item Capacity (MW) Generation/ Consumption (MW) A Power generation 1. From CPP Power Import from MSEB Sub-total (A) 28.0 B Power Consumption 1. Ammonia Plant (net) Urea Plant SGP+ WT+RWP Chemical Group of Plants Others (ETP, Pump House) Sub-Total (B)

17 3.3 Existing Steam Turbine Driven Equipment The following moving machines are steam driven: Sl. No. A Item HP Steam driven at 100 ata & C 1.0 Syn Gas Compressor 2.0 Ammonia Refrigeration Compressor III B MP Steam driven at 37 ata & C 1.0 Process Air Compressor 1/II 2.0 Process Air Compressor III 3.0 Ammonia Refrigeration Compressor I/II 4.0 GV Section Lean Solution Pump 5.0 Cooling Tower III Pump 6.0 Small BP Turbine 7.0 Flue Gas Fan (ID Turbine) 8.0 Combustion Air Blower (FD Turbine) 9.0 BFW Pump (TP 601 A or B) 10.0 Nitrogen Compressor ( CGP) C LP Steam driven at 3.5 ata & C 1.0 Cooling Tower I/II Pumps 2.0 BFW Pump (TP 605 D) 3-3

18 4.0 MODIFICATION OF STEAM & POWER SYSTEM 4.1 The existing steam and power system of Thal urea manufacturing complex has already been delineated in the Chapter-3 of the report. In the production of ammonia and urea, the main thrust is to optimise the configuration of the plant complex in such a way that the overall energy consumption shall be minimum. With the time, technological advancement with respect to main plants as well utilities have always attracted the attention of urea manufacturers. Various studies are also being conducted to find out the economics of energy saving vis-a-vis capital investment. In India, most of the ammonia and urea production plants have improved their energy efficiency over the years. The improvement in energy efficiency is as a result of concerted efforts of the industry by implementing various energy saving schemes. RCF Thal also is not behind and has implemented the various schemes which has enhanced the production capacity as well as reduced the energy. When energy prices are in the lower segment, capital investment is most likely not justified. It is to be mentioned here that past is gone, now it is expected that energy price, especially of natural gas, may surge and hence introspective action is required. It is likely that, with the spiralling NG price, the economics of saving in energy vis-svis investment will give a flip to the present proposal. For production of steam and power to this complex, it was originally based on coal as well as natural gas as fuel for steam and power generation. Accordingly, 3 (coal + NG) fired boilers were installed. However the coal handling system was dismantled after a period of around two years and the boilers were converted to only gas firing ones. Though, on technical front, continuing the existing steam and power system do not have any problem but, on energy front, prima-facie it looks to be incompatible. In this regard, RCF internally has also examined. Based on their internal assessment, RCF is in a unique position to think about the long-term implications of present day decisions to change over the steam and power generation system. Apparently, it is felt that, modification in the existing system of steam and power may be beneficial in the long run. With a view to reduce the overall energy of the complex, it is proposed that steam and power system have to be modified in such a way that both steam and power shall be adequate to run the main plants and 4-1

19 auxiliaries un-interrupted. On this subject, PDIL has conducted the detailed study with operating the Thal complex at full load. 4.2 The proposed modifications It is proposed to change the existing steam turbine driven machineries to motor driven. As per existing available data of RCF Thal, PDIL analysed the configuration by replacing the existing steam turbine driven machineries which are using HP, MP and LP steam to motor drives for Ammonia plant and auxiliaries to the maximum possible extent. The details of existing as well as proposed modification thereof are given below: Table-4.1 Details of existing as well as proposed modification S. No. Items Existing Drive Drive After modification 1.0 HP Steam driven machines 1.1 Syn Gas Compressor (TK 431) Steam Turbine No change 1.2 Ammonia Refrigeration Compressor III (TK 4451) Steam Turbine Motor Driven 2.0 MP Steam driven machines 2.1 Process Air compressor 1/II (TK 421 & 422) Steam Turbine No change 2.2 Process Air Compressor III (TK 4421) Steam Turbine No change 2.3 Ammonia Refrigeration Compressor I/II (TK 451&452) Steam Turbine No change 2.4 GV Section lean solution Pump TP 301 AB Steam Turbine Motor Driven 2.5 Cooling Tower III (TP 4801A) Steam Turbine Motor Driven 2.6 Small BP Turbine Steam Turbine No change 2.7 Flue Gas Fan (ID Turbine TK 201) Steam Turbine Motor Driven 2.8 Combustion Air Blower (FD Turbine TK 202) Steam Turbine Motor Driven 2.9 BFW Pump (TP 601 A or B) Steam Turbine No change 2.10 Nitrogen Compressor (51-k-612) (CGP Steam Turbine Motor Driven 3.0 LP Steam driven machines 3.1 Process Air Compressor III (TK 4421) Steam Turbine No change 3.2 Cooling Tower I&II pump (TP 801 C&D) Steam Turbine Motor Driven 3.3 BFW Turbine (TP 605 D) Steam Turbine No change 4-2

20 Note: The details of steam generation and consumption in ammonia plant for existing and after the proposed modifications are given at Annexure-IV. For the proposed modification, there is a change in the steam and power production. The existing auxiliary boiler placed in ammonia plant will be stopped and SGP (except for steam generation to urea plant) & STG shall also be stopped. After stopping of these boilers and captive power plant, it is proposed to install 2 32 MW ISO GTG and HRSG (with additional firing provision) of TPH. With the change in GTG and HRSG, additional steam, which is coming from auxiliary boiler of Ammonia plant, now will be supplemented from HRSG. Hence the BFW pump (TP 605 D) will be inoperative. In this option, the total power requirement of the complex will be met from the power generation in GTG. Steam required for BFW preheating & de-aeration for HP superheated steam generation in one of the existing boilers and MP steam supply to CGP shall be met through existing PRDS. Finally the changes required for the modification are: GTG ( 2 32 MW ISO) HRSG ( TPH) Motors in place of steam turbines Modification in Power Distribution System Capacity Fixation of GTG & HRSG PDIL has prepared the steam and power balance after installation of GTG/HRSG. After changeover, power requirement of the complex is hovering around 46 MW (normal operation). Because of different operating combinations of various processing units, two GTGs are proposed for energy efficient operation. Each GTG shall have its own Heat Recovery and Steam Generation (HRSG) unit supported with auxiliary firing and supplementary air to augment steam generation capacity. Apart from generation of HP steam in two HRSGs, balance steam required for the complex shall be catered by operating one of the three existing Gas Fired Boilers located in CPP area. BFW preparation will be continued utilizing existing setup in CPP. New BFW preparation system will be required for catering the steam generation in both the HRSGs. After modification of CPP area as mentioned above, there will be no need to operate existing Auxiliary Boilers (H1601 / 2601) of both the Ammonia Plants. Due to stoppage of both the STGs in 4-3

21 original configuration, requirement of Circulating Cooling Water in CPP will also be reduced drastically and it will be possible to stop the existing Cooling Tower in CPP. This will reduce equivalent energy consumption in CPP area. To reduce Capital Cost for CPP modification, it is proposed to utilize existing one Deaerator, two BFW Pumps and associated auxiliaries. 4.3 Replacement of Steam turbines with Motors For ammonia plant, major changes are envisaged wherein most of the steam turbine driven moving machineries are being shifted to motor drive. The changes envisaged are described as below: Ammonia Refrigeration compressor III steam turbine drive (TK common for Ammonia 1&2) HP steam is fed to this turbine and 100% MP steam is extracted from it. No condensing steam is coming out from it. This turbine will be replaced by a new motor. This motor will be of adequate capacity GV Section Semi-Lean Pump Steam Turbine Drive (TP-301 A/B) Altogether 4 nos. of motors for Ammonia 1 & 2 will be required. These turbines are driven by MP steam available from MP extraction header. All these four turbines will be replaced by new motors Cooling Tower III pump steam turbine drive (TP-4801A) This is common for Ammonia 1 & 2. This is also driven by MP Steam available from MP extraction header. This turbine shall be replaced by motor of adequate capacity Flue gas fan (ID Fan Turbine TK 1201 & TK-2201) (MP to LP Extraction) Provision is there that this fan can either be driven by steam turbine or motor. Steam turbine and motors are either side of fan. As discussed during site visit that steam turbine can take-up the load for revamped capacity but motor rating is not adequate for revamped capacity. On checking the specification sheets, it is found that existing motor and steam turbines ratings for both ammonia plants are of same rating i.e. 850 kw each. It is proposed to replace the existing motors with new motors of higher ratings of 1300 kw. The existing steam turbines need not required to be dismantled and shall remain as stand by. The only thing is that motors will be in line and turbines will be as standby. 4-4

22 4.3.5 Combustion Air Blower FD Fan steam Turbine Drive (TK-1202 & TK 2202) (MP steam to LP extraction) As mentioned above for ID Fan drive system, this machine is also provided with steam turbine and motor on either side of FD fan. Moreover, here, both the existing motors and steam turbines are equally capable of taking the load of ammonia plants. On checking of specification sheets, it is found that existing motors and steam turbine ratings are as 950 kw. It is envisaged that there is no need of turbines replacement by motors. The existing system will remain in place, but during operation, motors will be in line in place of steam turbines and steam turbine as standby. No new items to be purchased here Cooling Tower Circulation Pump Steam Turbine Drive (TP 1801C &D) (LP steam to condensing steam) The existing steam turbines shall be replaced by motors. The new motors shall be purchased and installed in place of existing turbines. The no. of motors in this case shall be 4 (four) BFW pump steam turbine (TP 605D) LP to condensing This pump is required to be in operation when auxiliary boilers installed in Battery Limit of Ammonia plants are in operation. It is envisaged that after changeover, the auxiliary boilers in the ammonia plants shall be stopped and hence this pump will also be stopped. Hence there is no need of replacement of steam turbine by motors. The list of motors with their ratings which are required to be purchased new are as follows: Sl. No. Item Quantity Absorbed Power (kw) Motor Rating each (kw) 1. Motor for ARC III Benfield Circulation Pump- P.1301A/B; P-2301A/B 3. Motor for CT III pump for P- 4801A 4. Motor for ID Fan K-1201 / K Motor for CT I/II pumps for P-801C/D

23 Sl. No. Item Quantity Absorbed Power (kw) 6. Motor for Nitrogen Compressor in Chemical Group of Plant 51-K-612 Motor Rating each (kw) Motor for supplementary Air Compressors for HRSG * * Maximum power requirement in option-iii is kw and hence motor rating of 750 kw each has been considered. 4.4 Power Requirement Sl. No. Item Existing (kw) After Change (kw) 1. Ammonia Plant Urea Plants CGP Bagging & ETP SGP, CPP, WTP & RWP Total Power Note: Break of total power requirement is given at Annexure-V. 4.5 Space Required for Various Installation a) 15 no. motors to be installed in the same space made available after removal of respective Steam Turbines. b) 2 nos. new motors for ID fans shall be installed in the same space made available after removal of respective existing motors. c) For each GTG-HRSG system, tentative area requirement is 45 meters x 30 meters. The minimum space between two sets shall be 5.5 meters, however, if adequate space is available, same can be maintained at 7.5 meters. 4-6

24 5.0 ELECTRICAL PHILOSOPHY 5.1 Scope of Study The scope of the assignment awarded to M/s PDIL also covers study of the existing Electrical Systems of Ammonia Plants and CPP with respect to change in load in Ammonia Plants and installation of new GTGs. The study broadly includes checking adequacy of following electrical equipment/facilities which are likely to cater the load of equipment (fan, pump, compressor) presently being driven by steam turbines and now proposed to be replaced by driver motors: Incoming power cables from 15/25 MVA Transformers at MSEB Switchyard to 11 kv Switchboard at CPP. 11 kv Switchboard at CPP. 11 kv Switchboard at Ammonia Substation. Suitability of different existing electrical substations for accommodating new additional switchboard/extension panel for motors. Availability of space on existing cable racks/trenches for accommodating new power / control cables, as the case may be. Earthing System for equipment where the driver turbine (for fan, pumps, compressor etc.) being considered to be replaced by driver motors. DC Control Supply to Switchboards. On the basis of study, M/s PDIL has to recommend the up-gradation/ modification/ addition of existing electrical equipment / facilities related to equipment where the driver turbines (for fan, pump, compressor) are being considered to be replaced by driver motors. 5.2 Observations Considering replacement of driver turbine (for fan, pumps, compressor) by driver motors, the electrical system of CPP and Ammonia Plants was studied with respect to capacity. After replacement of turbines by motors, the electrical load shall increase and modification/addition shall be required in the Electrical system of the plant. Plant wise details of the Power Generation and Power Consumption are as indicated in the Power Balance drawing for different options considered, attached elsewhere in the report. 5-1

25 5.2.1 CPP Presently 11 kv Switchboard at CPP is being fed by 2 Nos. 100/11 kv, 15/25 MVA Transformer through 2000A Incoming Feeders (Bus 1 & 2) and 2 Nos. 15 MW STG through 2000 A Incoming Feeders (Bus 4 & 5). Also, there are Bus 3 & Bus 6. Bus 1 & Bus 6 are tie in whereas Bus 2 & Bus 3 are tie-in. There are 6 Nos. Bus-couplers. The copper bus bar rating is 2000A. The make of this switchgear is Fuji, Japan and approximately years old. The 11 kv Switchboard is with MOCB, which are obsolete now-a-days. Also, RCF is facing problem to get spares for this switchboard Ammonia Substation Presently, there is one 11 kv Switchboard in Ammonia Substation, which is being fed by 4 Nos. feeders of 11 kv Switchboard in CPP (From Bus 1, 2 4 & 5). All the 11 kv motors in Ammonia-I and Ammonia-II, Ammonia Cooling Towers and various transformers of Ammonia- I and Ammonia-II plants are being fed by this 11 kv Switchboard. Sufficient feeders are not available in this 11 kv Switchboard to cater the additional load for equipment in which turbine drivers shall be replaced by driver motors. There is no space in Substation for extension of this switchboard. Also, the incoming feeders rating and bus bar rating are not adequate to cater the additional load for equipment in which driver turbines shall be replaced by driver motors. The existing 11 kv Switchboard in Ammonia Substation has feeders for MK 1301, MK 1302, MK 2301 and MK 2302 also General The existing cable trays (both for HT as well as LT Cables) have not enough space to accommodate new HT / LT Cables for new motors. Hence, it is advisable to provide new cable tray/rack. As, there is no existing support for laying these cable trays, exclusive support for cable trays will have to be provided. 5.3 Load List Following Turbine driven equipment have been considered for replacement of turbine by motors: 5-2

26 Sl. No. Equipment Tag No. Equipment Description Plant Tentative New Load : Motor Rating (kw) Existing Motor Rating kw 1 TK 1201 Flue Gas Blower Amm - I 1300 MK 1201 / MK 2 TK 2201 Flue Gas Blower Amm - II : 850 kw 3 TK 1202 Combustion Air Blower Amm - I 950 MK 1202 / MK 4 TK 2202 Combustion Air Blower Amm - II : 950 kw 5 TK 4451 Common Ammonia Refrigeration Compressor Amm I & II 6 TP 1301A Benfield Circulation Pump Amm - I 1300 MP1301C / MP 7 TP 1301B Benfield Circulation Pump Amm - I C : 1145 kw 8 TP 2301A Benfield Circulation Pump Amm - II TP 2301B Benfield Circulation Pump Amm - II TP 4801A Cooling Water Pump Turbine 11 TP 1801C Cooling Water Pump Turbine 12 TP 1801D Cooling Water Pump Turbine 13 TP 2801C Cooling Water Pump Turbine 14 TP 2801D Cooling Water Pump Turbine Amm- I & II 1220 MP 4801B : 1000 kw Amm - I 1220 MP 1801C / MP 2801C : Amm I kw Amm - II 1220 Amm - II TP 1605 BFW Pump Turbine Amm - I 650 Earlier Motor 16 TP 2605 BFW Pump Turbine Amm - I 650 Rating : 650 kw 17 51TK612 Nitrogen Compressor Turbine Chemical Group Plants of 2000 MK 1201 / MK 2201 The existing motors MK 1201 / MK 2201 of rating 850 kw shall be replaced by motors (MK 1201 / MK 2201) of rating 1300 kw. As per information received from RCF, existing motors of 850 kw rating are under performing. However, existing turbines (850 kw rating) are performing well. Though it is difficult to explain the peculiar phenomena, considering the operating experience of RCF, the existing motors of rating is 850 kw are proposed to be changed with motors of higher rating i.e kw, equal to existing HT motors in the complex. Hence, motors of rating 1300 kw have been selected for better inventory management. 5-3

27 The 1300 kw motors shall be main driver whereas the existing turbines shall be standby. MK 1202 / MK 2202 The existing motors MK 1202 / MK 2202 of rating 950 kw shall be used as the main driver whereas the existing turbine shall be standby. TK 4451 The driver turbine TK 4451 shall be replaced by motor (MK 4451) of rating 4500 kw. As per RCF Steam distribution diagram - PFDD10-H/T, the turbine rating is 2347 kw, using 47.5 MT/hr HP steam. Estimated absorbed power is 3702 kw. However, as per information received from RCF, the turbine rating is 4177 kw and the turbine consumes 75 MT/hr HP steam. Considering the criticality of this compressor & possible enhanced capacity operation, motor rating has been selected as 4500 kw. TP 1301A, TP 1301 B, TP 2301 A and TP 2301 B The driver turbines TP 1301A, TP 1301 B, TP 2301 A and TP 2301 B shall be replaced by motor (MP 1301A, MP 1301B, MP 2301A and MP 2301B respectively) of rating 1300 kw. The motors of rating 1300 kw have been selected, as RCF is replacing the existing motors MP 1301 C / MP 2301 C (rating 1145 kw) to 1300 kw. TP 4801A The driver turbine TP 4801A shall be replaced by motor (MP 4801A) of rating 1220 kw. The motor of rating 1220 kw has been selected, as the existing motor for P-4801B, MP 4801B is consuming 1000 kw continuously. TP 1801C, TP 1801D, TP 2801C and TP 2801D The driver turbines TP 1801C, TP 1801D, TP 2801C and TP 2801D shall be replaced by motor (MP 1801C, MP 1801D, MP 2801C and MP 2801D respectively) of rating 1220 kw. The motors of 1220 kw rating have been selected for better inventory management as existing motor MP 1801C and MP 2801C are of rating 1220 kw. TP 1605D, TP 2605D The driver turbines TP 1605D and TP 2605D shall be replaced by motors (MP 1605D and MP 2605D respectively) of rating 650 kw. The motors of 650 kw 5-4

28 Option Generation by GTGs (MW) Generation in Amm. Plants (MW) Import from MSEB (MW) Total Power required (MW) rating have been selected, as earlier 650 KW motors were being used to run P 1605D and P 2605D and these motors were replaced by steam turbine some time back. The motors are available with RCF and the same shall be used now to run P 1605D and P 2605D. 51TK612 The driver turbines for 51TK612 shall be replaced by motor (51MK612) of rating 2000 kw. The absorbed power is 1737 kw. Hence, motor of rating 2000 kw has been selected Approximate 1.4 MW power is generated in Ammonia Plants (by XG 1301 and XG 2301). 5.4 Power Balance Options The following 5 options have been considered : Description Remarks I Normal Operation: Both GTGs Working II Ammonia - 1 & 2 100% Load Urea 1,2 & 3 100% Load Normal Operation : Both GTGs Working One Ammonia Plant - 100% Load Second Ammonia Plant : Syn Gas Compressor under start-up ( ) MW by each GTG) ( ) MW by each GTG) Ammonia 1&2 : MW Urea 1,2&3:12.50 MW Chemical Gr of Plants : MW Bagging, ETP etc. : 0.30 MW Boiler : 2.50 MW GTGs : MW Total : MW Ammonia 1&2 : MW Urea 1,2&3 : MW Chemical Gr of Plants : MW Bagging, ETP etc. : 0.30 MW Boiler : 2.50 MW GTGs : MW Total : MW Urea 1,2 & 3 100% Load 5-5

29 III Normal Operation : Both GTGs Working Ammonia 1 & 2 100% Load Two Urea Plants (1&2) 100% Load One Urea Plant (3) Ready for start-up IV One GTG/HRSG working and second GTG/ HRSG ready for start-up Ammonia 1 & 2 100% Load Urea 1,2 & 3 100% Load V GTG-1/HRSG-1 & GTG- 2/HRSG-2 ready for startup Ammonia 1 & 2 100% Load Two Urea Plants (1 & 2)- 100% Load One Urea Plant (3) : Ready for start-up (18.335) MW by each GTG) (By working GTG) Ammonia 1&2 : MW Urea 1,2&3 : 9.00 MW Chemical Gr of Plants : 0 MW Bagging, ETP etc. : 0.30 MW Boiler : 0 MW GTGs : MW Total : MW Ammonia 1&2 : MW Urea 1,2&3 : MW Chemical Gr of Plants : 0 MW Bagging, ETP etc. : 0.30 MW Boiler : 2.50 MW GTGs : MW Total : MW Ammonia 1&2 : MW Urea 1,2&3 : 9.00 MW Chemical Gr of Plants : 0 MW Bagging, ETP etc. : 0.30 MW Boiler : 2.50 MW GTGs : 0 MW Total : MW 5.5 Power Plant s Existing Generation and Consumption Details Steam Turbine Generators (STGs) The existing STGs (2 x15 MW) do not have sufficient capacity to cater all the new loads (Replacement of Turbines to motors as indicated above). For the existing electrical load, the STG is capable to cater but after changeover, due to replacement of turbines by motors, it shall not be able to meet the requirement. Presently STGs feed all the loads of Power Plant, Urea Plants, Ammonia Plants, Chemical Group of Plants, Others (PHP + ETP). The present consumption (Plant-wise) is as follows: Sl. No. Plant Load (MW) 1. Ammonia Plants Urea Plants

30 3 STG + WTP + Raw Water Pump House Chemical Group of Plants Others (PHP + ETP) 0.3 Total 28.0 Out of Total 28 MW Consumption, 27 MW is fed by existing 2 Nos. 15 MW STG and balance from MSEB Grid. There is MSEB Switchyard inside the RCF Plant from where power is being fed to 11 kv Switchboard at CPP through 2 Nos. 100/11 kv, 15/25 MVA Dyn11 Power Transformers. Presently RCF has contract with MSEB for 6 MVA Fixed Load and Maximum Load of 16 MVA. It is proposed to replace the existing STGs with 2 Nos. new GTG of capacity 32 MW (ISO) each for catering the existing loads plus loads for equipment in which driver turbine are being replaced by driver motors. Moreover, the present contract load with MSEB may require to be enhanced considering the increase in demand, in case both GTGs trips. The same shall be explored and finalized during detailed engineering stage. 5.6 Proposed Modification CPP Based upon the above observations & discussion with RCF during the visit, following modification/ up gradation / additions are being proposed in existing electrical facilities / plant: Option I The existing 11 kv Switchboard at CPP needs to be replaced by new one (Feeder List as per Annexure I and SLD as per Drawing No. FS A). Based on the additional load, the New 11 kv Switchboard shall have the following: 4 Nos. incoming 4000A VCB (2 Nos. from New GTG and 2 Nos. from MSEB Grid) 6 Nos. Bus Section 4000A Aluminum bus bar 6 Nos. Bus coupler 2 Nos. Bus duct as per existing scheme. 5-7

31 Outgoing feeder as per existing one 8 Nos. Spare Feeder 1250A VCB 3 Nos. 2000A Outgoing Feeders to new 11 kv Switchboard near existing Ammonia Substation (to cater new load of motors where driver turbine is to be replace by driver motor + 3 Nos. 2000A Spare Feeder Line & Bus PTs The store room and other room shall be vacated and walls between Substation Room and Store Room shall be dismantled to make space for New 11 kv Switchboard. Also, floor shall be cut for entry of cables. Installation, testing & commissioning of New 11 kv Switchboard shall be done Bus Section-wise. The same shall be planned in such a way that operation of running plants is minimum affected. The existing cables from the MSEB Switchyard shall be used for New 11 KV Switchboard at CPP. Other cables may also be used depending upon the length required. In case the length comes short, the existing cable shall be replaced with new one, so that cable joints are avoided for critical 11 kv Switchboard like Ammonia Plants and Urea Plants. The existing Control room for STGs shall be used for Control Room of GTGs. The Motor for Nitrogen Compressor (51 MK612) shall be fed from existing 11 kv Switchboard at CO/FAP Substation (Extension of Switchboard : Addition of 1 No. Panel). It has been envisage that there is sufficient space for extension of 11 kv Switchboard at CO/FAP Substation. New cable for same shall be laid in existing cable tray and additional cable tray, if required. The existing cables (PILC type) may be replaced by XLPE cables, if required. Option II The existing 11 kv Switchboard at CPP shall remain in use. However, the MOCBs of existing 11kV Switchboard shall be replaced by VCBs in phased manner. One new additional 11 kv Switchboard (Feeder List as per Annexure II and SLD as per Drawing No. FS B) shall be placed adjacent to existing 11 kv Switchboard. The existing 2 Nos. Incoming MESB supply to existing 11 kv Switchboard at CPP shall be removed and connected to New Additional 11 kv Switchboard at CPP as 5-8

32 Incoming. Supply from 32 MW (ISO) GTG (2 Nos.) shall be connected to New Additional 11 kv Switchboard at CPP as Incoming. The store room and other room shall be vacated and walls between Substation Room and Store Room & shall be dismantled to make space for New 11 kv Switchboard. Also, floor shall be cut for entry of cables. Installation, testing & commissioning of New Additional 11 kv Switchboard shall be done prior to shutdown, so that operation of running plants is minimum affected. The existing Control room for STGs shall be used for Control Room of GTGs. The Motor for Nitrogen Compressor (51 MK612) shall be fed from existing 11 kv Switchboard at CO/FAP Substation (Extension of Switchboard : Addition of 1 No. Panel). It ahs been envisage that there is sufficient space for extension of 11 kv Switchboard at CO/FAP Substation. New cable for same shall be laid in existing cable tray and additional cable tray, if required. The existing cables (PILC type) may be replaced by XLPE cables. The New Additional 11 KV Switchboard at CPP shall have the following : 4 Nos. of Incomers (2 from 11 kv MSEB Switchyard and 2 from GTGs) 4000 A VCB 4 Nos. Bus Couplers 2 Nos. outgoing supply to Existing 11 kv Switchboard at CPP (GTG Supply) 3 Nos. 2000A outgoing feeders to new 11kV Switch Board near Ammonia Substation (1No. MSEB Supply + 2 Nos. GTG Supply) 6 No. 2000A Spare outgoing feeders Line/Bus PT Ammonia Substation Option I New 11 kv Switchboard (Feeder List as per Annexure III and SLD as per Drawing No. FS A) shall be required to feed additional load (for equipment in which turbine drivers shall be replaced by motors) of Ammonia Plants and Cooling Tower. This Switchboard shall be installed in New Building near Ammonia Substation. This 11 kv Switchboard shall be fed from New 11 kv Switchboard at CPP (replacement of complete existing 11 kv Switchboard at CPP : OPTION I ). 5-9

33 There shall be 3 Nos. new Incoming Cables to New 11 kv Switchboard near Ammonia Substation from New 11 kv Switchboard at CPP (Replacement of complete Existing 11 kv Switchboard at CPP : OPTION I). New Building shall be made at vacant space available near Ammonia Substation and New 11 kv Switchboard shall be installed in this building. This new building (tentative size 17 M x 16 M) shall be made such that it shall be extension of existing Ammonia Urea Substation. Based on the additional load, the new 11 kv Switchboard shall have the following: a. 3 Nos. incoming 2000A VCB b. 2 Nos. Bus coupler 2000 A VCB c. Bus & Line PT d. 1 No. Bus Duct e. Outgoing feeder for motors Bus Section A 1. MP 1301A Benfield Circulation Pump 2. MP 1301B Benfield Circulation Pump 3. MP 1801C Cooling water Pump Turbine 4. MP 1801D Cooling water Pump Turbine 5. 1 No. Spare Feeder Bus Section B 1. MK 4451 Common Ammonia Refrigeration Compressor 2. MP 4801A Cooling water Pump Turbine 3. 1No. Spare Feeder Bus Section C 1. MP 2301A Benfield Circulation Pump 2. MP 2301B Benfield Circulation Pump 3. MP 2801C Cooling water Pump Turbine 4. MP 2801D Cooling water Pump Turbine 5. 1No. Spare Feeder MK 1201, MK 1202, MK 2201 and MK 2202 are presently being fed by existing 11 kv Switchboard in Ammonia Substation and the same shall remain unchanged. There are feeders available in 3.3 kv Switchboard at Ammonia Substation for MP 1605D and MP 2605D and same shall be utilised. Option II New 11 kv Switchboard (Feeder List as per Annexure III and SLD as per Drawing No. FS B) shall be required to feed additional load (for equipment in 5-10

34 which turbine driver shall be replaced by motors) of Ammonia Plants and Cooling Tower. This Switchboard shall be installed near Ammonia Substation. This 11 kv Switchboard shall be fed from Additional New 11 kv Switchboard at CPP (existing 11 kv Switchboard at CPP shall remain in use). There shall be 3 Nos. incoming new cables to new 11 kv switchboard near Ammonia Substation from new Additional 11 kv Switchboard at CPP : Option-II. New Building shall be made at vacant space available near Ammonia Substation and New 11 kv Switchboard shall be installed in this building. This new building (tentative size 17 M x 16 M) shall be made such that it shall be extension of existing Ammonia Urea Substation. Based on the additional load, the new 11 kv Switchboard shall have the following: a. 3 Nos. incoming 2000A VCB b. 2 Nos. Bus coupler 2000 A VCB c. Bus & Line PT d. 1 No. Bus Duct e. Outgoing feeder for motors Bus Section A 1. MP 1301A Benfield Circulation Pump 2. MP 1301B Benfield Circulation Pump 3. MP 1801C Cooling water Pump Turbine 4. MP 1801D Cooling water Pump Turbine 5. 1 No. Spare Feeder Bus Section B 1. MK 4451 Common Ammonia Refrigeration Compressor 2. MP 4801A Cooling water Pump Turbine 3. 1No. Spare Feeder Bus Section C 1. MP 2301A Benfield Circulation Pump 2. MP 2301B Benfield Circulation Pump 3. MP 2801C Cooling water Pump Turbine 4. MP 2801D Cooling water Pump Turbine 5. 1No. Spare Feeder MK 1201, MK 1202, MK 2201 and MK 2202 are presently being fed by existing 11 kv Switchboard in Ammonia Substation and the same shall remain unchanged. There are feeders available in 3.3 kv Switchboard at Ammonia Substation for MP 1605D and MP 2605D and same shall be utilised. 5-11

35 5.6.3 General New cable trays shall be laid and also exclusive support for these cable trays will have to be provided. The route of new cable trays for motors excluding for K4451 and P4801A shall be along the existing one. However, for motors for K4451 and P4801A, the cable tray route shall be through Cooling Tower Area and Compressor House Area. The existing cables for MP 1605D and MP 2605D shall be utilised. Soft Starter shall be provided for motor for Ammonia Refrigeration Compressor (MK 4451) to limit the starting current. The modification in the existing Load Management System shall be also be required for the equipment where the driver turbines (for fan, pump, compressor) are considered to be replaced by driver motors and motors are used as main driver and turbine as standby driver for Flue Gas Blowers and Combustion Air Blowers. Further, the modification in the existing Load Management System of CPP shall also be required against addition of 2 Nos. 32 MW GTGs. Islanding Logic shall be implemented in line with existing system by carrying out required modification (hardware as well as software) in existing PLC based LMS system. Series reactor of suitable rating shall also be provided, which shall be finalised during detailed engineering stage. The new 11 kv motors shall be considered as pressurised type (Exp) for Ammonia Plants and Chemical Group of Plants whereas Safe Area type for Cooling Tower Area. The existing foundation of driver turbines shall be modified to accommodate the motors. However, in case modification is not possible, new foundation will be required. The existing Earthing System in the plant is healthy and adequate. For new equipments, proper earthing shall be done and further connected to existing earthing grid. However, new earthing pits shall be made as per requirement based upon relevant IS Standards. The existing Spare feeders of existing MLDB shall be utilised and LDBs shall be installed in New building for New 11 kv Switchboard of Ammonia Plant. 5-12

36 The DC control Supply for New 11 kv Switchboards (at CPP and near existing Ammonia Substations for New Loads) shall be provided from existing DC Distribution Board. It has been envisaged that there are Spare feeders available in the DC Distribution Board. The Auxiliary Supply for New 11 kv Switchboards (at CPP and near existing Ammonia Substations for New Loads) shall be provided from existing Auxiliary Supply Distribution Board. It has been envisaged that there are Spare feeders available in the Auxiliary Supply Distribution Board. Power supply to New 32 MW GTGs Auxiliaries shall be fed from existing Switchboards as far as possible. Modification shall be carried out in existing feeders to suit new load requirement. Also, existing power/control cables, cable trays etc. shall also be used as far as possible. 5-13

37 6.0 PLANT OPERATION UNDER DIFFERENT SCENARIOS 6.1 Option-I Normal operation: Both Ammonia plants-1&2 are running at 100% load. Three Urea plants-1, 2 & 3 are running at 100% load and CPP-Boiler is generating around 228 MTPH HP steam. Both GTG units are ~22.8 MW power in each unit along with around 60.7 MTPH HP steam in respective HRSGs. No power is imported and steam supply to CGP is maintained at 20 MTPH through existing PRDS. Details are given at Drg. No: FS A. 6.2 Option-II One Ammonia Plant & Three Urea Plants-1, 2 &3 are running at 100% load. Other Ammonia Plant Syn Gas Compressor (SGC) is under Start-up condition. CPP Boiler is generating at 260 MTPH HP steam. Both GTGs are power in each unit with about 97.9 MTPH HP steam in respective HRSGs. No power is imported and steam supply to CGP is maintained at 20 MTPH through existing PRDS. Details are given at Drg. No: FS B. 6.3 Option-III Both Ammonia Plants-1&2 and Urea Plants-1&2 are running at 100% load. Both GTGs are ~18.3 MW power in each unit with 96 MTPH HP steam in respective HRSGs. No power is imported. CPP- Boiler, Urea Plant 3 and CGP are ready for Start-up. Details are given at Drg. No: FS C. 6.4 Option-IV Both Ammonia Plants-1&2 and all the three Urea plants are running at 100% load. CPP-Boiler is generating 260 MTPH HP steam. One GTG is ~29.3 MW power along with around 75.7 MTPH HP steam in HRSG. Second GTG/HRSG and CGP are ready for start-up. Power Import is 12 MW to sustain plant load. Details are given at Drg. No: FS D. 6.5 Option-V Both Ammonia Plants-1&2 and Urea Plants- 1&2 are running at 100% load. CPP- Boiler is generating MTPH HP steam. Both GTG/HRSGs and CGP are ready for start-up. Power Import is maintained at about 37.7 MW to sustain plant load. Details are given at Drg. No: FS E. 6-1

38 7.0 ENVIRONMENT IMPACT ASSESSMENT 7.1 Identification and prediction of impacts Land Environment The proposed project is limited to changeover scheme from Steam and Power Generation through STG to GTG and HRSG in offsites and minor modification in the existing Ammonia plant. Due to changeover scheme, no additional land is required and activity shall be confined to the existing plant area. No major levelling and grading activities are anticipated. Hence, due to proposed project, no change in land use pattern is envisaged. The proposed changeover scheme will generate marginal construction waste like civil debris, metal scrap, lube oil etc. The solid waste generated due to construction/demolition activities with respect to civil debris will be used for filling low lying areas. Metal scraps and lube oil shall be stored at one place and sold to outside agencies. As such there will be no adverse impact on the land environment due to proposed scheme. During operation phase, nature and quantity of solid waste shall remain same rather less than that in the existing system which shall be handled, stored and disposed off as per existing rule. It is, therefore, concluded that proposed scheme will have no impact on land environment Air Environment Sources of Air Pollution due to proposed changeover scheme Construction Phase During construction phase, there will be minor generation of dust due to minor excavation work. But it will be for a limited period only. Dust generation will be suppressed by spraying water. Operation Phase The sources of air pollution in changeover project will not increase rather it will decrease because the objective of the proposed scheme is to reduce the energy consumed in steam and power production/generation. The details are given as follows: 7-1

39 In the proposed modification, there is absolutely no change in urea production quantity. The production quantity will remain same. The quality and quantity of inputs required for urea production are unchanged. In ammonia production process, there are modifications in moving machineries. The drive turbines are being replaced with motors. In ammonia plants also, there is no change in quantity but input steam is replaced with electrical power. In the existing system, driving the machines with steam turbine may generate some liquid effluent in terms of blowdowns, but after changeover, there is no possibility of any type of emission (solid, liquid or gaseous). Presently steam is generated by direct firing of natural gas in Steam Generation Plant and further this steam is used in Urea plant and power generation. After changeover scheme, power shall be generated through gas turbine and exhaust gas from GTG will be used for generating the high pressure steam. Due to use of GTG system, it is likely that consumption of steam will be substantially reduced thereby reducing the consumption of natural gas. Hence reduction of liquid as well as gaseous effluents Water Environment With the implementation of changeover scheme, water requirement for the plant shall be reduced due to reduction of steam and cooling water circulation requirement. Hence, total quantity of effluent generation after implementation of changeover scheme shall not be increased rather it will be reduced. So, no additional treatment facility is required Noise environment Sources of Noise due to proposed changeover scheme No major installation of moving machineries is envisaged in the proposed changeover scheme. Exiting Steam Turbine Generator shall be replaced with Gas Turbine Generator and HRSG & the existing steam turbines shall be replaced by motor drives. However, all necessary precautions are being taken itself from design stage so that noise level inside the plant as well as to factory boundary remains well within the permissible limit Socio-Economic Environment In the existing complex, total number of officers and workers are 485 and 1060 respectively. As no major change in process activity/facility is proposed, the 7-2

40 existing manpower is sufficient to cater the requirement of the proposed changeover scheme. During construction phase, around temporary labourers shall be required. This manpower shall be available from the surrounding area. Hence, there will be no influx of job seekers from outside and impact on demographic profile is ruled out. But there will be temporary positive socio-economic impact. 7.2 As per MOEF procedure and guidelines, any investment for a project in India, whether it is modernisation or expansion of existing project, a detailed project Report covering Environment Impact Assessment (EIA) aspect needs to be submitted to MOEF. 7-3

41 8.0 PROJECT IMPLEMENTATION PLAN AND TIME SCHEDULE 8.1 After obtaining the approval from the Board of Directors, for implementation of the proposed modifications on cost plus fees mode, a contract will be signed with Consultant for detailed engineering and commissioning. A competent Indian engineering Consultant shall be selected to carry out the detailed engineering, procurement, inspection & expediting, construction and commissioning supervision of the proposed energy saving project. 8.2 The ordering and procurement of equipment shall be done in-house by M/s. RCF with the necessary help of Indian Engineering Consultant who will be also responsible for engineering and expediting. For commissioning, consultant s experts shall be deputed to site as and when required. 8.3 For the proposed modification, there shall be two types of activities. The major activities shall be related to installation of GTG and HRSG which is completely new set of facilities to be executed adjacent to the existing CPP area. The other installations are related to in-plant modifications/replacement. The new set of facilities shall be installed separately by following the appropriate procedure. These new equipment and portions of the equipment, which shall be needed to modify for the new duty shall be procured and kept ready at site. In the proposed revamp scheme, some of the steam turbines, specifically Ammonia Refrigeration Compressor III turbine, shall be replaced by motors. Though the motors will be procured and kept ready at site but its installation requires opportune time after plant shutdown of the particular equipment i.e steam turbine. The steps will be like- dismantling of existing turbine, preparation of suitable civil foundation for motor, setting of civil foundation etc. All these steps may require around one month s time. The installation of motor in place of ARC III turbine is planned in such a way that loss of urea production is minimum to the extent possible. One month prior to beginning of normal shutdown, ARC III turbine will be taken offline and above steps will be followed. By doing so, ammonia - urea plants will be in operation but at lower load. The final erection and hooking up will be done during the annual turn around period, which is expected to last for days. Hence one month partial production loss has been envisaged for dismantling of existing turbine, preparation of suitable civil foundation for motor and setting of civil foundation. 8-1

42 8.4 Pre-project Activities The pre-project activities to be completed before physical execution of the project are briefly enumerated below: Approval of the project by the company Board of Directors. Submission of application for environmental clearance to the State and Central Pollution Control Boards. Appointment of owner s Project Management team. Appointment of Indian Engineering Consultant. Firming up of division list for procurement. All the pre-project activities mentioned above shall be completed before the zero date of the project. 8.5 Physical Execution of the Project Based on above philosophy, RCF shall implement the changeover scheme by entering into agreement with a reputed Indian engineering consultant, who has been actively involved in the implementation of similar type of projects. The services to be rendered by Indian engineering consultant cover the following: Detail engineering and procurement services in respect of GTG and HRSG along with motor drives. Inspection and expediting services by posting necessary specialist at the vendors/fabrication shops. Scheduling and monitoring services. Construction supervision Commissioning supervision Procurement assistance to Owner Assistance to owner for selection of civil & construction contractors. 8.6 It is envisaged that major time shall be required in execution of GTG and HRSG without affecting the operation of ammonia and urea. The total time schedule for completion of project, especially GTG and HRSG would be about 24 months after receipt of approval from concerned authorities. The zero date will commence after completion of all the pre-project activities. 8-2

43 9.0 BENEFITS & SAVINGS 9.1 After installation /implementation of proposed scheme in the existing RCF Thal complex, the savings on various counts are as follows: 9.2 Natural Gas Besides consumption of natural gas in ammonia plant as feed and fuel to reformer, it is also consumed in generation/production of steam. The steam is used for generation of power and driving turbines. After changeover scheme, natural gas will be used in GTG for generation of power required for the complex and steam through HRSG. However balance steam required for the complex shall be generated by direct firing of natural gas in the SGP boiler. For the existing case (Base Case, Drg. No. FS ), the natural gas consumption for steam generation is given below: Sl. No. Item NG (NCV kcal/sm 3 ) Consumption Sm 3 /hr 1. Auxiliary Boiler in Ammonia Plant Steam Generation in SGP Total After implementation of changeover scheme (Option-I, Drg. No. FS A), the natural gas consumption for generation of power (in GTG), steam generation in HRSG and SGP for are as follows: Sl. No. Item NG (NCV kcal/sm 3 ) Consumption Sm 3 /hr 1. GTG (Power) HRSG (Steam) SGP Total From above tables, it shows that there is substantial saving in consumption of natural gas after changeover i.e Sm 3 /hr. 9.3 Process Water It is evident from the study that for the changeover scheme, there is less consumption of steam compared to existing system. The lower the steam 9-1

44 generation, more is the saving in water consumption. At the same time, due to changeover from steam turbine drive to motor drive, there is reduction in cooling water circulation to the extent reduction of steam going through condensing type steam turbine. The reduction in cooling water circulation will certainly decrease the make-up water requirement of cooling water circulation in the complex. The reduction in make-up water due to above for Option-I is given below: Sl. No. Item Option-I 1. Due to reduction in steam (m 3 /hr) Due to reduction in CW Circulation (m 3 /hr) Total reduction in make-up water(m 3 /hr) Details of calculation are given at F.S Besides natural gas and water, other savings, though not substantial, may happen like power in lube oil pumps, turbine condensate transfer pumps, instrument air, etc. Additionally, it is expected that repair & maintenance cost of new facilities in comparison to existing ones will be lesser. 9.5 Other benefit against redundant assets can also be considered while evaluating the economics of changeover scheme. These redundant assets either can gainfully be utilized or sold as scrap items. However these savings have not been considered while calculating the financial benefits given at financial statement. 9.6 While installing the motor in place of ARC III turbine, it is required to plan in such a way that loss of urea production is minimum to the extent possible. Motor will be procured and kept ready at site. One month prior to beginning of normal shutdown, ARC III turbine will be taken offline. When steam turbine temperature becomes normal, the steps will be followed like- dismantling of existing turbine, preparation of suitable civil foundation for motor, setting of civil foundation etc. All these steps may require around one month s time. By doing so, ammonia - urea plants will be in operation but at lower load. Hence one month partial production loss has been envisaged for dismantling of existing turbine, preparation of suitable civil foundation for motor and setting of civil foundation. It has been envisaged by RCF that due to operation of the plant at lower load, RCF may incur losses of around 34 laks per day. The cumulative loss for one month will be around 10.2 crores. 9-2

45 10.0 PROJECT COST & ECONOMICS 10.1 Project Cost The project cost estimates for the facilities installed as described in chapter-4.0 for the proposed changeover scheme has been worked out to Rs Crores. An approximate break-up of the project cost estimates is given in Table-10.1 and details are presented in FS 02. Sl. No. A Particulars / Items Erected Cost Table Project Cost Estimates (Rs Lakhs) Cost 1.0 Gas Turbine Generator (2 32 MW ISO) HRSG (2 100 MTPH) 4000 B Supplies 1.0 All motors and its accessories Pipes valves & Fittings Electrical & Instrumentation 1342 C Total Supplies 2369 Incidentals on (B) Excise 12.36% 293 Sales 2% 53 Inland 3% 71 1% 28 D Erection 245 E Civil Works including extension of buildings 175 F Design Engineering & Procurement 830 G Contingency (5%) 1598 H Revenue Loss on account of forced shutdown 1020 Total Cost

46 10.2 Basis of Estimation The basis of estimates is as below: Equipment Cost For cost of GTG and HRSG, in-house cost data bank of PDIL has been used and also discussed with supplier of the equipments. Costs of these facilities are erected ones. Related to electrical facilities, costs of individual items have been estimated to arrive at total cost of electrical facilities Incidental Charges The incidentals charges have been estimated based on the following rates: Excise Duty & Education Cess Sales Tax Inland Handling Insurance 12.36% on supplies 2.0% on supplies and duty 3.0% on supplies 1.0% of Installed cost Construction Cost The civil construction cost and erection charges have been estimated based on facilities considered in the modification Contingencies A contingency provision of 5% has also been considered to cover the unforeseen expenses during project execution Revenue Loss on account of forced shutdown As mentioned in Chapter-9 that, for installation of motor in place of ARC III steam turbine, ammonia urea plants will be in operation but at lower load for one month. As envisaged by RCF that, due to lower load of operation, there will be a loss of Rs. 34 lakhs per day. The cumulative loss for one month will be around 10.2 crores. Since this revenue loss is before the start of operation of revamped scheme and onetime, its cost has been capitalized

47 10.3 Project Economics Annual Savings As mentioned in Chapter 9, the total annual savings, likely to be achieved after implementation of proposed changeover scheme, is expected to be around Rs crores. Considering gas US$ 4.2/MMbtu and water Rs. 30/m 3, annual savings has been worked to Rs lakhs for saving in natural gas (assuming exchange rate 1 US$ = Rs. 60) and Rs. 658 Lakhs for saving in Water against total investment (inclusive of production loss) of Rs Crores. The details of calculations are given at F.S Pay Back Period The additional capital investment will be paid back in about 4.57 years time by annual cash accruals including depreciation at nominal rated capacity of operation. Details are presented in F S Internal Rate of Return (IRR) The IRR is a discount rate at which the present worth of benefits and costs are equal. The IRR calculations take into account 24 months of construction period and 15 years of operating period of the project. On the above basis, the IRR of change over scheme is estimated as 17.80%. The details of the same are given in F.S Sensitivity Analysis To have an idea of weaknesses and strengths of the project proposal, sensitivity analysis has been done. Though, as per scope of work covered by PDIL mentioned under Chapter-2 of the report, the sensitivity analysis of the proposed project has to be carried out w.r.t. to gas price, power cost, foreign exchange rate, capital cost, generation capacity, etc. but it is to be appreciated here that while calculating the IRR and Payback period for the proposed study, the power cost and generation capacity have no role to affect the IRR and Payback period. These could have been considered when power generation system is analyzed in isolation. Here the economics of the project is based on the differential savings/benefits of proposed 10-3

48 modification over existing one. Hence the meaningful sensitivity may be with respect to change in project capital cost, Energy (NG) price and amount of savings in energy. The effect of these variations on IRR and Payback have been worked out and presented at F.S

49 11.0 CONCLUSIONS AND RECOMMENDATIONS 11.1 Conclusion Ammonia and urea plants have improved their energy efficiency over the years. Improvement in energy efficiency is a result of concerted efforts of the industry by implementing various energy saving schemes. The declining trend in energy consumption of ammonia and urea plants over the years is the testimony to the hard work imparted by company. This present study focuses on the energy efficiency in generation of steam and power which are being used in the RCF Thal s complex for the manufacture of ammonia and urea. In the preceding chapters, the details of existing system and proposed modification system and its techno-financial results have been analysed and finally, based on the results, it is concluded that the proposal is technically and economically feasible. The IRR and pay back periods are attractive. Though the existing facilities have no technical problem in operation but on energy front, which looks to be major concern, is consuming more energy than whatever alternative option has been evaluated. Various sensitivity analyses have also been conducted. Even with pessimistic approach, attractive financial results are seen. Though the investment pertaining to modification is substantial even then savings accrual is far ahead of investment Recommendation Considering the results of study, wherein IRR and pay back is attractive with NG price of US$ 4.2/MMBtu, PDIL strongly recommends for early implementation of the proposed modifications. 11-1

50 F.S -01 Saving/Benefit after Changeover Sl.No. Particulars Base case Option-I Savings A Natural Gas Natural Gas Consumption in Auxiliary Boiler (Sm3/hr) Natural Gas Consumption in SGP (Sm3/hr) Natural Gas Consumption in GTG (Sm3/hr) Natural Gas Consumption in HRSG (Sm3/hr) Total Natural Gas Consumption (Sm3/hr) Net reduction in NG Consumption (Sm3/hr) Calorific Value of Natural Gas (Kcal/Sm3) Energy saved (Kcal/hr) Energy saved (MMBtu/hr) Natural Gas price (US$/MMBtu) 4.2 Cost of Energy saved (Rs. Lakhs/hr) 0.92 Annual cost of Energy saved (Rs. Lakhs) 7286 B Process Water 1 Production/generation of Steam 1.1 From Auxiliary Boiler in ammonia plants (MT/hr) From SGP (MT/hr) From HRSG (MT/hr) Total Steam Generation (MT/hr) Make up water reduction due to reduced steam generation (m3/hr) Reduction in Cooling water load Reduction in steam generation which finally goes as steam condensate 3.1 (m 3 /h.) Cooling water load reduction due less condesate cooling with 10 deg 3.2 temp. Diff.( m 3 /hr) Make-up Water due to reduced CW circulation (m3/hr) Total make up water reduction (m3/hr) Cost of make up Water (Rs.30/m3) 30 Annual Cost of make water (Rs. Lakhs) Total Annual savings (Rs Lakhs) 7944

51 F.S 02 CAPITAL COST ESTIMATE (Rs. Lakhs) Sl.no Particulars / Items Cost A Erected Cost Gas Turbine Generator (2x32 MW ISO) Erected cost HRSG (2x100 MTPH) Erected cost 4000 B Supply Cost Cost of all motors 927 Pipes valves & Fittings 100 Electrical & Instrumentation 1342 Total Supplies (B) 2369 C Incidentals on (B) Excise 12.36% 293 Sales 2% 53 Inland 3% 71 1% 28 D Erection 245 E Civil Works including extention of buildings 175 F Design Engineering & Procurement 830 G Contingency (5%) 1598 H Revenue Loss due to shutdown (@ Rs 34.0 lakhs for 30 days) 1020 Total Capital Cost

52 F.S PAY BACK PERIOD Rs. Lakhs Sl. Particulars Cash Cumulative Cash No. Accruals Cash Outflow Accruals 1.0 Total Capital Outlay Cash Accruals during Period 1st Year of Operation nd Year of Operation rd Year of Operation th Year of Operation th Year of Operation th Year of Operation th Year of Operation th Year of Operation th Year of Operation Pay Back Period 4.57 Years

53 INTERNAL RATE OF RETURN F.S Rs. Lakhs Sl. Period Cash Cash Net Discount Net No. Outflow Inflow Cash Present Flow 17.80% Value 1.0 1st Year of construction nd Year of construction st Year of operation nd Year,, rd Year,, th Year,, th Year,, th Year,, th Year,, th Year,, th Year,, th Year,, th Year,, th Year,, th Year,, th Year,, th Year,, Net Present Value Internal Rate of Return (IRR) 17.80%

54 F.S SENSITIVITY ANALYSIS Sl.No. Particulars Capex Gas Price Pay back period IRR (%) Rs. Lakhs US$/MMBtu (Years) A Base Case % B With variation of gas price % % % C D E F G H With Variation in Project Capital Cost by (+10%) % (+20%) % With Variation in saving in Energy only (-10%) % (-20%) % With Variation in Project Capital Cost by +10 and energy saving -10% With Variation in Project Capital Cost by +20 and energy saving -20% With Variation in Project Capital Cost by +10 and energy saving -10% With Variation in Project Capital Cost by +20 and energy saving -20% % % % %

55 Feeder List : Complete Replacement of Existing 11 kv Switchboard at CPP Annexure I No. Bus Section Feeder Description Plant Feeder Type Rating (A) Ratting Remark 1 Bus Section 1 Incomer from Tr-1 (Grid) Incomer Bus Section 1 Bus PT Bus PT 11000/ 3 / 110/ 3 & 110/ 3 3 Bus Section 1 O/G to Formic - I Chemical Gr of Plants Outgoing Bus Section 1 O/G to Transformer - 14 (DMF Plant) (Chemical Gr of Plants) Transformer Bus Section 1 O/G to Ammonia - I (Grid Supply) Ammonia - I Outgoing Bus Section 1 Bus Duct to Bus 6 Bus Tie 4000 A 7 Bus Section 1 O/G to Transformer - 12 (750 KVA), 11/0.433 kv ETP Transformer Bus Section 1 O/G to Urea Urea Outgoing Bus Section 1 Spare Bus Section 1 Bus Coupler with Bus 2 Bus Coupler Bus Section 2 Incomer from Tr-2 (Grid) Incomer Bus Section 2 Bus PT Bus PT 11000/ 3 / 110/ 3 & 110/ 3 13 Bus Section 2 O/G to Transformer - 24 (DMF Plant) (Chemical Gr of Plants) Outgoing Bus Section 2 O/G to Ammonia - II (Grid Supply) Ammonia - I Outgoing Bus Section 2 Bus Duct to Bus 3 Bus Tie 4000 A 16 Bus Section 2 O/G to Transformer - 22 (750 KVA), 11/0.433 kv ETP Transformer Bus Section 2 Spare Feeder Spare Bus Section 2 O/G to Transformer - 23 (2000 KVA), 11/0.433 kv PHP Transformer Bus Section 2 O/G to Formic - II Chemical Gr Plant Outgoing Bus Section 3 Bus Coupler with Bus 2 Bus Coupler Bus Section 3 O/G to Transformer - 13 (2000 KVA), 11/0.433 kv PHP Transformer Bus Section 3 Bus PT Bus PT 11000/ 3 / 110/ 3 & 110/ 3 23 Bus Section 3 Spare Feeder Spare Bus Section 3 O/G to Urea Urea Outgoing Bus Section 3 O/G to Transformer - 31 (2000 KVA), 11/0.433 kv Steam Generation Plant Transformer Bus Section 3 O/G to Transformer - 32 (6000 KVA), 11/3.3kV Steam Generation Plant Transformer Bus Section 3 O/G to Transformer - 33 (1600 KVA), 11/3.3kV Steam Generation Plant Transformer Bus Section 3 O/G to Motor for BFW Pump KW Steam Generation Plant Motor Bus Section 3 Bus Coupler with Bus 4 Bus Coupler Bus Section 4 Bus PT Bus PT 11000/ 3 / 110/ 3 & 110/ 3 31 Bus Section 4 O/G to Transformer - 41 (6000/10000 KVA), 11/3.3 kv : Standby Steam Generation Plant Transformer Bus Section 4 Series Reactor between Bus 4 & Bus 5, Bus Section 4 O/G to Ammonia - II (GTG Supply) Ammonia - II Outgoing Bus Section 4 Spare Feeder Spare Bus Section 4 Incomer from GTG - 2 Incomer Bus Section 4 Bus Coupler with Bus 5 Bus Coupler Bus Section 5 Incomer from GTG - 1 Incomer Bus Section 5 Spare Feeder Steam Generation Plant Bus Section 5 Series Reactor between Bus 4 & Bus Bus Section 5 O/G to Ammonia - I (GTG Supply) Ammonia - I Outgoing Bus Section 5 Spare Feeder Spare Bus Section 5 Spare Feeder Spare Bus Section 5 Bus PT Bus PT 11000/ 3 / 110/ 3 & 110/ 3 44 Bus Section 5 Bus Coupler with Bus 6 Bus Coupler 4000 Sheet 1 of 2

56 Feeder List : Complete Replacement of Existing 11 kv Switchboard at CPP Annexure I No. Bus Section Feeder Description Plant Feeder Type Rating (A) Ratting Remark 45 Bus Section 6 O/G to Motor for BFW Pump KW Steam Generation Plant Motor Bus Section 6 Spare Feeder Bus Section 6 O/G to Transformer - 62 (6000/10000 KVA), 11/3.3 kvsteam Generation Plant Transformer Bus Section 6 O/G to Transformer - 63(1600 KVA), 11/3.3kV Steam Generation Plant Transformer Bus Section 6 O/G to Transformer - 61(2000 KVA), 11/3.3kV Steam Generation Plant Transformer 50 Bus Section 6 Bus PT 11000/ 3 / 110/ 3 & 110/ 3 51 Bus Section 6 Bus Duct to Bus 1 Bus Tie 4000 A New Feeder 52 Bus Section 1 O/G to New Switchboard Near Ammonia Substation Ammonia Additional Load Outgoing 2000 : Bus B 53 Bus Section 4 O/G to New Switchboard Near Ammonia Substation Ammonia Additional Load Outgoing 2000 : Bus C 54 Bus Section 5 O/G to New Switchboard Near Ammonia Substation Ammonia Additional Load Outgoing 2000 : Bus A Spare Feeder 55 Bus Section 1 Spare Feeder Bus Section 1 Spare Feeder Bus Section 2 Spare Feeder Bus Section 3 Spare Feeder Bus Section 3 Spare Feeder Bus Section 4 Spare Feeder Bus Section 4 Spare Feeder Bus Section 5 Spare Feeder Bus Section 5 Spare Feeder Bus Section 6 Spare Feeder Bus Section 6 Spare Feeder 1250 Notes 1 All Incomer A in place of 2000 A 2 All Bus coupler A in place of 2000 A 3 Busbar rating 4000 A in place of 2000 A Sheet 2 of 2

57 Feeder List : Additional 11 kv Switchboard at CPP in addition to Existing 11 kv Switchboard at CPP Annexure II No. Bus Section Feeder Description Plant Feeder Type Rating (A) Ratting Remark 1 Bus Section A Incomer from (MSEB Switchyard) Incomer Bus Section A Bus PT 11000/ 3 / 110/ 3 & 110/ 3 3 Bus Section A O/G to New Switchboard Near Ammonia Substation Ammonia Additional Load Outgoing 2000 : Bus B 4 Bus Section A Spare Feeder Bus Section A Bus Coupler with Bus B Bus Coupler Bus Section B Incomer from (MSEB Switchyard) Incomer Bus Section B Bus PT 11000/ 3 / 110/ 3 & 110/ 3 8 Bus Section B Bus Duct to Bus C Bus Tie 4000 A 9 Bus Section B Spare Feeder Bus Section C Incomer from GTG - 2 Incomer Bus Section C Bus PT 11000/ 3 / 110/ 3 & 110/ 3 12 Bus Section C Series Reactor between Bus C & Bus D Bus Section C O/G to Existing 11 kv Switchboard at CPP where 11 kv Switchboard at CPP Outgoing 200 presently 15 MW STG supply is being fed 14 Bus Section C O/G to New Switchboard Near Ammonia Substation Ammonia Additional Load Outgoing 2000 : Bus C 15 Bus Section C Spare Feeder Bus Section C Spare Feeder Bus Section C Bus Coupler with Bus D Bus Coupler Bus Section D Incomer from GTG - 1 Incomer Bus Section D Bus PT 11000/ 3 / 110/ 3 & 110/ 3 20 Bus Section D Series Reactor between Bus C & Bus D Bus Section D O/G to Existing 11 kv Switchboard at CPP where 11 kv Switchboard at CPP Outgoing 200 presently 15 MW STG supply is being fed 22 Bus Section D O/G to New Switchboard Near Ammonia Substation Ammonia Additional Load Outgoing 2000 : Bus A 23 Bus Section D Spare Feeder Bus Section D Spare Feeder Bus Section D Bus Duct to Bus A Bus Tie 4000 A Sheet 1 of 1

58 Annexure-IV Steam Balance of Ammonia Plants Figures in MT/hr Sl. No. Items Existing After modification A Ammonia Plant HP Steam production at 100 ata & 500 deg C RG Boiler/CG Boiler Syn Loop Boiler Auxiliary Boiler 97 0 Sub Total above Import from HRSG 0 12 Sub-Total (1.0) Remarks 2.0 HP Steam consumption at 100 ata & 500 deg C Syn Gas Compressor (TK 431) Ammonia Refrigeration Compressor III (TK 4431) 75 0 Shifted to Motor PRDS 10 0 Sub-Total (2.0) MP Steam Production at 37 ata & 370 deg C Syn Gas Compressor (TK 431) Ammonia Refrigeration Compressor III (TK 4431) 75 0 No production PRDS+Quench 10 0 Sub-Total (3.0) MP Steam consumption at 37 ata & 370 deg C Process steam in H Process Air compressor I/II (TK 421 &422) Process Air Compressor III (TK 4421) Ammonia Refrign. Compr. I/II (TK 451&452) GV Section lean solution Pump TP 301 AB 29 0 Shifted to Motor Cooling Tower III (TP 4801A) Shifted to Motor Small BP Turbine 2 2 Flue Gas Fan (ID Turbine TK 201) 26 0 Shifted to Motor Combustion Air Blower (FD Turbine TK 202) 26 0 Shifted to Motor BFW Pump (TP 601 A or B) HGRU (X 9000) 2 2 PGRU Reboiler (E 521) PRDS (SM-SL) Sub-Total (4.0) LP Steam Production at 3.5 ata & 214 deg C Blow down Flashing (B 603) Flue Gas Fan (ID Turbine TK 201) 26 0 No production Combustion Air Blower (FD Turbine TK 202) 26 0 No production BFW Pump (TP 601 A or B) SL PRDS & Desuperheating Sub-Total (5.0) LP Steam consumption at 3.5 ata & 214 deg C GV Section Regenerator (F 301) Deaerator Steam (B 601) Cooling Tower I/II pump (TP 801 C&D) 40 0 Shifted to Motor BFW Pump (TP 605 D) 10 0 Pump stopped Trap losses and various Users 2 0 Sub-Total (6.0)

59 Annexure-V Power Balance of the Complex Figures in kw Sl. No. Items Existing After modification Remarks 1.0 Ammonia Plant (Existing) Ammonia Plants after modification 2.1 Ammonia Refrigeration Compressor III (TK 4431) GV Section lean solution Pump TP 301 AB Cooling Tower III (TP 4801A) Flue Gas Fan (ID Turbine TK 201) Combustion Air Blower (FD Turbine TK 202) Cooling Tower I/II pump (TP 801 C&D) 4000 Sub-total (2.0) Total Ammonia Plant Urea Plant Chemical Group of Plants (existing) Chemical Group of Plants (after mdification) Bagging & ETP SGP, CPP, WTP & RWP Total Power

60 Feeder List : New 11 kv Switchboard Near Ammonia Substation Annexure III 6 No. Bus Section Feeder Description Plant Feeder Type Rating (A) Ratting Remark 1 Bus Section A Incomer from 11 kv Switchboard at CPP : Bus (GTG) Incomer Bus Section A Bus PT 11000/ 3 / 110/ 3 & 110/ 3 3 Bus Section A O/G to Motor for Benfield Circulation Pump MP 1301A Ammonia - I Motor Bus Section A O/G to Motor for Benfield Circulation Pump MP 1301B Ammonia - I Motor Bus Section A O/G to Motor for Cooling water Pump MP 1801C Ammonia - I Bus Section A O/G to Motor for Cooling water Pump MP 1801D Ammonia - I Bus Section A Spare Motor Feeder Motor Bus Section A Bus Coupler with Bus B Bus Coupler Bus Section B Incomer from 11 kv Switchboard at CPP : Bus (Grid) Incomer Bus Section B Bus PT 11000/ 3 / 110/ 3 & 110/ 3 11 Bus Section B O/G to Motor for Common Ammonia Refrigeration CompreAmmonia - I & II (Common) Motor Bus Section B O/G to Motor for Cooling water Pump MP 4801A Ammonia - I & II (Common) Motor Bus Section B Spare Motor Feeder Motor Bus Section B Bus Coupler with Bus C Bus Coupler Bus Section C Incomer from 11 kv Switchboard at CPP : Bus (GTG) Incomer Bus Section C Bus PT 11000/ 3 / 110/ 3 & 110/ 3 17 Bus Section C O/G to Motor for Benfield Circulation Pump MP 2301A Ammonia - II Motor Bus Section C O/G to Motor for Benfield Circulation Pump MP 2301B Ammonia - II Motor Bus Section C O/G to Motor for Cooling water Pump MP 2801C Ammonia - II Bus Section C O/G to Motor for Cooling water Pump MP 2801D Ammonia - II Bus Section C Spare Motor Feeder Motor 1250 Notes 1 Busbar rating 2000 A Sheet 1 of 1

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69 TENTATIVE TIME SCHEDULE FOR GTG HRSG INSTALLATION AT RCF THAL Task Name RCF Thal GTG HRSG Installation M-1 M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13 M14 M15 M16 M17 M18 M19 M20 M21 M22 M23 M24 M25 Project Zero Date Design Engineering Procurment Engineering Gas Turbine Generator (32 MW X 2) MR Preparation & Approval ITB issue Receive Bids Technical Recommendation Commercial Recommendation LOI Placement Delivery at site HRSG (100TX 2) MR Preparation & Approval ITB issue Receive Bids Technical Recommendation Commercial Recommendation LOI Placement Delivery at site 13 HT Motors MR Preparation & Approval ITB issue Receive Bids Technical Recommendation Commercial Recommendation LOI Placement Delivery at site Construction Construction works before annual turn around Construction works during annual turn around & Hook-up Project End CLIENT:M/S RASHTRIYA CHEMICALS & FERTILISERS LIMITED, THAL JOB NO.- FS-91 TIME- IN MONTHS Task Milestone Summary Page 1