Job No. FS-00097 August 2014

IN-DEPTH STUDY & PREPARATION OF TEFR

FOR INSTALLATION OF GAS TURBINE AT

RCF THAL FOR ENERGY REDUCTION

PREPARED FOR

RASHTRIYA CHEMICALS & FERTILIZERS LTD.,

MUMBAI

द्वारा पे्रषित

प्रोजेक्ट्स एण्ड डवेऱऩमेंट इण्ण्डया लऱलमटेड (भारत सरकार का उऩक्रम)

ऩी.डी.आई.एऱ. भवन, ए-14, सेक्टटर-1, नौएडा-201301 (ण्जऱा गौतमबुद्ध नगर) उ.प्र.

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

LIST OF ANNEXURE

Sl. No. Title Annexure No.

1.0 Feeder List: Complete Replacement of

Existing 11 kV Switchboard at CPP

I

2.0 Feeder List: Additional 11 kV

Switchboard at CPP in addition to

Existing 11 kV Switchboard at CPP

II

3.0 Feeder List: New 11 kV Switchboard

Near Ammonia Substation

III

4.0 Steam Balance of Ammonia Plants IV

5.0 Power Balance of the Complex V

LIST OF FINANCIAL STATEMENTS

Sl. No. Item F.S. No.

1.0 Saving/Benefit after Changeover 01

2.0 Capital Cost Estimate 02

3.0 Pay Back Period 03

4.0 Internal Rate of Return 04

5.0 Sensitivity Analysis 05

LIST OF DRAWINGS

Sl. No Title Drawing No.

1.0 Base Case - Reference Operation FS97-0000-0041

2.0 Option-1 – Normal Operation FS97-0000-0041A

3.0 Option-2 – Normal Operation FS97-0000-0041B

4.0 Option-3 – Normal Operation FS97-0000-0041C

5.0 Option-4 – Normal Operation FS97-0000-0041D

6.0 Option-5 – Normal Operation FS97-0000-0041E

7.0 Single Line Diagram -Option-I FS97-7313-0985A

8.0 Single Line Diagram -Option-II FS97-7313-0985B

0 - 1

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 1985. 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 2012-13. 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 - 2

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 socio-

economic 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 - 3

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 15-20 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. FS97-0000-0041), the natural gas

consumption for steam generation is given below:

Sl.

No.

Item NG (NCV-8700.16 kcal/Sm3)

Consumption Sm3/hr

1. Auxiliary Boiler in Ammonia Plant 8314

2. Steam Generation in SGP 38130

Total 46444

After implementation of changeover scheme (Option-I, Drg No FS97-0000-

0041A), 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-8700.16 kcal/Sm3)

Consumption Sm3/hr

1. GTG (Power) 12988

2. HRSG (Steam) 4888

0 - 4

3. SGP 17967

Total 35843

From above tables, it shows that there is substantial saving in consumption of

natural gas after changeover i.e 10601 Sm3/hr.

The details have been presented in Chapter -9.0 of the report.

0.10 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. 362.82 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.

Table - 0.1

Project Cost Estimates

(Rs Lakhs)

Sl.no Particulars / Items Cost

A Erected Cost

1.0 Gas Turbine Generator (2×32 MW ISO) 25600

2.0 HRSG (2×100 MTPH) 4000

B Supplies

1.0 All motors and its accessories 927

2.0 Pipes valves & Fittings 100

3.0 Electrical & Instrumentation 1342

Total Supplies 2369

C Incidentals on (B)

Excise Duty @ 12.36% 293

Sales Tax @ 2% 53

Inland Handling @ 3% 71

Insurance @ 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 36282

0 - 5

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 -10.0 of the

report.

0.11 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.

1 - 1

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 1978. 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 1985. 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 2012-13. 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 - 2

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.

2 - 1

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 - 2

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.

3 - 1

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.:

FS97-0000-0041 also):

3.2.1 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, 5100C)

1. RG / CG Boiler - 470

2. Syn Loop Boiler - 158

3. Auxiliary Boiler (in Ammonia

plant)

- 97

4. SGP Plant (Offsite) 3×275 485

Sub-total (A) 1210

3 - 2

Sl.

No.

Item Capacity

(MT/hr)

Generation/

Consumption (MT/hr)

B Steam Consumption at 100

ata, 5000C

1. Ammonia Syn Gas Compressor - 640

2. Amm. Refrg. Compr -III - 75

3. PRDS + Quench - 10

4. Urea Plant - 270

5. Captive Power Plant - 155

6. BFW Pump (SGP) - 30

7. Chemical Group Plants - 30

Sub-Total (B) 1210

3.2.2 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 2 × 15 27.0

2. Power Import from MSEB - 1.0

Sub-total (A) 28.0

B Power Consumption

1. Ammonia Plant (net) - 8.7

2. Urea Plant - 12.5

3. SGP+ WT+RWP - 4.0

4. Chemical Group of Plants - 2.5

5. Others (ETP, Pump House) - 0.3

Sub-Total (B) 28.0

3 - 3

3.3 Existing Steam Turbine Driven Equipment

The following moving machines are steam driven:

Sl. No. Item

A HP Steam driven at 100 ata & 5000C

1.0 Syn Gas Compressor

2.0 Ammonia Refrigeration Compressor III

B MP Steam driven at 37 ata & 3700C

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 & 2140C

1.0 Cooling Tower I/II Pumps

2.0 BFW Pump (TP 605 D)

4 - 1

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-s-

vis 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 - 2

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 - 3

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 2×100 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 ( 2×100 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 - 4

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:

4.3.1 Ammonia Refrigeration compressor–III steam turbine drive (TK 4451 -

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.

4.3.2 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.

4.3.3 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.

4.3.4 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 - 5

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.

4.3.6 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).

4.3.7 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 1 3702 4500

2. Benfield Circulation Pump-

P.1301A/B; P-2301A/B

4 4×1080 4×1300

3. Motor for CT III pump for P-

4801A

1 1000 1220

4. Motor for ID Fan K-1201 / K-

2201

2 2×1232 2×1300

5. Motor for CT I/II pumps for

P-801C/D

4 4×1000 4×1220

4 - 6

Sl. No.

Item Quantity Absorbed Power (kW)

Motor Rating each

(kW)

6. Motor for Nitrogen

Compressor in Chemical

Group of Plant 51-K-612

1 1737 2000

7. Motor for supplementary Air

Compressors for HRSG

2 2×142 2×750*

* Maximum power requirement in option-III is 2×742 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 8700 25886

2. Urea Plants 12500 12500

3. CGP 2500 4237

4. Bagging & ETP 300 300

5. SGP, CPP, WTP & RWP 4000 2790

Total Power 28000 45713

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.

5 - 1

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 - 2

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 32-33 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.

5.2.2 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.

5.2.3 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 - 3

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. 1300 kW, equal to existing HT motors in the complex. Hence,

motors of rating 1300 kW have been selected for better inventory management.

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

2201 : 850 kW 2 TK 2201 Flue Gas Blower Amm - II 1300

3 TK 1202 Combustion Air Blower Amm - I 950 MK 1202 / MK

2202 : 950 kW 4 TK 2202 Combustion Air Blower Amm - II 950

5 TK 4451 Common Ammonia

Refrigeration Compressor

Amm– I &

II

4500

6 TP 1301A Benfield Circulation Pump Amm - I 1300 MP1301C / MP

2301C : 1145

kW

7 TP 1301B Benfield Circulation Pump Amm - I 1300

8 TP 2301A Benfield Circulation Pump Amm - II 1300

9 TP 2301B Benfield Circulation Pump Amm - II 1300

10 TP 4801A Cooling Water Pump

Turbine

Amm- I & II 1220 MP 4801B :

1000 kW

11 TP 1801C Cooling Water Pump

Turbine

Amm - I 1220 MP 1801C /

MP 2801C :

1220 kW 12 TP 1801D Cooling Water Pump

Turbine

Amm– I 1220

13 TP 2801C Cooling Water Pump

Turbine

Amm - II 1220

14 TP 2801D Cooling Water Pump

Turbine

Amm - II 1220

15 TP 1605 BFW Pump Turbine Amm - I 650

Earlier Motor

Rating : 650

kW 16 TP 2605 BFW Pump Turbine Amm - I 650

17 51TK612 Nitrogen Compressor

Turbine

Chemical

Group of

Plants

2000

5 - 4

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 - 5

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.

5.3.1 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 :

Op

tio

n Description

Gen

erat

ion

by

GTG

s (M

W)

Gen

erat

ion

in A

mm

. Pla

nts

(M

W)

Imp

ort

fro

m M

SEB

(M

W)

Tota

l Po

wer

req

uir

ed

(MW

) Remarks

I Normal Operation: Both GTGs Working Ammonia - 1 & 2 – 100% Load Urea – 1,2 & 3 – 100% Load

45.713 (22.8565) MW by each GTG)

1.4 0 47.113 Ammonia 1&2 : 27.286 MW Urea 1,2&3:12.50 MW Chemical Gr of Plants : 4.237 MW Bagging, ETP etc. : 0.30 MW Boiler : 2.50 MW GTGs : 0.290 MW Total : 47.113 MW

II Normal Operation : Both GTGs Working One Ammonia Plant - 100% Load Second Ammonia Plant : Syn Gas Compressor under start-up Urea – 1,2 & 3 – 100% Load

46.671 (23.3355) MW by each GTG)

1.4 0 48.071 Ammonia 1&2 : 27.286 MW Urea 1,2&3 : 12.50 MW Chemical Gr of Plants : 4.237 MW Bagging, ETP etc. : 0.30 MW Boiler : 2.50 MW GTGs : 1.248 MW Total : 48.071 MW

5 - 6

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

36.67 (18.335) MW by each GTG)

1.4 0 38.07 Ammonia 1&2 : 27.286 MW Urea 1,2&3 : 9.00 MW Chemical Gr of Plants : 0 MW Bagging, ETP etc. : 0.30 MW Boiler : 0 MW GTGs : 1.484 MW Total : 38.07 MW

IV One GTG/HRSG working and second GTG/ HRSG ready for start-up Ammonia 1 & 2 – 100% Load Urea – 1,2 & 3 – 100% Load

29.344 (By working GTG)

1.4 12.0 42.744 Ammonia 1&2 : 27.286 MW Urea 1,2&3 : 12.50 MW Chemical Gr of Plants : 0 MW Bagging, ETP etc. : 0.30 MW Boiler : 2.50 MW GTGs : 0.158 MW Total : 42.744 MW

V GTG-1/HRSG-1 & GTG-2/HRSG-2 ready for start-up Ammonia 1 & 2 – 100% Load Two Urea Plants (1 & 2)- 100% Load One Urea Plant (3) : Ready for start-up

0 1.4 37.686 39.086 Ammonia 1&2 : 27.286 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 : 39.086 MW

5.5 Power Plant’s Existing Generation and Consumption Details

5.5.1 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 8.7

2 Urea Plants 12.5

5 - 7

3 STG + WTP + Raw Water Pump House 4.0

4 Chemical Group of Plants 2.5

5 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

Based upon the above observations & discussion with RCF during the visit,

following modification/ up gradation / additions are being proposed in existing

electrical facilities / plant:

5.6.1 CPP

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. FS97-7313-0985A). 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 - 8

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. FS97-7313-0985B) 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 - 9

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 .

5.6.2 Ammonia Substation

Option – I

New 11 kV Switchboard (Feeder List as per Annexure III and SLD as per Drawing

No. FS97-7313-0985A) 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 - 10

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. FS97-7313-0985B) shall be required to feed additional load (for equipment in

5 - 11

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 - 12

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 - 13

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.

6 - 1

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 generating @ ~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: FS97-0000-0041A.

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 generating

@~23.3MW 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: FS97-0000-0041B.

6.3 Option-III

Both Ammonia Plants-1&2 and Urea Plants-1&2 are running at 100% load. Both

GTGs are generating @ ~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: FS97-0000-0041C.

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 generating @ ~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 maintained @ 12

MW to sustain plant load. Details are given at Drg. No: FS97-0000-0041D.

6.5 Option-V

Both Ammonia Plants-1&2 and Urea Plants- 1&2 are running at 100% load. CPP-

Boiler is generating 242.3 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: FS97-0000-0041E.

7 - 1

7.0 ENVIRONMENT IMPACT ASSESSMENT

7.1 Identification and prediction of impacts

7.1.1 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.

7.1.2 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 - 2

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.

7.1.3 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.

7.1.4 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.

7.1.5 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 - 3

existing manpower is sufficient to cater the requirement of the proposed

changeover scheme.

During construction phase, around 100-200 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.

8 - 1

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 15-20 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 - 2

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.

9 - 1

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. FS97-0000-0041), the natural gas

consumption for steam generation is given below:

Sl.

No.

Item NG (NCV-8700.16 kcal/Sm3)

Consumption Sm3/hr

1. Auxiliary Boiler in Ammonia Plant 8314

2. Steam Generation in SGP 38130

Total 46444

After implementation of changeover scheme (Option-I, Drg. No. FS97-0000-

0041A), 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-8700.16 kcal/Sm3)

Consumption Sm3/hr

1. GTG (Power) 12988

2. HRSG (Steam) 4888

3. SGP 17967

Total 35843

From above tables, it shows that there is substantial saving in consumption of

natural gas after changeover i.e 10601 Sm3/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 - 2

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 (m3/hr) 34.89

2. Due to reduction in CW Circulation (m3/hr) 241.93

Total reduction in make-up water(m3/hr) 276.82

Details of calculation are given at F.S - 01.

9.4 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.

10 - 1

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. 362.82 Crores. An

approximate break-up of the project cost estimates is given in Table-10.1 and

details are presented in FS – 02.

Table - 10.1

Project Cost Estimates

(Rs Lakhs)

Sl.

No.

Particulars / Items Cost

A Erected Cost

1.0 Gas Turbine Generator (2×32 MW ISO) 25600

2.0 HRSG (2×100 MTPH) 4000

B Supplies

1.0 All motors and its accessories 927

2.0 Pipes valves & Fittings 100

3.0 Electrical & Instrumentation 1342

Total Supplies 2369

C Incidentals on (B)

Excise Duty @ 12.36% 293

Sales Tax @ 2% 53

Inland Handling @ 3% 71

Insurance @ 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 36282

10 - 2

10.2 Basis of Estimation

The basis of estimates is as below:

10.2.1 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.

10.2.2 Incidental Charges

The incidentals charges have been estimated based on the following rates:

Excise Duty & Education Cess 12.36% on supplies

Sales Tax 2.0% on supplies and duty

Inland Handling 3.0% on supplies

Insurance 1.0% of Installed cost

10.2.3 Construction Cost

The civil construction cost and erection charges have been estimated based on

facilities considered in the modification.

10.2.4 Contingencies

A contingency provision of 5% has also been considered to cover the unforeseen

expenses during project execution.

10.2.5 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.

.

10 - 3

10.3 Project Economics

10.3.1 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.

79.44 crores. Considering gas price @ US$ 4.2/MMbtu and water price @ Rs.

30/m3, annual savings has been worked to Rs. 7286 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. 362.82 Crores. The

details of calculations are given at F.S-01

10.3.2 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 -03.

10.3.3 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- 04.

10.4 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 - 4

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.-05.

11 - 1

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.

11.2 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.

F.S -01

Sl.No. Particulars Base case Option-I Savings

A Natural Gas

Natural Gas Consumption in Auxiliary Boiler (Sm3/hr) 8314 0 8314

Natural Gas Consumption in SGP (Sm3/hr) 38130 17967 20163

Natural Gas Consumption in GTG (Sm3/hr) 12988 -12988

Natural Gas Consumption in HRSG (Sm3/hr) 4888 -4888

Total Natural Gas Consumption (Sm3/hr) 46444 35843 10601

Net reduction in NG Consumption (Sm3/hr) 10601

Calorific Value of Natural Gas (Kcal/Sm3) 8700.16

Energy saved (Kcal/hr) 92230396.2

Energy saved (MMBtu/hr) 365.993636

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) 97 0 97

1.2 From SGP (MT/hr) 485 228 257

1.3 From HRSG (MT/hr) 0 121.374 -121.374

Total Steam Generation (MT/hr) 582 349.374 232.626

2.0 34.89

3.0 Reduction in Cooling water load

3.1 232.626

3.2 12096.552

3.3 Make-up Water due to reduced CW circulation (m3/hr) 241.93

4.0 Total make up water reduction (m3/hr) 276.82

5.0 Cost of make up Water (Rs.30/m3) 30

Annual Cost of make water (Rs. Lakhs) 658

6 Total Annual savings (Rs Lakhs) 7944

Saving/Benefit after Changeover

Reduction in steam generation which finally goes as steam condensate

(m3/h.)

Cooling water load reduction due less condesate cooling with 10 deg

temp. Diff.( m3/hr)

Make up water reduction due to reduced steam generation (m3/hr)

F.S 02

(Rs. Lakhs)

Sl.no Particulars / Items Cost

A Erected Cost

Gas Turbine Generator (2x32 MW ISO) Erected cost 25600

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 Duty @ 12.36% 293

Sales Tax @ 2% 53

Inland Handling @ 3% 71

Insurance @ 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 36282 1

CAPITAL COST ESTIMATE

F.S. - 03

Rs. Lakhs

Sl. Particulars Cash Cumulative Cash

No. Accruals Cash Outflow

Accruals

1.0 Total Capital Outlay 36282

2.0 Cash Accruals during Period

1st Year of Operation 7944 7944

2nd Year of Operation 7944 15888

3rd Year of Operation 7944 23832

4th Year of Operation 7944 31776

5th Year of Operation 7944 39720

6th Year of Operation 7944 47664

7th Year of Operation 7944 55608

8th Year of Operation 7944 63552

9th Year of Operation 7944 71496

3.0 Pay Back Period 4.57 Years

PAY BACK PERIOD

F.S. - 04

Rs. Lakhs

Sl. Period Cash Cash Net Discount Net

No. Outflow Inflow Cash Factor @ Present

Flow 17.80% Value

1.0 1st Year of construction -25397 -25397 0.849 -21559

2.0 2nd Year of construction -10885 -10885 0.721 -7844

3.0 1st Year of operation 0 7944 7944 0.612 4859

4.0 2nd Year ,, 0 7944 7944 0.519 4125

5.0 3rd Year ,, 0 7944 7944 0.441 3502

6.0 4th Year ,, 0 7944 7944 0.374 2973

7.0 5th Year ,, 0 7944 7944 0.318 2523

8.0 6th Year ,, 0 7944 7944 0.270 2142

9.0 7th Year ,, 0 7944 7944 0.229 1818

10.0 8th Year ,, 0 7944 7944 0.194 1544

11.0 9th Year ,, 0 7944 7944 0.165 1310

12.0 10th Year ,, 0 7944 7944 0.140 1112

13.0 11th Year ,, 0 7944 7944 0.119 944

14.0 12th Year ,, 0 7944 7944 0.101 802

15.0 13th Year ,, 0 7944 7944 0.086 680

16.0 14th Year ,, 0 7944 7944 0.073 578

17.0 15th Year ,, 0 7944 7944 0.062 490

18.0 Net Present Value 0

19.0 Internal Rate of Return (IRR) 17.80%

INTERNAL RATE OF RETURN

F.S. - 05

Sl.No. Particulars Capex Gas Price IRR (%)

Rs. Lakhs US$/MMBtu

A Base Case 36282 4.2 4.57 17.80%

B With variation of gas price 36282 6.5 3.03 27.01%

36282 8.5 2.35 34.01%

36282 10 2.01 38.9%

C With Variation in Project Capital Cost by

(+10%) 39910 4.2 5.03 15.96%

(+20%) 43538 4.2 5.49 14.4%

D With Variation in saving in Energy only

(-10%) 36282 4.2 5.02 15.98%

(-20%) 36282 4.2 5.57 14.08%

E With Variation in Project Capital Cost by +10 and energy

saving -10%39910 4.2 5.53 14.25%

F With Variation in Project Capital Cost by +20 and energy

saving -20%43538 4.2 6.69 10.99%

G With Variation in Project Capital Cost by +10 and energy

saving -10%39910 6.5 3.7 22.26%

H With Variation in Project Capital Cost by +20 and energy

saving -20%43538 6.5 4.5 18.12%

Pay back

period

(Years)

SENSITIVITY ANALYSIS

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 40002 Bus Section 1 Bus PT Bus PT 11000/√3 / 110/√3 &

110/√33 Bus Section 1 O/G to Formic - I Chemical Gr of Plants Outgoing 12504 Bus Section 1 O/G to Transformer - 14 (DMF Plant) (Chemical Gr of Plants) Transformer 12505 Bus Section 1 O/G to Ammonia - I (Grid Supply) Ammonia - I Outgoing 12506 Bus Section 1 Bus Duct to Bus 6 Bus Tie 4000 A7 Bus Section 1 O/G to Transformer - 12 (750 KVA), 11/0.433 kV ETP Transformer 12508 Bus Section 1 O/G to Urea Urea Outgoing 12509 Bus Section 1 Spare - 125010 Bus Section 1 Bus Coupler with Bus 2 Bus Coupler 4000

11 Bus Section 2 Incomer from Tr-2 (Grid) Incomer 400012 Bus Section 2 Bus PT Bus PT 11000/√3 / 110/√3 & 110/√313 Bus Section 2 O/G to Transformer - 24 (DMF Plant) (Chemical Gr of Plants) Outgoing 125014 Bus Section 2 O/G to Ammonia - II (Grid Supply) Ammonia - I Outgoing 125015 Bus Section 2 Bus Duct to Bus 3 Bus Tie 4000 A16 Bus Section 2 O/G to Transformer - 22 (750 KVA), 11/0.433 kV ETP Transformer 125017 Bus Section 2 Spare Feeder Spare 125018 Bus Section 2 O/G to Transformer - 23 (2000 KVA), 11/0.433 kV PHP Transformer 125019 Bus Section 2 O/G to Formic - II Chemical Gr Plant Outgoing 1250

20 Bus Section 3 Bus Coupler with Bus 2 Bus Coupler 400021 Bus Section 3 O/G to Transformer - 13 (2000 KVA), 11/0.433 kV PHP Transformer 125022 Bus Section 3 Bus PT Bus PT 11000/√3 / 110/√3 & 110/√323 Bus Section 3 Spare Feeder Spare 125024 Bus Section 3 O/G to Urea Urea Outgoing 125025 Bus Section 3 O/G to Transformer - 31 (2000 KVA), 11/0.433 kV Steam Generation Plant Transformer 125026 Bus Section 3 O/G to Transformer - 32 (6000 KVA), 11/3.3kV Steam Generation Plant Transformer 125027 Bus Section 3 O/G to Transformer - 33 (1600 KVA), 11/3.3kV Steam Generation Plant Transformer 125028 Bus Section 3 O/G to Motor for BFW Pump 1 - 1755 KW Steam Generation Plant Motor 125029 Bus Section 3 Bus Coupler with Bus 4 Bus Coupler 4000

30 Bus Section 4 Bus PT Bus PT 11000/√3 / 110/√3 & 110/√331 Bus Section 4 O/G to Transformer - 41 (6000/10000 KVA), 11/3.3

kV : Standby Steam Generation Plant Transformer 125032 Bus Section 4 Series Reactor between Bus 4 & Bus 5, 125033 Bus Section 4 O/G to Ammonia - II (GTG Supply) Ammonia - II Outgoing 200034 Bus Section 4 Spare Feeder Spare 125035 Bus Section 4 Incomer from GTG - 2 Incomer 400036 Bus Section 4 Bus Coupler with Bus 5 Bus Coupler 4000

37 Bus Section 5 Incomer from GTG - 1 Incomer 400038 Bus Section 5 Spare Feeder Steam Generation Plant 125039 Bus Section 5 Series Reactor between Bus 4 & Bus 5 125040 Bus Section 5 O/G to Ammonia - I (GTG Supply) Ammonia - I Outgoing 200041 Bus Section 5 Spare Feeder Spare 125042 Bus Section 5 Spare Feeder Spare 125043 Bus Section 5 Bus PT Bus PT 11000/√3 / 110/√3 & 110/√344 Bus Section 5 Bus Coupler with Bus 6 Bus Coupler 4000

Sheet 1 of  2

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 2 - 1755 KW Steam Generation Plant Motor 125046 Bus Section 6 Spare Feeder 125047 Bus Section 6 O/G to Transformer - 62 (6000/10000 KVA), 11/3.3 kVSteam Generation Plant Transformer 125048 Bus Section 6 O/G to Transformer - 63(1600 KVA), 11/3.3kV Steam Generation Plant Transformer 125049 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/√351 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: Bus B

Ammonia Additional Load Outgoing 2000

53 Bus Section 4 O/G to New Switchboard Near Ammonia Substation: Bus C

Ammonia Additional Load Outgoing 2000

54 Bus Section 5 O/G to New Switchboard Near Ammonia Substation: Bus A

Ammonia Additional Load Outgoing 2000

Spare Feeder 55 Bus Section 1 Spare Feeder 200056 Bus Section 1 Spare Feeder 125057 Bus Section 2 Spare Feeder 125058 Bus Section 3 Spare Feeder 125059 Bus Section 3 Spare Feeder 125060 Bus Section 4 Spare Feeder 200061 Bus Section 4 Spare Feeder 125062 Bus Section 5 Spare Feeder 200063 Bus Section 5 Spare Feeder 125064 Bus Section 6 Spare Feeder 125065 Bus Section 6 Spare Feeder 1250

Notes1 All Incomer 40000 A in place of 2000 A2 All Bus coupler 40000 A in place of 2000 A3 Busbar rating 4000 A in place of 2000 A

Sheet 2 of  2

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 40002 Bus Section A Bus PT 11000/√3 / 110/√3 &

110/√33 Bus Section A O/G to New Switchboard Near Ammonia Substation

: Bus BAmmonia Additional Load Outgoing 2000

4 Bus Section A Spare Feeder 20005 Bus Section A Bus Coupler with Bus B Bus Coupler 4000

6 Bus Section B Incomer from (MSEB Switchyard) Incomer 40007 Bus Section B Bus PT 11000/√3 / 110/√3 & 110/√38 Bus Section B Bus Duct to Bus C Bus Tie 4000 A9 Bus Section B Spare Feeder 2000

10 Bus Section C Incomer from GTG - 2 Incomer 400011 Bus Section C Bus PT 11000/√3 / 110/√3 &

110/√312 Bus Section C Series Reactor between Bus C & Bus D 200013 Bus Section C O/G to Existing 11 kV Switchboard at CPP where

presently 15 MW STG supply is being fed 11 kV Switchboard at CPP Outgoing 200

14 Bus Section C O/G to New Switchboard Near Ammonia Substation: Bus C

Ammonia Additional Load Outgoing 2000

15 Bus Section C Spare Feeder 200016 Bus Section C Spare Feeder 200017 Bus Section C Bus Coupler with Bus D Bus Coupler 4000

18 Bus Section D Incomer from GTG - 1 Incomer 320019 Bus Section D Bus PT 11000/√3 / 110/√3 &

110/√320 Bus Section D Series Reactor between Bus C & Bus D 200021 Bus Section D O/G to Existing 11 kV Switchboard at CPP where

presently 15 MW STG supply is being fed 11 kV Switchboard at CPP Outgoing 200

22 Bus Section D O/G to New Switchboard Near Ammonia Substation: Bus A

Ammonia Additional Load Outgoing 2000

23 Bus Section D Spare Feeder 200024 Bus Section D Spare Feeder 200025 Bus Section D Bus Duct to Bus A Bus Tie 4000 A

Sheet 1 of  1

Annexure-IV

Sl. No. Items Existing After

modification

Remarks

A Ammonia Plant 2 2

1.0 HP Steam production at 100 ata & 500 deg C

RG Boiler/CG Boiler 470 470

Syn Loop Boiler 158 158

Auxiliary Boiler 97 0

Sub Total above 725 628

Import from HRSG 0 12

Sub-Total (1.0) 725 640

2.0 HP Steam consumption at 100 ata & 500 deg C

Syn Gas Compressor (TK 431) 640 640

Ammonia Refrigeration Compressor III (TK 4431) 75 0 Shifted to Motor

PRDS 10 0

Sub-Total (2.0) 725 640

3.0 MP Steam Production at 37 ata & 370 deg C

Syn Gas Compressor (TK 431) 516 516

Ammonia Refrigeration Compressor III (TK 4431) 75 0 No production

PRDS+Quench 10 0

Sub-Total (3.0) 601 516

4.0 MP Steam consumption at 37 ata & 370 deg C

Process steam in H 201 274 274

Process Air compressor I/II (TK 421 &422) 120 120

Process Air Compressor III (TK 4421) 46 46

Ammonia Refrign. Compr. I/II (TK 451&452) 22 22

GV Section lean solution Pump TP 301 AB 29 0 Shifted to Motor

Cooling Tower III (TP 4801A) 6.5 0 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) 46 46

HGRU (X 9000) 2 2

PGRU Reboiler (E 521) 1.5 1.5

PRDS (SM-SL) 0 2.5

Sub-Total (4.0) 601 516

5.0 LP Steam Production at 3.5 ata & 214 deg C

Blow down Flashing (B 603) 10 10

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) 46 46

SL PRDS & Desuperheating 4 2.5

Sub-Total (5.0) 112 58.5

6.0 LP Steam consumption at 3.5 ata & 214 deg C

GV Section Regenerator (F 301) 40 40

Deaerator Steam (B 601) 20 18.5

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) 112 58.5

Steam Balance of Ammonia Plants

Figures in MT/hr

Annexure-V

Sl. No. Items Existing After

modification

Remarks

1.0 Ammonia Plant (Existing) 8700 8700

2.0 Ammonia Plants after modification

2.1 Ammonia Refrigeration Compressor III (TK 4431) 3702

2.2 GV Section lean solution Pump TP 301 AB 4320

2.3 Cooling Tower III (TP 4801A) 1000

2.4 Flue Gas Fan (ID Turbine TK 201) 2464

2.5 Combustion Air Blower (FD Turbine TK 202) 1700

2.6 Cooling Tower I/II pump (TP 801 C&D) 4000

Sub-total (2.0) 17186

Total Ammonia Plant 25886

3.0 Urea Plant 12500 12500

4.0 Chemical Group of Plants (existing) 2500 2500

5.0 Chemical Group of Plants (after mdification) 1737

6.0 Bagging & ETP 300 300

7.0 SGP, CPP, WTP & RWP 4000 2790

Total Power 28000 45713

Power Balance of the Complex

Figures in kW

Feeder List : New 11 kV Switchboard Near Ammonia Substation Annexure ‐ III

6No. 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 20002 Bus Section A Bus PT 11000/√3 / 110/√3 &

110/√33 Bus Section A O/G to Motor for Benfield Circulation Pump MP 1301A Ammonia - I Motor 12504 Bus Section A O/G to Motor for Benfield Circulation Pump MP 1301B Ammonia - I Motor 12505 Bus Section A O/G to Motor for Cooling water Pump MP 1801C Ammonia - I 12506 Bus Section A O/G to Motor for Cooling water Pump MP 1801D Ammonia - I 12507 Bus Section A Spare Motor Feeder Motor 12508 Bus Section A Bus Coupler with Bus B Bus Coupler 2000

9 Bus Section B Incomer from 11 kV Switchboard at CPP : Bus (Grid) Incomer 200010 Bus Section B Bus PT 11000/√3 / 110/√3 &

110/√311 Bus Section B O/G to Motor for Common Ammonia Refrigeration CompreAmmonia - I & II (Common) Motor 125012 Bus Section B O/G to Motor for Cooling water Pump MP 4801A Ammonia - I & II (Common) Motor 125013 Bus Section B Spare Motor Feeder Motor 125014 Bus Section B Bus Coupler with Bus C Bus Coupler 2000

15 Bus Section C Incomer from 11 kV Switchboard at CPP : Bus (GTG) Incomer 200016 Bus Section C Bus PT 11000/√3 / 110/√3 &

110/√317 Bus Section C O/G to Motor for Benfield Circulation Pump MP 2301A Ammonia - II Motor 125018 Bus Section C O/G to Motor for Benfield Circulation Pump MP 2301B Ammonia - II Motor 125019 Bus Section C O/G to Motor for Cooling water Pump MP 2801C Ammonia - II 125020 Bus Section C O/G to Motor for Cooling water Pump MP 2801D Ammonia - II 125021 Bus Section C Spare Motor Feeder Motor 1250

Notes1 Busbar rating 2000 A

Sheet 1 of 1

Task NameRCF Thal GTG HRSG Installation

Project Zero DateDesign EngineeringProcurment Engineering

Gas Turbine Generator (32 MW X 2)

MR Preparation & ApprovalITB issueReceive BidsTechnical RecommendationCommercial RecommendationLOI PlacementDelivery at site

HRSG (100TX 2)MR Preparation & ApprovalITB issueReceive BidsTechnical RecommendationCommercial RecommendationLOI PlacementDelivery at site

13 HT MotorsMR Preparation & ApprovalITB issueReceive BidsTechnical RecommendationCommercial RecommendationLOI PlacementDelivery at site

Construction

Construction works before annual turn around

Construction works during annual turn around &Hook-up

Project End

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

Task Milestone Summary

TENTATIVE TIME SCHEDULE FOR GTG HRSG INSTALLATION AT RCF THAL

Page 1

CLIENT:M/S RASHTRIYA CHEMICALS & FERTILISERS LIMITED, THALJOB NO.- FS-91TIME- IN MONTHS