02 Feb 2018 14030957051U9XV6BPFR PDF

DETAILED FEASIBILITY REPORT
FOR
ADDITIONAL COGENERATION UNIT GT-IV
AT URAN PLANT
OIL AND NATURAL GAS CORPORATION
Doc No.: A333-RP-14-41-0001

28th August 2012
This report is prepared for M/s ONGC and it is for use by M/s ONGC
or their assigned representatives/organizations only.
The matter contained in the report is confidential.
Document No.
DETAILED FEASIBILITY REPORT A333-RP-14-41-0001
FOR ADDITIONAL COGENERATION Rev. No. 0
UNIT- GT-IV AT URAN PLANT
Page 2 of 95
CONTENTS
SECTION DESCRIPTION PAGE NO.
1.0 EXECUTIVE SUMMARY 5
1.1 PURPOSE 5
1.2 SCOPE 6
1.3 BACKGROUND 6
1.4 PROJECT HIGHLIGHTS 7
1.5 PROJECT COST & FINANCIAL HIGHLIGHTS 9
1.6 CONCLUSIONS 11
2.0 EXISTING COGENERATION PLANT 13
2.1 EXISTING CAPTIVE POWER PLANT DESCRIPTION 13

2.2 REQUIREMENT OF CPP CAPACITY ENHANCEMENT 15
3.0 CONFIGURATION COMPARISON 19
3.1 PROPOSED SYSTEM 19

3.2 COMPARISONS WITH EXISTING SYSTEM 23
4.0 PROJECT DESCRIPTION (MAIN PLANT) 27
4.1 DESIGN BASIS 27

4.2 MAIN PLANT DESCRIPTION 33
4.3 ELECTRICALPOWERSYSTEM 40
4.4 PIPING SYSTEM AND FUTURE HOOK UP 49
4.5 CIVIL & INFRASTRUCTURE 56
4.6 CONTROL AND INSTRUMENTATION 58
5.0 PROJECT DESCRIPTION (DM PLANT) 60
5.1 PROCESS DESIGN BASIS 61

5.2 OPERATION OF THE DM PLANT 62
5.3 ENGINEERING DESIGN DATA 62
5.4 COST ANALYSIS 64
6.0 SAFETY AND ENVIRONMENTAL ASPECTS 66
6.1 INTRODUCTION 66
6.2 INDIAN ENVIRONMENTAL LEGISLATION 66
6.3 POLLUTION CONTROL MEASURES 67
6.4 PERMISSIONS AND CLEARANCES 74
6.5 OTHER BENEFITS FROM PROJECT 75
7.0 STATUTORY APPROVALS AND CLEARANCES 78
8.0 PROJECT COST ESTIMATE 81
8.1 CAPITAL COST ESTIMATE & FINANCIAL ANALYSIS 81

8.2 BASIS OF COST ESTIMATE 82
Copyrights EIL – All rights reserved

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8.3 PLANT & MACHINERY 82

8.4 STATUTORY & INDIRECT COSTS 83
8.5 CONTINGENCY 83
8.6 PMC CHARGES & TPI 83
8.7 DISMANTLING /SCRAP MATERIALS SALES 83
8.8 EXCLUSIONS 83
9.0 FINANCIAL ANALYSIS 85
9.1 OPERATING COST & FINANCIAL ANALYSIS 85
10.0 PROJECT IMPLEMANTATION AND SCHEDULE 88
10.1 PROJECT IMPLEMENTATION METHODOLOGY 88

10.2 AFTER AWARD OF WORK THE CONTRACTOR SHALL COMPLY WITH: 89
10.3 PROGRESS MEASUREMENT METHODOLOGY 90
11.0 RISKS AND MITIGATIONS 93
ATTACHMENTS
Annexure-1 : Overall Plot Plan

Annexure-2 : Main Single Line Diagram & Emergency Power Distribution System
Annexure-3 : Key Single Line Diagram for GT –IV
Annexure-4 : Preliminary System Study Report
Annexure-A : Load Flow Studies
Annexure-B : Short circuit Studies
Annexure-5 : Cost Estimate
Annexure-6 : Cash Flow
Annexure-7 : Project Schedule

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SECTION 1.0
EXECUTIVE SUMMARY

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1.0 EXECUTIVE SUMMARY
Oil and Natural Gas Corporation Ltd (ONGC), Uran Plant is an On-shore installation
located at sea shore with an average distance of approximately 205 Km from the Off-
shore platform. It is well connected by road off the Mumbai - Panvel road at Uran. It is
about 65 Km from the city of Mumbai. It is also connected by sea opposite to the
Mumbai port. Location wise, it is approximately seven Km away from JNPT (Jawaharlal
Nehru Port at Nhava Sheva).
Crude Oil and Associated Gas produced at Mumbai High and other satellite fields are
being transported to Uran via 203 Km long subsea pipeline viz. 30” and 26” pipeline
respectively. Crude received at Uran is finally stabilized at the CSU plant and water is
separated out by de-hydrator before sending to storage tanks. Besides, oil processing
huge quantity of gas is processed at Uran to produce value added products like LPG,
LAN, and C2-C3 etc. Following are process units of Uran plant.
Crude Stabilization Unit : 05 Trains

LPG Plants : 02 Units
Gas Sweetening Units : 02 Units
Ethane Propane recovery Units : 01 Unit
Condensate Fractionating Units : 02 Units
Offsite and Storage : 02 Units
Co- Generation Plant with HRSG : 03 Units
Effluent Treatment Plant : 01 Unit
Utilities and Flare : 02 No
The processing complex at ONGC, Uran is of strategic importance as it handles 60% of

hydrocarbons India Produces. ONGC, Uran plant has won many safety awards from
Ministry of P&NG for its safe working & safe planning. In view of its importance,
everybody inside the plant has to ensure that care for the safety of the plant is given top
most priority. Every job inside the plant has to be thoroughly planned and executed,
without any safety violation. No relaxation is permitted in safety aspects.
1.1 PURPOSE
The purpose of present study is to prepare a techno-economic Detailed Feasibility study

of Gas Turbine based Co- generation power plant of approximate capacity of 20 MW
Gas Turbine and 90 TPH (60 TPH + 30 TPH Supplementary Fired) HRSG at ONGC
Uran Plant, district Raigad in Maharashtra.
This project report highlights the features of the existing cogeneration plant, fuel gas and
process water requirements, technical features of the main plant equipments, plant
mechanical, electrical, Instrumentation and Control Systems, civil and infrastructure
works involved, effluent and utilities system, evacuation of power, hook-up with existing

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system, environmental aspects, estimates of project cost, project implementation

schedule etc. of the proposed power project.
1.2 SCOPE
The scope of feasibility is to be carried out considering, but not limited to, the GT and
HRSG with various details including existing cogeneration plant data, location, technical
features of major equipments and equipment layout for different configurations, electrical
system study, environmental aspects, project capital cost and financial analysis, project
implementation plan etc. of project.
1.3 BACKGROUND
Uran plant has three Gas Turbines GE Frame V of 19.6 MW (at 40 deg Celsius ambient)
each. The first two Gas Turbines were commissioned in the year 1984. Subsequently
with the increase in plant power & steam loads, third Gas Turbine was commissioned
during the year 2000. These machines, apart from generating power, also fulfil steam
requirement of the process plant.
1.3.1 Existing Power & Steam Scenario
The Cogeneration plant Uran is run in synchronism with M.S.E.D.C.L grid. The power is
either exported or imported from/ to M.S.E.D.C.L as per plant power requirements.
The installed capacity of the Plant is 58.8 MW of Power & 300 Tons of Steam per hour
Present plant load is 48.80 MW (app) with installation & commissioning new
motor driven propane compressor (3.35 MW) of LPG-1 & taking in to
consideration of oil pumping as well as GT (1,2,3) internal consumptions.
Existing steam requirement of plant is 143 TPH
1.3.2 Requirement of Power & Steam for upcoming Units
In order to process additional C-series gas from offshore, commissioning of additional

LPG-III, GSU-III, CFU-III& CHU-IV are under installation.
Additional process plant is expected to be in operation in FY 13-14.

Requirement of Power for other coming up projects viz. Firewater Network, Air
Compressor, etc. other than APUs.
Power requirement is approximately 20 MW (Continuous) and 60 TPH Steam from

HRSG (with provision of another 30 TPH steam augmentation from HRSG with
supplementary firing).

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1.4 PROJECT HIGHLIGHTS
Table 1-1 Highlights of the project
S.
DESCRIPTION/ DETAILS
NO.
Detailed Feasibility Report for Additional Cogeneration
1. Project
Unit- GT-IV at Uran Plant
The Proposed Cogeneration Unit shall be located at Uran
2. Location
Plant
3. Accessibility to Site
Nearest Highway Mumbai JNPT Highway
Domestic airport : Mumbai – 58 km

Nearest Airport
International airport : Mumbai– 58 km
Nearest sea port Jawaharlal Nehru Port at Nhava Sheva – 7 km
Nearest Railway Panvel Railway station
Site : ONGC Uran

4. Site Features District : Raigad
State : Maharashtra
Latitude - Longitude : 18.86525o - 72.92784o
Elevation above MSL : 3 to 5 m
5. Fuel, Water and Electricity
Main Fuel Natural Gas
Gas cost with

Royalty
Rs 7.72/SM3
(NCV-8350
Kcal/SM3)
Gas Consumption
385 SM3/MWh
in GT
Gas Consumption
75 SM3/MT/hr
in APU Boiler
Nearest Raw
MIDC Supply
water source

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Raw Water Rs. 25 /kL
DA/DM Water Rs 40 /kL (Inclusive of Raw water cost)
Imported Power
Rs 9 /kWh
with taxes
Fixed Demand
Rs 190/kVA
Charges
Electricity Duty Rs 0.3/kWh
Gas Turbine Generator

Heat Recovery and Steam Generator System
Auxiliary systems for Gas Turbine and HRSG
Water systems
Main plant &
Balance of plant systems
Auxiliary systems
Electrical systems
Power evacuation arrangement
Instrumentation and control systems
6. Civil and structural works
Unit size Approx. 20 MW GT + 90 TPH HRSG
Unit type Cogeneration cycle
Cooling water
Closed Circuit Cooling Water System
system
Overall Project
7. 37 Months
Schedule
Capital cost Rs 249.69 Cr
Project capital
8. Tariff (deemed
Cost & Tariff Rs 9.00/ kWh
import)

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1.5 PROJECT COST & FINANCIAL HIGHLIGHTS
Capital cost estimate & financial analysis for DFR has been worked out and summarized
below:
Table 1-2 Project Cost
DESCRIPTION COST IN ` CRORES
Power Plant
Major Items 102.03
Bulks, Spares & Chemicals 20.82
Construction Cost 42.48
Plant Buildings 8.40
Indirect Cost 34.90
Contingency 10.42
PMC Charges &TPI 8.00
Dismantling/Scrap Materials Sales -1.00
DM Water Plant 23.62
TOTAL 249.69
1.5.1 Financial Highlights for the Project
Operating cost & financial analysis has been worked out based on following:
Table 1-3 Operating Cost
S.NO. DESCRIPTION ASSUMPTIONS MADE

1 Natural Gas price Rs 7.72 / SCM
2 Raw Water Rs 40.00 /SCM
3 Electricity Duty Rs. 0.30 /kWh
4 Annual O & M charges Rs 17.50 lakhs/MW
5 Deemed Import of Power Rs. 9 /kWh
6 Fixed Demand Charges Rs. 190 / kVA
7 Construction Period 28 months
8 Project Life in Years 15
9 Debt/ Equity Ratio 100% Equity
10 Working capital Excluded

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P&M-@ 5.28% SLM; @ 15% WDV

11 Depreciation
; @ 5% Salvage Value
1st 6 months - 10%
2nd 6 months - 20%
12 Capital Phasing (half yearly) 3rd 6 months - 25%
4th 6 months - 35%
Last 3 months 10%
13 Capacity Build-up 1st year onwards - 100%
14 Operating hours (Annual) 330 days
15 Deemed import of Power 19.5 MW
16 Corporate Tax Rate Basic 30% + 5% + 3% = 32.45%
17 MAT (%) Basic 18.5% + 5% + 3% = 20.01%
Yearly variable operating cost comprising of cost for Natural Gas, Raw Water and
Electricity duty has been escalated @ 8% pa as per ONGC input. Yearly fixed operating
cost has been considered to take care of Salary & wages, Repair and maintenance,
General administrative expenses and Insurance @ Rs 17.50 lakh / MWH in 1st year of
operation. Yearly fixed operating cost has been escalated @ 5.72% pa (CERC guide
lines) 2nd year onward over the life of the plant.
Annual Sales revenue has been calculated considering saving in energy import, saving
in demand charges and saving in gas consumption by HRSG-4. No escalation has been
considered in the yearly revenue over the life of the plant as suggested by ONGC as per
their norms.
Capital cost has been escalated by 6% as per ONGC norms for financial analysis.
Based on above assumptions, Operating cost, sales revenue, Cash flow, NPV, Internal
rate of return and Payback period has been worked out for the project and are
summarized in Table 1-4.
Table 1-4 Financial Analysis
SL.NO DESCRIPTION VALUES

Capital Cost (Rs. lakh) for IRR payback period calculations
1 26466
using 6% escalation as per ONGC norms
2 Total operating Cost (Rs. lakh) 5771
3 Annual revenue (Rs. lakh) 16878

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4 IRR (%) on total capital

Before Tax 19.66%
After Tax 15.07%
5 Payback period (years) on Total Capital

Before Tax 2.9
After Tax 3.7
1.6 CONCLUSIONS
The project, in view of above, has been considered economically viable and has
been recommended for implementation.

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SECTION 2.0
EXISTING COGENERATION PLANT

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2.0 EXISTING COGENERATION PLANT
2.1 EXISTING CAPTIVE POWER PLANT DESCRIPTION
The existing Captive Power Plant (CPP) of Uran Complex comprises of three Gas
Turbine Generators (henceforth shall be mentioned as GTG) of Frame-V model and one
Heat Recovery Steam Generator (henceforth shall be mentioned as HRSG) associated
with each GTG. The HRSGs are of supplementary fired type and also have Forced Draft
fan (FD fan) for Forced Draft mode of operation. Each GTG produce 19.6 MW at site at
ambient condition and each HRSG produce 60 TPH saturated steam at medium
pressure (design pressure of 13.5 Kg/cm2) without any supplementary firing. The
HRSG-1 & 2 can achieve up to 75 TPH of steam generation with supplementary firing
where as the HRSG-3 can achieve up to 90 TPH with supplementary firing.
In the existing CPP, there is one package Boiler from Thermax which is installed in 1990
and is old and has reliability/ maintainability issue for sustained operation.
The IAEC boiler house in the CPP premises is currently not in use and the same is being
used as store room.
The existing DA/DM (De-alkaline/ De-mineralised) plant with capacity of 57.5 DA & 2.5
DM caters to the DA/DM water requirement of the entire Uran complex including CPP.
There is one returned Condensate Stabilization System (vessel V-306, V-308 & T-303)
which receives the returned condensate coming from CSU along other process units. It
separates the steam from the condensate and the recovered condensate is further used
in deaerator for HRSGs.
One new gas fired boiler (APU boiler of 90 TPH), as a part of ongoing APU project is
being installed.
The Uran complex also has provision of Power import/ export from M.S.E.D.C.L. The
Cogeneration plant Uran is run in synchronism with M.S.E.D.C.L grid. The power is
either exported or imported from/ to M.S.E.D.C.L as per plant power requirements.

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Following are the power Supply- Demand scenario of the ONGC Uran Complex (all data
below table are in MW unit):
Table 2-1 Power supply- demand scenario (Existing)
INSTALLED EXISTING DEMAND

DESCRIPTION
CAPACITY (MW) (MW)
GAS TURBINE GENERATOR-1 19.6 48.8 – (with new
GAS TURBINE GENERATOR-2 19.6 propane compressor
(3.35 MW) & GT-1, 2, 3
GAS TURBINE GENERATOR-3 19.6 internal consumptions.)
TOTAL INSTALLED
58.8
GENERATION CAPACITY
Existing: CPP is capable of meeting the demand
however for approximate 3 months power is
REMARKS imported from grid considering one month
shutdown per gas turbine & during unplanned shut
down of GT/s
Following are the steam Supply- Demand scenario of the ONGC Uran Complex (in TPH
unit);
2.2 Steam Supply demand scenario (Existing)
YEAR INSTALLED/ NET USABLE

EXISTING
OF CAPACITY (TPH) CAPACITY (TPH)
DEMAND
INSTAL-
UNFIRED WITH SF UNFIRED WITH SF (TPH)
LATION
HRSG-1 1984 60 75 54 67.5
HRSG-2 1984 60 75 54 67.5
HRSG-3 2000 60 90 57.5 85
143
Thermax
1990 60 54
Boiler
TOTAL NA 240 300 220 275
Normal operation philosophy- Plant steam demand is met through three
HRSGs during 9 months of the year. During shutdown, due to annual
statutory inspection, for 30 days/year of each HRSG, Thermax boiler is
REMARKS used to meet steam demand deficiency. Also, Thermax boiler is required
during plant start-up due to power failure/ unplanned shutdown of any
turbine & part load operation of turbine (due to technical/ grid isolation
condition)

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2.2 REQUIREMENT OF CPP CAPACITY ENHANCEMENT
The Uran complex is undergoing revamp and capacity addition. In order to process
additional C-series gas from offshore, commissioning of additional LPG-III, GSU-III,
CFU-III, CHU-IV and firewater network are under installation There is also planning for
new facilities in near future like air compressor system and desalination unit. To cater to
the increased power and steam demand, an additional Gas Turbine of approximate 20
MW and HRSG of 90 TPH (60 TPH in HRSG mode and another 30 TPH steam
augmentation provision with supplementary firing) needs to be installed.
Table 2.3 Power Scenario of the existing and Proposed Plant
INSTALLED DEMAND (MW)

CAPACITY (MW) [UPDATED WITH NEW FACILITIES]
GAS TURBINE 48.8 - Existing with new propane

19.6
GENERATOR-1 compressor (3.35 MW) & GT-1, 2, 3
GAS TURBINE internal consumptions.
19.6 22- APU
GENERATOR-2
2.5- Air Comp & Fire water network
GAS TURBINE
19.6 05- Desalination approximate
GENERATOR-3
Total = 78.3 approximate
GAS TURBINE With all internal consumption of GT-
20 Approximate. HRSG-4, demand will become 78.8
GENERATOR-4
MW.
TOTAL INSTALLED
78.8 Approximate
GENERATION CAPACITY
As shown in the table above,GT-4 of 20 MW (app)
capacity shall meet power shortfall meeting its internal
REMARKS
consumption also otherwise this shortfall needs to be
imported from MSEDCL
Table 2.4 Steam scenario of the existing and proposed plant
INSTALLED/ NET USABLE

YEAR OF CAPACITY (TPH) CAPACITY EXISTING
UNIT INSTALL DEMAND
ATION (TPH)
UNFIRED WITH SF UNFIRED WITH SF
HRSG-1 1984 60 75 54 67.5 143 + 77=

HRSG-2 1984 60 75 54 67.5 220
HRSG-3 2000 60 90 57.5 85

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Thermax 1990 0 0
APU
2012 90 90
Boiler
HRSG-4 -------- 60 90 60 90
TOTAL NA 330 390 316 370(app)
Table 2.5 Steam scenario in HRSG (unfired) mode of operation
USABLE CAPACITY SETAM DEMAND WITH APU

UNIT
(TPH) (TPH)
HRSG 1 54
HRSG 2 54
HRSG 3 57 220
HRSG 4 60
TOTAL 225
REMARKS Operation Philosophy:
Total availability of steam from HRSG is matching the steam demand

without any supplementary firing. Thermax boiler is considered for de-
commissioning because of reliability and maintenance issue and for
creation of space for installation of new GT and HRSG. In order to
retain existing operation philosophy, plant steam demand shall be met
through four HRSGs during 8 months of the year. This will also enable
to achieve high efficiency of cogeneration cycle over simple cycle.
During shutdown, due to annual statutory inspection, for 1 month/year
of each HRSG, APU boiler (gas fired) shall be in operation for 4
months/year to meet steam demand deficiency. Also APU boiler will be
required during plant start up after power failure with MSEDCL power,
unplanned shutdown of any turbine & part load operation of turbine/
turbines (due to technical/grid isolation condition)
Replacing gas fired THERMAX boiler by HRSG-4 will save fuel gas of
the tune of 32 MMSCM/year amounting to savings of 25 Cr/year
Surplus steam (in gas fired mode) shall be utilized in upcoming projects
such as desalination, etc. (estimated demand = 60 TPH)

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Based on the above one steam generator in HRSG mode is justified for energy efficient
mode of operation of the CPP.
Heat Recovery Steam Generator at downstream of gas Turbine Generator will generate
steam from the hot exhaust of Gas Turbine and maximise the fuel efficiency. Typically
HRSG downstream of a GT of 20 MW (at site condition) will produce 60 TPH of steam
without supplementary firing. Supplementary firing provision of 30 TPH steam output
augmentation will be useful to maintain steam output even at GT part load condition
without much bearing of additional space and cost.
Thus with new proposed gas turbine of approximately 20 MW to meet the additional
power requirement of the complex, one 90 TPH HRSG downstream of it will meet the
steam demand of the complex. Additionally, the overall installed steam generation
capacity will also supplement the steam requirement of the future units.

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SECTION 3.0
CONFIGURATION COMPARISON

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3.0 CONFIGURATION COMPARISON
3.1 PROPOSED SYSTEM
The following are the power and steam scenario in the complex with new and future
process units.
Power : Capacity 20 MW to meet plant power demand with new facilities

Steam : 90 TPH ( 60 TPH unfired + 30 TPH with supplementary firing) HRSG
Fuel : Fuel gas
Considering the fuel type the most efficient way of power and steam generation shall be
co-generation mode by using one Gas Turbine to generate power and to generate steam
Heat Recovery Steam Generator with the hot exhaust gas from the Gas turbine. Typical
HRSG downstream of one standard Gas Turbine of approximately 20 MW will give 60
tonnes of steam per hour without supplementary firing. Thus one gas turbine + one
HRSG shall be required to meet to the generate steam and power demands of the
complex.
The power and steam scenario will be as follows;
Considering the above, Gas turbine shall be rated for approximately 20 MW in site rated
design condition and HRSG shall be optimally sized for 90 TPH with supplementary
firing mode and this will give power and steam reliability to the complex and even allow
to maintained steam output with GT part load also.
This also gives a distinct advantage of most reliable operation as sudden failure of one
HRSG will have no significant effect on complex’s steam scenario as the remaining three
HRSG will ramp up to meet the demand. However the power to be imported in case of
tripping of any gas turbine or load shedding is resorted to non critical facilities. It may be
however noted that both GTG and HRSG s are very reliable equipment.
Non-availability of space in the current plot of Uran complex is a constraint for installing
this new unit. To accommodate the new units the old Thermax boiler, IAEC boiler shed
(store) is considered for dismantling. This area is adjacent to the existing GT- HRSG
area. Hence the new unit once installed will seamlessly integrate with the existing GT-
HRSG plot. For this the following existing facility need to be dismantled.

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Table 3-1 Facilities which need to be dismantled for installation of additional GT-IV
FACILITY STATUS REMARKS

IAEC Boiler Not In Service. No impact as these storage requirement shall be
House Currently used taken care by other existing storage facility in the
as store. complex
Thermax Old and Have Total availability of steam from HRSG is matching the
Boiler reliability/ steam demand without any supplementary firing.
maintainability Thermax boiler is considered for decommissioning
problem. because of reliability and maintenance issue and for
creation of space for new GT with HRSG. In order to
retain existing operation philosophy Plant steam
demand shall be met through four HRSGs during 8
months of the year. This will also enable to achieve
high efficiency of cogeneration cycle over simple
cycle. During s/d due to annual statutory inspection
for 1 month/year of each HRSG, APU (gas fired) shall
be in operation during 4 months/year to meet steam
demand deficiency. Also APU boiler will be required
during plant start up after power failure with MSEDCL
power, unplanned s/d of any turbine & part load
operation of turbine/ turbines (due to technical/grid
isolation condition)
Even for non availability of two steam generator, the

complex’s demand including upcoming APU can be
met. Hence the Thermax boiler becomes redundant.
But for non availability of two steam generator, the

steam demand of the complex with upcoming APU
and future Desalination plant cannot be met, for this
steam shedding shall be done in non critical utilities
such as desalination plant.
Existing In service. As per present industrial practices a new DM water
DA/DM plant However it is plant is installed as a part of ongoing APU project.
highly corroded This will give uniformity &improved quality of water
and need and hence longer life of equipments.
replacement.
For this one new DM plant is to be installed at new
location (i.e. NGL unloading area) to replace the
existing DA plant which is highly corroded.
Existing In service. This unit is old and under frequent maintenance. Thus
returned However is very new facility shall come first before replacing this
condensate old and highly existing unit. For this, new facility need be created in
stabilization eroded, needs respective units, i.e. in CSU where un-stabilized
system frequent condensate is generated. All other unit are currently
(vessel V-306 maintenance. producing stabilized condensate.
&V-308& T-
303) In CSU, there is probability of condensate

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contamination also. SO along with condenser

stabilizer Vessel, Condensate Polishing Unit (CPU) is
also to be installed in CSU
Existing DA Not in service This existing facility need to be dismantled to
tank accommodate the new DM water tank.
Gas Metering In active This need to be dismantled to accommodate the
Station For service. extension of control room.
GT-1&2
New facility of gas conditioning and metering facility
for GT-4 shall be designed to cater GT-1 & 2 also.
During the execution of the GT-HRSG-4, the
installation of gas metering system for GT-1 & 2 shall
be installed first before dismantling otherwise the GT-
1&2 need to be run on emergency gas.
Pipe rack Some pipes in A new pipe rack will be erected to accommodate the
around service some pipes of Steam, returned condensate and utilities lines
Thermax not. required for the new facility as well as the pipes need
boiler rerouting due to this new GT-HRSG unit first and then
lines for HRSG-1+2 and 3 shall be hooked up one by
one.
Road at the In service The Road at the south side of CPP shall be widened
south of the and the culvert on this road need to be strengthened
CPP and as required for the dismantling and
culvert erecting/construction of the new GT-HRSG system.
The proposed system shall be based on standard Gas turbine model from Gas turbine
manufacturer. Gas turbine model of site rated output of 20 MW will meet the requirement
of complex for 8 month and approx 19 to 20 MW of power to be imported from grid for
the balance 4 months from grid considering one month shutdown per gas turbine.
The available gas turbine model in this class is as follows.
Table 3-2 Gas Turbine Models
APPROX SITE
MODEL MANUFACTURER ISO OUT PUT
RATED OUT PUT
Frame-V BHEL/GE 26.3 20.7

H25 Hitachi 32.0 25.8
SGT 700 Siemens 31.2 24.3
Frame-VI B BHEL/GE 42.0 33.0
Some gas turbine model are in marginal zone for the requirement such as SGT-600
model of Gas Turbine from Siemens with ISO rating 24.77 MW is expected to produce
approximately 19.4 MW at site design condition.

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Current engineering practice followed by Gas turbine vendors is to enhance the power
output of gas turbine by providing inlet air chiller. With chiller the turbine inlet air temp is
reduced and as the gas turbine output is largely affected by inlet air temperature, the
output of the gas turbine is increased.
Some of the other Gas turbine models such as SGT 500 (from Siemens), Titan-250
(from Solar Turbines) are having lesser output in site rated condition (approx14 to 15MW
without chiller and 18 to 19.5 MW with chiller) than the required approximately 20MW.
The chiller with its necessary refrigeration system will require some more space.
The comparative advantages and disadvantages of chiller system are as follows.
Table 3-3 Comparative advantages and disadvantages of chiller system
ADVANTAGE OF CHILLER DISADVANTAGE OF CHILLER

o Improve gas turbine performance.
o Gas turbine output can be maintained o Requires additional chiller and
irrespective of ambient dry bulb and wet refrigeration system
bulb temperature. o Requires more area,
o This gives an option to utilizing the chiller approximately 20 X 5 m2 footprint
capacity in certain ambient condition to per 1000 TR of VAM chiller and
generate surplus power if export option is approx6 meter more GT inlet
available. duct length.
o Considering the typical ambient condition o Requires more aux power/ steam
of this site, the chiller may be required for consumption.
approx 190 days (for approximately 26 o High installation cost
MW ISO Gas Turbine model. This data o Additional maintenance involved.
shall vary with different GT model) in a
year with different loading factor.
However considering the scarcity of space in the complex and concern of effectiveness
in high humid atmosphere at Uran, gas turbine with chiller is not preferable.
Similarly sometimes supplementary fired HRSGs are designed for operating in FD

(forced draft) fan also, to enable the HRSG to operate when Gas Turbine is not
available. The advantage and disadvantages of this FD mode system are as follows.

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Table 3-4 Comparative advantage and disadvantages of this FD mode system
ADVANTAGE OF FD MODE DISADVANTAGE OF FD MODE
o Requires more maintenance.

o Requires more electrical,
instrumentation.
It gives operational flexibility to generate
o Space requirement is more.
steam independent of associated gas
o Operationally and control wise
turbine is running or not.
comparatively complex.
o Initial cost is more.
The proposed HRSG of 90 TPH is similar to that of existing HRSG-3. However

considering the reliability of gas turbine and all the other HRSGs already having FD fan
mode, the FD fan mode for the proposed HRSG will be redundant. Hence, FD fan mode
in HRSG is not considered.
3.2 COMPARISONS WITH EXISTING SYSTEM
3.2.1 Main Plant
The current gas turbines are of Frame –V model and 2 no’s of HRSGs (1&2) are of 75
TPH capacity each and the HRSG-3 is of 90 TPH capacity. All the HRSGs are
supplementary fired and have FD fan operation mode available. Proposed GT is similar
to the existing GT capacity
Some of the higher rating gas turbine models like Frame-VIB will be able to generate
much higher power than the requirement and will, thus, require running on part load as
per the demand. This will result in inefficient performance of gas turbine. Hence too large
size of gas turbine model will not be suitable for this project unless the excess capacity
is exported to grid. Other different model of gas turbine can also meet the requirement
with or without inlet chiller as mentioned earlier.
Options of different competitive established Gas Turbine models from various

manufacturers are available in the required range. The final GT model will be selected
during tendering stage.
The proposed HRSG of 90 TPH is similar to that of existing HRSG-3. Only difference will
be that, there will be no FD fan mode in the proposed HRSG-4.
3.2.2 Balance of plant

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Deaerator
One dedicated deaerator of 20 minutes holdup between normal and low level will meet
the feed water requirement of proposed HRSG-4.
Boiler Feed water pump
Three no’s of Boiler feed water pumps (2 running +1 standby) will meet the boiler feed
water topping requirement of the proposed HRSG-4.
De Mineralized (DM) Water plant
The current DA/DM plant is very old and highly corroded. The lines, acid & alkali
tanks & other associated equipments have got deteriorated in corrosive
atmosphere. This DA/DM plant needs replacement. One DM plant is already
coming up with APU. This new DM plant as replacement of existing DA/DM plant will
provide uniformity in terms of water quality also eliminate DA and DM water mixing
possibility in water and steam cycle of this entire complex.
ONGC process units are also intended to shift to entirely DM water system as per current
industry practice instead of present DA & DM combined system for better
performance with respect to erosion/ deposition in piping and equipment system.
Table 3-5 Capacity of Existing DA/DM plant
UNIT CAPACITY
CAPACITY/HR REMARKS
DESCRIPTION / DAY
Existing DA plant 57.5M3–Double Streams 1380 M3 24 Hrs basis
APU DM plant 75 M3 –Single stream 1500 M3 20 Hrs basis
Total Capacity 2800 M3

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Table 3-6 DM Water Consumption
CONSUMPTION UNIT/HR UNIT/DAY REMARKS
Return Condensate
Existing plant 143 X 0.4 = 57.2 1373
@ 60 % considered
Return Condensate
APU 77 X 0.3 = 23.1 555
@ 70 % considered
Acid Scrubber 16 384 New requirement
Jacket cooling &

Process 1.5 36
others
Total consumption 2348
However in monsoon conditions, due to municipality water quality issues, regeneration is

required to be carried out much before 20 hours & thus usable capacity is effectively
reduced for 4 months during the year.
Also as APU DM plant configuration is 1X 75 M3/Hr, during planned/unplanned

maintenance of the unit, net availability will be reduced to nil.
In view of the above mentioned factors & to have 2 running & one standby philosophy for
more reliability, new DM plant of the size 2 X 75 M3/Hr is required selected. This will
offer self sufficiency with reliability of DM water.
One DM water storage tank for 1000 to 1200 m3/hr may be considered in place of
existing DA tank (1000 m3 capacity) which is not in use or the same DA tank may be
upgraded to store DM water. This DM water storage tank is in addition to the DM
water storage tanks in APU DM plant. The feed of treated water to proposed DM plant
shall be sourced from existing facility.

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SECTION 4.0
PROJECT DESCRIPTION (MAIN PLANT)

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4.0 PROJECT DESCRIPTION (MAIN PLANT)
4.1 DESIGN BASIS
4.1.1 Site Condition
The site is situated near Mumbai, Maharashtra. The plant is located near sea. The site
ambient condition is as follows;
Table 4-1 Site Conditions
NORMAL/
S. NO. PARAMETER MINIMUM MAXIMUM/DESIGN
AVERAGE
1. Metrological data
Elevation above mean sea level
2. 3 to 5
(meter)
3. Barometric pressure , mbar 999 1005 1015
4. Ambient temperature, oC 10 27 40
5. Relative humidity, % 65 75 85
Rain fall in mm
6. (a) for 1 hr period 62.5 83.3 125
(b) for 24 hr period 350
Wind data wind velocity, km/hr 160 @ is 875

7. South-
Prevailing wind direction South-west
west
ZONE-III (as per IS
8. Earth quake design criteria
1873)
9. Data for equipment design
10. Dry bulb temperature ,oC 40
11. Wet bulb temperature , oC 29
Low ambient temperature for
12. 10
MDMT , oC
13. Designed ambient condition for gas turbine without inlet chiller
14. Barometric pressure , mbar 999
15. Ambient temperature, oC 40
16. Relative humidity, % 65

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4.1.2 Fuels & Fuel Specification
4.1.2.1 Fuel Type
Table 4-2 Fuel used in GT and HRSG
GAS TURBINE
Normal Fuel Fuel Gas
Alternate Fuel Emergency Fuel Gas
Starting Diesel Engine Fuel Diesel
HRSG
Normal Fuel Fuel Gas
Alternate fuel Emergency Fuel Gas
4.1.2.2 Fuel Specifications
Table 4-3 Fuel specifications for Fuel Gas
FUEL GAS DESIGNED FUEL

ALTERNATE FOR EMERGENCY GAS
COMPOSITION (%) GAS (NORMAL)
C1 96.29 97.22 55.75
C2 2.42 1.28 30.10
C3 0.78 13.87
i-C4 0.07 0.01
n-C4 0.09
CO2 0.05 0.01
N2 1.49
H2O Saturated Saturated
H2S 20 ppm
MOL WT 16.72
NET CV
8381
(KCAL/SM3)
GROSS CV
9298
(KCAL/SM3)
Gas turbine and HRSG shall be designed for firing emergency gas also. Dew point of
Emergency fuel gas is 40oC @ 26 kg/cm2a.

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Battery Limit parameter for Fuel Gas:
Table 4-4 Battery Limit parameter for Fuel Gas
NORMAL MINIMUM MAXIMUM DESIGNED

PRESSURE
38 32 44.5 53
(kg/cm2a)
TEMPERATURE 30 to 35 18 35 65
Battery Limit parameter for Emergency Fuel Gas:
Table 4-5 Battery Limit parameter for Emergency Fuel Gas
NORMAL MINIMUM MAXIMUM DESIGNED

PRESSURE
17.5 14 18.5 20
(kg/cm2a)
TEMPERATURE 30 to 35 18 45 65
4.1.3 Pollution Control
The stack pollutions level shall not exceed the following limits
Table 4-6 Stack pollutions level
S.N PARAMETER TYPE OF FUEL MG/NM3

1 Oxides of Nitrogen (NOX) Gas Firing 100
2 Particulate Matter(PM) Gas Firing 5
3 Carbon Monoxide (CO) Gas Firing 100
Latest Pollution control measures to be applied such as DLN burner for Gas turbine and
Low NOx burner for HRSG.
Continuous on-line stack monitoring system consisting of sampling probes, piping,

analysers, etc. for analysis of SOx, NOx, UHC, CO & SPM shall be provided on the main
stack of HRSG. The analysers and recorder shall be located in a suitable air conditioned
enclosure near the stack.
The stack height shall be as per Statutory Pollution control Board regulation.

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4.1.3.1 Noise Level
The noise level shall not exceed than 85 dB at a distance of 1 meter from source of
Individual Equipment. Acoustic enclosure is to be used for Gas turbine for minimising the
sound exposure to surrounding.
4.1.4 Steam
The steam shall be generated in the Heat Recovery Steam Generators (HRSGs) to be
located in CPP. The HRSG shall deliver the required quantities of steam to the Process
units.
LP Steam required for Deaerator shall be met internally.
4.1.4.1 Steam Parameters at Power Block Header
Process requirement of MP steam at Battery limit of CPP for proposed HRSG-4 are
defined as below.
Table 4-7Steam parameters of MP steam at Battery limit
PRESSURE (kg/cm²a) TEMP (°C)

SERVICE REQUIRED QTY
NORMAL MAX MIN DESIGN NORMAL DESIGN
60 TPH without
supplementary
firing at GT base
load
90 TPH with
supplementary
MP
8.5 13.5 7.5 15 193 (sat) <200 firing at GT base
steam
load
35 TPH with/
without
supplementary
firing at GT
turndown

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4.1.4.2 Steam Quality
Table 4-8 Steam Quality at Battery limit
S. NO. PARAMETER VALUE

1 Steam dryness 99.9 % (minimum)
2 Conductivity 1µS/cm (Max)
3 Silica 0.02 ppm (Max)
4 Sodium 5 ppb (Max)
5 pH 8.3 (Minimum)
4.1.5 Boiler Feed Water Quality
Table 4-9 Boiler feed water quality

1 Turbidity NIL
2 Conductivity < 5µS/cm
4 Dissolve Oxygen 0.005 mg/l (max)
5 Dissolve CO2 NIL
6 pH 8.5 to 9
4.1.6 DM Water Quality
Table 4-10 DM water quality
1 Turbidity NIL
2 Conductivity < 5µS/cm
4 pH 6.5 to 7.5
4.1.7 Miscellaneous
The Broad design consideration for the additional unit is;

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The HRSG shall be designed as per IBR

The Gas turbine shall be designed as per API.
The fuel firing system shall be designed as per NFPA-85.
All relevant statutory code, standards and regulation shall be complied.
The GTG and HRSG shall be designed for minimum turndown.

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4.2 MAIN PLANT DESCRIPTION
4.2.1 Gas Turbine
In order to ensure reliability in the gas turbine, its design philosophy is based upon
simplicity, robustness and the use of proven technology. The gas turbines are of heavy
duty industrial type which are already proven with numerous power producing installation
and this class of gas turbine in the capacity range of approx 20 to 35 MW range are still
the most commonly installed gas turbine in the country and abroad. One of such heavy
duty gas turbine in this range is itself operating in the Uran complex for decades.
The gas turbine in this class are having a frame design with a minimum number of parts
in a single-shaft arrangement operating at approximately 5000 rpm rotor speed. The
compressor rotor and the turbine module form a single shaft, which rests in standard
hydrodynamic bearings of the tilting pad type.
Modularization, few parts, long component life and easy inspection ensure long
time between overhauls and low maintenance costs.
Borescope ports are available for inspection of each compressor stage.
Manholes are standard feature in this class of turbine for easy inspection of the
compressor inlet bell mouth during standstill and operation.
The compressor casing is in general vertically split in the longitudinal direction,

which allows half of it to be removed for easy access to the rotor and stator parts.
The rotor centre line is approx 1.5m /5ft above the grating, making inspections
very convenient.
An overhead crane is in general installed inside the gas turbine enclosure to facilitate
maintenance and enough space is available to allow operating personnel to walk around
the machine.
4.2.1.1 Compressor Section
The compressor is of a transonic type with the latest compressor aerodynamic design. It
is typically a 17 stages compressor with ISO pressure ratio of10. To minimise leakage
over the blade tips, generally abradable seals are applied. The vane carrier of the high-
pressure section, stages where the blades are the shortest, is made from a low
expansion material that helps keep clearances to a minimum.
Cooling air for the hot section of the turbine is extracted from the compressor at different
stages is extracted external or internal.

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4.2.1.2 Turbine section
The typical two-stage turbine is built as one module with tie-bolts for ease of
maintenance and bolted to the stub shaft of the compressor. It has an advanced
aerodynamic design with a fully 3D-analyzed flow path with cylindrical sections over the
first, second stage blades. The airfoils of first and second stage vanes and blades are
cooled. The exhaust is either radial or axial.
4.2.1.3 Combustors
Multiple numbers typically 10 no’s of combustors are standard feature in this range of
gas turbine. Dual fuel combustors are also available as standard feature of different gas
turbine model. Some manufacturer offer dry low NOx combustor option also where as
some offer water / steam injection for NOx control. DLN combustor with less than 25
ppm NOx is also available for this class of gas turbine.
DLN system of combustor shall be preferable for this project.
4.2.1.4 Generator
The driven electric generator is connected to the gas turbine shaft with gear box
arrangement.
4.2.1.5 Heat and Noise Attenuation
The “core engine” has external insulation for personnel protection to reduce temperature
on exposed surfaces and to minimise noise levels within the enclosure. Often acoustic
enclosures are also provided.
Acoustic enclosure shall be used for the proposed gas turbine generator.
4.2.1.6 Control and Automation
The control system is built up standard control system as applicable to different

manufacturer. These control system are designed for integration to different DCS
system.
4.2.1.7 Measuring Equipment
Signals from the GT process are connected to I/O modules located in electrical/control
room cabinets or in skid mounted junction boxes. In the process stations the signals are
scaled and checked to be within the nominal signal range. When alarm or shutdown is
derived from a measurement, this is performed in the process stations, with annunciation
in the operator’s station.

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4.2.1.8 Flame Condition Measurements
Thermocouples or flame scanners are used for monitoring the temperature/ flame
condition inside the gas turbine and thermocouples for the gas turbine exhaust. The
exhaust temperature is measured in multiple points. The detectors together with the
difference spread signal between the average and the minimum exhaust temperatures
constitute the flameout protection.
4.2.1.9 Vibration
The gas turbine, gearbox and generator bearings are monitored by vibration sensors.
The vibration sensors are connected to the vibration measuring rack, where signal
conditioning and protection is performed. The information in the measuring rack is
transferred to the control system via bus.
4.2.1.10 Gas Detection System
The gas detection system detects gas in the ventilation outlet duct to the gas turbine
enclosure, other area like AIFH, GCV, SRV, GCS and metering skid, etc. The gas
detectors sense the gas concentration of the air. The central unit receives and analyses
the signals from the two detectors, carries out any signal treatment required and gives
necessary alarm.
The central unit located in the control panel has light diodes and buzzers for alarms.
Detection of a high gas concentration releases an alarm. A high-high detected gas
concentration shuts down the gas turbine, by closing the fuel shut off valve and the fire
valves of the external fuel system.
The system detects gas fuel leakage during all operation modes and standstill. It can
only be shut down from the control room.
Smoke detections system as required at suitable places shall be provided.
4.2.1.11 CO2 Fire Extinguishing System
Automatic fire extinguishing system based on Carbon Dioxide purging is a standard

feature for fire protection purpose.
4.2.1.12 Starting System
Typical starting system for this type of machine is either Diesel generator based or static
frequency based or starting motor based. Since for the Uran complex no additional
margin on power in existing DG set is available for black start of proposed gas turbine,

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the gas turbine generator shall have on board Diesel Generator based start up system
like the existing gas turbine generator.
4.2.1.13 NOx Control
DLN combustor with typically as low as 9 to 25 ppm NOx is also available for many this
class of gas turbine. However some gas turbine model is having only conventional
combustor with wet NOx control system (steam/ DM water injection).Gas turbines with
both the types of NOx control system are in operation in several installations.
DLN system of combustor shall be preferable for this project.
4.2.1.14 Mist Eliminator
The mist eliminator is standard feature of this class of gas turbine and the same shall be
provided.
4.2.1.15 Inlet Air Filter
Pulse jet (self cleaning filters) is commonly installed. In line with existing gas turbine inlet
filter system, high-efficiency pulse jet filters to be installed and material of constructions
of all metallic components shall be stainless steel.
4.2.1.16 Online oil cleaning system
Centrifuge based portable oil purification system are optionally provided as per the
requirement of Gas turbine oil purification.
4.2.1.17 Online & Off Line Gas Turbine Compressor Cleaning System
The online water wash reduces the compressor fouling. For online water wash DM water
is used and gas turbine continues to produce power during water wash. However this is
not very effective in removing the compressor fouling. For this offline water wash is
resorted. During off line water wash the gas turbine is desynchronized and used to rotate
in slow speed and specific chemical solution is injected to gas turbine compressor for
cleaning. This restores compressor performance and hence GT output.

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4.2.2 Heat Recovery Steam Generator (HRSG)
The Heat Recovery Steam Generators shall be of natural circulation, single drum and
single pressure type. It shall have supplementary firing. Economisers shall be non-
steaming at all loads and turndown. MP steam will be generated in HRSG. The burner
shall be ultra Low-NOx type.
Make up water heater (MUH) to be provided in each HRSG. It is to be ensure that
The metal temperatures of the MUH shall be maintained minimum 5 deg C above
acid dew point under all conditions.
There shall be no steaming inside the make-up water preheater section even at
low flow and lowest turndown condition.
Only seamless tubes shall be used. First few rows of the tubes shall be plain tubes and
rest of the tubes shall be finned.
The design of HRSG shall ensure minimum pressure drop through the HRSG and the
flow through the stack.
Steam drum shall be designed with minimum 2 minutes of capacity of storage between
normal water level and drum dry level.
Necessary dosing System including unloading, storage etc. of chemicals at various

points to maintain BFW and boiler water quality, which is required, finally to ensure the
desired steam purity shall be provided.
Continuous on-line stack monitoring system consisting of sampling probes, piping,

analysers, etc. for analysis of SOx, NOx, UHC, CO & SPM shall be provided on the main
stack of HRSG. The analysers and recorder shall be located in a suitable air conditioned
enclosure near the stack.
Blow down from HRSGs shall be collected in pit after being quenched with service water
to 60 Deg C.
The diverter damper shall be electrically operated. For complete isolation there shall be
one electrical Guillotine damper downstream of diverter damper.
Separate HP chemical dosing systems shall be provided for each HRSG.

Following on-line analyzer shall be provided in SWAS system;
pH, Conductivity, silica analyser at BFW header.

pH, Conductivity at condensate inlet to MUH

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pH, Silica & Conductivity for superheated steam and drum water for HRSG.
4.2.3 Process Water system
The existing water shall be used to generate DM water. Currently Reverse Osmosis
(RO) based and ion exchange based DM water generation technology is used to
produce DM water. Before the water is passed through the DM chain, it is generally
pre-treated in Sand bed or duel bed filer. The DM water chains generally run for
approximately 20 hours a day and regeneration shall be carried out in the rest of the
time.
The ion exchanged based technology uses chemical for regeneration and the same is
neutralised in DM plant neutralisation pit and then sent to Effluent treatment plant. On
the other hand with RO technology the RO membranes are regenerated by back wash
and the RO reject is also sent to ETP. In both the technology, this DM plant effluent is
mixed to other incoming effluent in effluent treatment plant. The boiler blowdown water
is also sent to ETP. In line with industrial practice of using ion exchanged based DM
water technology in general, Ion exchange based DM technology shall be used for the
proposed DM plant. The same technology is already in use in APU DM plant. This will
give added advantage in terms of commonality in O&M and inventory. The DM water is
stored in one storage tank in addition to the tanks in APU DM plant and this DM water is
supplied to process units or to CPP steam water system as per demand. The DM water
in CPP is first deaerated in Deaerator and sent to HRSG. Necessary chemical dosing as
per requirement is dosed in process water.
4.2.4 Cooling water system
The Gas Turbine Generator and HRSG with their associated system generally need
some cooling water. Currently there is no significant margin available in the existing
cooling water system. Thus the cooling water consumption shall be tried to be minimum
by adopting good engineering practice. The cooling water requirement for the system
shall be met with new FRP cooling tower/ fin fan cooler.
4.2.5 Condensate Stabilizing Unit
As the old and eroded Condensate Stabilisation Unit (vessel V-306, V308) situated in
CPP complex will be dismantled, the same shall need to be installed in respective unit
(i.e. CSU) producing unstable condensate. As there is a possibility of contamination of
condensate in CSU, condensate polishing unit shall also be installed along with
condensate stabilization system.
4.2.6 Fuel Gas Conditioning Skid
One fuel gas conditioning skid with the capacity to treat the combined fuel gas quantity
of GT-4 and GT-1 & 2 shall be installed. This will subsequently enable to spare the

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existing old and eroded gas conditioning skid for GT-1&2. This fuel gas conditioning skid
comprises of 2 x 50% knock out drum, 2 X 100 % coalescer filter and 2 x 100% heater
(one steam +one electric type). Metering of Fuel gas flow to individual gas turbine shall
be installed adjacent to this skid.
4.2.7 Emissions
Clean gaseous fuel shall be used in the complex hence emission will be inherently low.
To further reduce the emission, Dry low NOx burner shall be used in gas turbine and
Low NOx burner shall be used in HRSG. Latest emission measuring instruments shall
be installed in stack as per statutory pollution control board regulation.
No significant liquid and solid effluent is generated in gas based CPP. Only some
transformer oil, etc. are generated during schedule replacement of oil which is taken
care as per OEM recommendation. The DM plant liquid effluent and Boiler blowdown
shall be treated in the existing effluent treatment plant.
4.2.8 Utilities
This new GT HRSG unit requires Instrument Air (IA), Plant Air (PA), Service Water
(SW), N2 and Cooling water. The Existing IA, PA, SW and N2 (only intermittent
requirement) system in the complex shall take care of the requirement of IA, PA, SW
and this quantity are also very small quantity. The proposed GT shall be capable of
Black start and for this one FRP cooling tower with one spare shell is to be installed.
However the requirement of CW shall be restricted to minimum usage by adopting good
engineering practice. Rest of the cooling water requirement shall be met through cooling
tower or fin fan cooler. Service Water shall be used for HRSG blowdown water cooling.

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4.3 ELECTRICALPOWERSYSTEM
In the existing plant, the electrical power is generated at 11kV, three phase, 50Hz by the
3 nos. existing GTG (Gas Turbine Generators) (GTG-1&2 rated at 23.8635MVA and
GTG-3 rated at 21.83MW). The details included are for the addition of suitable rated
GTG 4 and its other electrical equipments as required.
The existing GTGs generate power at 11kV at 22kV Co-gen bus which is stepped up
through 11kV/ 22kV generator transformers (TR-751 rated at 28MVA for GTG-1, TR-752
rated at 40MVA for GTG-2, TR-753 rated at 28MVA for GTG-3) and connected to 22kV
COGEN bus. The rating of the existing 22kV switchboard is 22kV, 2000A, 26.2kA for 1
sec. The 22kV COGEN bus is further connected to 22kV HBB bus via two 22kV,
40/48MVA series reactors. The rating of the 22kV switchboard at HBB is 22kV, 3000A,
26.2kA for 1 sec. Power from 220kV grid of MSEB is imported and stepped down to
22kV using 2 Nos. 60/75MVA 220/22kV grid transformers. These are hooked up at 22kV
HBB bus. Auxiliary power for GT auxiliaries at 415V is obtained through 11/0.433kV Unit
Auxiliary Transformer (UAT) by tapping from the main run of the cable between
Generator circuit breaker and Generator transformer of Gas Turbine Generator (GTG)
unit. The electrical power distribution system for the existing plant is shown in the
enclosed as Annexure-2 “Main Single Line Diagram & Emergency Power
Distribution System at LPG/ CSU Plant, Uran”- (ONG-URN-ELE-04-B-001)
The new GTG-4 shall also generate power at 11kV which shall be stepped up to 22kV
using generator transformer. It is intended to hook up the new generator at 22kV HBB
bus instead of hook-up to the 22kV COGEN as is the case with the existing generators.
Since bulk of the power including the new APU is being utilized from HBB and the series
reactor rating is limited to 40/48MVA due to constraints of the short circuit level, in order
to get maximum advantage and reliability for power evacuation, GT-4 shall be connected
to the 22kV HBB bus. The auxiliary power (415V) for unit auxiliaries shall be obtained
through UAT as followed in the existing electrical system.
Electrical Auxiliary power distribution arrangement & Power Evacuation Arrangement is

shown in the enclosed as Annexure-3 “Electrical Key Single Line diagram”- (A333-
000-16-50-00001 Rev. A)
During normal operation, all four generators would be running and grid shall be
connected at the 22kV HBB bus with HBB bus coupler NO. Preliminary power system
studies were carried out on E-TAP software and following were the broad observations
for the same:
The short circuit rating of existing 22kV switchboards at COGEN as well HBB is
not found adequate. With addition of new generator the short circuit rating of
22kV switchboard both at COGEN as well HBB shall exceed the existing rating.

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Based on the report outputs, both switchboards are to be replaced by 22kV,

2500A, 40kArms/ 100kA (peak) for 1sec GIS.
The existing series reactors with new generator connected to HBB bus are found
to be of adequate and the same shall be retained with new GIS.
For complete details of the power system studies, refer the report enclosed Annexure-4
Preliminary Power System Studies- (A333-000-16-50-CAL-4001)
The following major electrical equipment is envisaged for the project:

Electrics for GT-4, generator transformer, Unit Auxiliary Transformer, Cabling,
lighting etc.
Synchronising panel, relay & protection panel for GT-4 and generator transformer
22kV, 40kA GIS switchgears at COGEN and HBB. 22kV, 40kA GIS isolator
breaker panel.
Adequately rated 22kV cable shall be laid between generator circuit breaker
(GCB) at CO-GEN substation and 22kV HBB bus.
New 22kV busduct/ cable shall be provided between grid transformers and the
22kV HBB bus.
Cable joints shall be provided in existing power & control feeder cables in
existing 22kV panels at COGEN & HBB to facilitate their termination at new 22kV
GIS at both the substations.
The electrical equipment for the project shall be installed in the following substations:
22kV GIS at CO-GEN shall be installed in the switchgear room for the existing
main substation at CO-GEN after dismantling the existing 22kV switchboard.
Generator Circuit breaker and UAT Circuit breaker shall be installed in the
switchgear room in the existing CO-GEN substation.
All electrical control, synchronizing and annunciation equipment shall be installed
in the existing control room building in CO-GEN. It is proposed to extend this
building to accommodate the control system equipment for new GTG.
All GT aux 415V, MCCs, PCCs, LDB, ASB and UAT shall be accommodated in
the new GTG switchgear hall.
Generator transformer shall be accommodated in the transformer bay near the
new GT switchgear hall.

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22kV GIS at HBB shall be installed in the existing switchgear room in HBB by
dismantling the existing 22kV switchboard.
For emergency power requirement of the entire project & during blackout condition,
emergency 415V power supply from existing EPMC shall be provided for black start of
the GTG and to feed all the essential loads and for safe shutdown of the Units.
Motors rated upto160kW shall be connected to 415V bus and motors of rating above
160kW shall be connected to 6.6kV bus. MV motors up to55 kW will be fed from Motor
Control Centres (MCCs) whereas; motors rated above 55kW and up to 160 kW shall be
fed from Power Control Centres (PCCs)
415V PCCs shall be provided with Auto/manual transfer arrangement between the two
incomers and bus coupler.
Normal, emergency and DC critical lighting has been envisaged for the plant.
The lighting loads of the newly added buildings, equipments and areas shall be fed
through lighting Distribution Boards (LDBs) connected to 415/415V lighting transformers
which draw power from 415V switchboard. 20% to 25% of plant lighting shall be on AC
emergency. Emergency lighting load shall be fed through suitable nos. and rated
emergency lighting feeders (to be provided by Client) which in turn shall get feed from
Emergency Lighting Distribution Boards (ELDBs) having supply through 415V/415V
Emergency lighting transformers.
Auxiliary Service Boards (ASBs) shall be provided to feed new power panels, welding
receptacles, miscellaneous loads etc, as required.
To provide uninterrupted power supply to DCS and other Control Panels, a dedicated
110V AC UPS system shall be provided. To feed GTG essential loads, such as the
emergency oil pumps 125V DC system shall be provided. For the control Supply to
Switchgears / Panels, Emergency DC lighting etc, 110 V DC supply backed by DC
Batteries shall be provided.
4.3.1 System Design Philosophy
4.3.1.1 Voltage Levels in the power plant shall be as follows:
Power evacuation : 22kV (+10%,-10%), 3 phase, 3 wire, 50Hz

Generation Voltage : 11kV,3phase,50 Hz
Plant LT Auxiliary Supply : 415V (±10%), 3 phase, 4 wire, 50Hz
Plant DC Supply : 110V (±10%), DC 2 wire.
DC system for GTG-4 : As Required

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Plant UPS Supply : 110 (±10%), 1 phase, 2 wires 50 Hz, A.C.

Voltage level for AC Motors : 240 V, Single phase, 50 Hz, with DOL start.
Below 0.2kW
Voltage level for AC Motors : 415 V, Three phase, 50 Hz, with DOL start.
From 0.2kW to 160kW
4.3.1.2 Design short circuit levels shall be at least the following and has to be supported
by calculation:
Three phase symmetrical short circuit ratings of 22kV System: 40 kA for 1 sec.
Three phase symmetrical short circuit ratings of 415V System: 50kA for 1 sec
4.3.1.3 The Electrical system shall be designed to provide:
Safety to personnel and equipment both during operation and maintenance

Reliability of service.
Minimal fire risk.
Ease of maintenance and convenience of operation.
Automatic protection of all electrical equipment through selective relaying
system.
Electrical supply to equipment and machinery within the design operating limits.
Adequate provision for future extension and modification.
Suitability for applicable environmental factors.
Maximum inter-changeability of equipment.
4.3.2 Electrical Equipment
Electrical equipment and components shall be designed in accordance with applicable

Indian Standards and shall conform to statutory regulations.
4.3.2.1 Generator Circuit Breaker (GCB-4)
The generator circuit breaker (GCB-4) shall be installed inside the switchgear room (first
floor of the control room).The circuit breakers shall be designed for natural air cooling.
The GCB shall be of VCB, metal enclosed, indoor and free standing type with an
operating duty of CO-30 min-CO for short circuit current and O-3min-CO-3 min-CO for
load current.
The voltage rating of generator transformer primary shall preferably be 11kV same as

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that of the existing system and the same will be matched with the generator voltage
after finalization of generator particulars. The ratings of Generator Circuit Breaker
(GCB) shall be matched with the generator particulars. The preferred voltage rating of
GCB shall also be 11kV same as that of the existing system.
The short circuit rating of the GCB shall be arrived at by the following criteria:
Fault contribution from the generator.
OR
Fault contribution from the 22kV system and from the motors through Unit Auxiliary
Transformer. For this purpose the 22kV system fault contribution shall be considered as
limited only by the impedance of the Generator Transformer.
The higher of the two values shall govern the selection of the short circuit rating of the
GCB.
4.3.2.2 Generator (GTG-4) Relay Panel
All protective relays, auxiliary relays, timers, etc., to protect the complete generator, its
Subsystems, generator transformer (GT) shall be housed in Generator relay panel
(GRP). All protective relays shall be numerical communicable type with serial interface
facility. All protective relays and meters shall be provided with test terminal blocks for
secondary injection testing.
The relay panel shall be of free standing, floor mounting, sheet steel enclosed, with a
degree of protection of not less than IP 42. The panel shall be located in the control
room. The panel shall be fabricated out of CRCA sheet steel of not less than 2 mm
thickness.GRP shall also accommodate a digital tri-vector meter (TVM) and energy
accounting /auditmeters. The accuracy class of TVM/energy accounting/audit meters
shall be Cl.0.2S. Tri-vectormeters shall have pulse output for interfacing with DCS.
HMI consisting of operator and engineering workstations, data concentrator panels etc.
shall be provided for the generator relay control panel.
4.3.2.3 Transformers
Following transformers are envisaged in the project:
Generator Transformer for GTG-4.

1 No. of Unit Auxiliary Transformer (UAT)
Generator transformers shall be three phase, oil immersed double wound type, suitable
for outdoor use. Unit Auxiliary Transformer shall be dry type transformer suitable for
indoor use. The percentage impedance of each transformer shall generally be as per
Indian Standards.

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Generator Transformer
Generator Transformer shall be used to connect Generator to 22 kV network to evacuate

power. The rating of the generator transformers shall be selected such that there will not
be any limitation on the generator transformer for evacuating the full Gas Turbine output
under all operating conditions at site. The generator transformer for GTG shall be
suitable for bidirectional power flow.
Unit Auxiliary Transformer
1 x100% UAT shall be provided for supplying plant auxiliaries as per the Single line
diagram. The rating of Unit Auxiliary Transformers shall be chosen such that each
transformer can take the entire loads of complete plant. It shall be of dry-type and shall
be installed inside the GT-4 rack room. Starting requirements of higher size motors shall
be duly considered while sizing the transformer.
4.3.2.4 Gas Insulated Switchgears (GIS)
22kV Switchboards at COGEN and HBB shall be gas insulated switchboards. The GIS
shall have double busbar arrangement. The minimum degree of enclosure protection
shall be IP-4X.
The switchgear gas enclosures shall be sectionalized with gas tight barriers between
sections. The power connections from one compartment to the other shall be done using
gas tight high voltage bushings. Suitable busbar disconnectors and earthing switch shall
be provided for each circuit breaker/ isolator to permit safe isolation and earthing of any
feeder circuit. Suitable gas release mechanism shall be provided for different
enclosures.SF6 / VCB circuit breakers shall be used in the switchboard. The existing
numerical relays in the existing relay and control panels shall be utilized for the
GIS switchboards. However, the protection relays for GT-4 incomer shall be
mounted on the existing relay & control panel.
The connection between the 220kV grid transformers and 22kV GIS incomers at HBB
shall be through busduct/ cables.
4.3.2.5 MV Switchgear
All the switchgears shall have rating at least equal to the maximum demand plus a
provision for 10% future load growth. Incomers of switchgear shall be designed to cater
to the complete load including 10% margin for future load growth. Spare outgoing
feeders shall be provided in all switchgears. At least one number of each rating & type or
10%, whichever is more, shall be provided as spares. Service breaking capacities for all
breakers shall be equal to or higher than the maximum value of the short-circuit at the
point of installation. Numerical relays are envisaged for PCCs along with data
concentrator & HMI.

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Switchboards (e.g. PCC, MCC, ASB and LDB etc.) shall be with two fully rated incomers
and one buscoupler with interlock. Normal operation shall be with both incomers ON and
buscoupler OFF. Upon failure of any one of the incomer due to loss of power supply, the
buscoupler will be closed.415VMCC/ASB incomers shall be heavy-duty switch having
mechanical interlock &415VLDBincomersshall be MCCB having mechanical interlock.
4.3.2.6 DC System (Battery charger, battery bank and DCDB)
Battery Charger and Distribution board shall be floor mounted, free standing, metal
enclosed and vermin proof type having hinged door for front access and shall be suitable
for indoor use.
The battery charger/rectifier shall feed the load and keep the batteries under fully
charged condition.
Provision shall also be made for necessary boost charging/initial charging of

battery. Batteries shall be of adequate capacity to meet the back-up requirements as
envisaged on the duty cycle.
While sizing the battery, temperature correction factor and ageing factor shall be
considered in addition to the maintenance factor.
4.3.2.7 Uninterrupted Power Supply System
UPS system shall include a set of storage batteries, rectifier transformer, rectifier- cum-
charger, inverter, set of filter circuit, static switches, bypass transformer, facility for
manual transfer between inverter supply and bypass line, facility for bypassing inverter
& static switch for maintenance, AC Distribution board and other associated accessories.
4.3.2.8 Motors
In general, three phase squirrel cage induction motors designed for direction line starting
shall be used. Motors shall be totally enclosed, fan cooled type and suitable for
continuous outdoor use.
Motors rated up to 160KWshall be fed from 415V and 6.6KV above 160KW.
Motors above 22KW shall be provided with space heaters.
4.3.2.9 Cables and Wires
HV power cables shall be XLPE insulated, PVC sheathed, armoured type with
aluminium/ copper conductors and MV power and control cables shall be PVC insulated,
PVC sheathed, armoured type with aluminium/copper conductors.

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The sizing of high voltage cables shall be based on short-circuit withstand capacity for a
minimum period in addition to the maximum anticipated load current.
4.3.2.10 Lighting system
The lighting system of the complete area shall be designed as per good engineering
practices to achieve the specified illumination levels.
The lighting system shall include
Normal lighting
Emergency Lighting
DC critical lighting
Lighting distribution system shall consist of normal & emergency lighting transformers,
normal & emergency lighting distribution board, lighting panels etc. Lighting transformers
shall receive power from PCC in substation and distribute to LDB. Lighting transformers
shall be dry type, 415/415Vand provided with ±2.5% & ±5% taps.
For indoor lighting in the buildings, HPMV/ fluorescent lighting fixtures shall be used.
For general outdoor lighting, 30m tubular telescopic type flood lighting high mast
shall be provided.
For street lighting, HPSV lamps on bent arm street lighting pole of9m/11m height shall
be provided.
DC lighting shall be provided in the critical areas/building for safety of plant operations.
Aviation warning lights shall be provided for all tall structures, stacks chimneys etc. as
per statutory regulations.
4.3.2.11 Earthing and lightning protection
Earthing and lightning protection shall be provided for plant safety and shall be designed
in accordance with IS-3043.
The earthing system shall be provided with adequate numbers of GI earth electrodes in
test pit and interconnected network of GI earth strips to achieve designed value of earth
resistance.
4.3.3 Salient Features of Electrical System/Facilities
The following are some of the important features of electrical system/facilities envisaged:

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All protection relays for HV switchboards, PCCs and Generators shall be

numerical microprocessor based communicable type and provided with data
concentrator and HMI system.
Fire alarm devices have been considered for the new facilities which shall be
hooked up to the existing fire alarm system.
Field call stations etc. have been considered for the new faculties and the same
shall be hooked up to the existing plant communication system.

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4.4 PIPING SYSTEM AND FUTURE HOOK UP
Suitable tap off connection shall be provided in all applicable headers such as steam
header tapping for future Desalination unit. This will enable future unit hook up without
shut down.
4.4.1 Codes and Standards
All piping shall be designed as per ASME B31.3, Boiler external piping which required to
conform to ASME B31.1 as per also be complied. Steam, boiler feed water and
condensate lines falling under the purview of the IBR shall be meeting the requirement
of Indian Boiler Regulation (IBR).
4.4.2 Equipment/Piping Layout Criteria
Equipment Layout shall meet all the aspects of erection, maintenance, operation,
safety etc.
In general foundation height of pumps and equipment shall be minimum 300mm

above HPP (Highest Point of Paving).
Piping passing through structure (RCC floors) or passing near the concrete
column etc. should have adequate annular space to avoid restriction of line
movement during thermal expansion. The gap should be taken care for hot lines
along with insulation thickness. The gap should be sufficient to take care of any
fouling with fireproofing etc.
All branches from headers shall be taken from top (utilities) unless restrained by
P&ID requirement.
4.4.3 Pump Piping
Monorail shall be provided along with chain pulley blocks for pumps as per the
requirement for maintenance of pumps, exchangers, etc.
Operation and maintenance access shall be clearly marked around the pumps. All
auxiliary piping shall be routed in such a way so as to ensure that there is no hindrance
in the access areas.
Cone type temporary strainers shall not be used in pump suction piping.
4.4.4 Pipe Rack
To design the pipe rack/sleeper with a minimum of 25% extra future space of the total
width of the pipe rack(all tiers combined together)/sleeper up to widths of 16 metres and

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10% extra future space for widths above 16 meters, shall be earmarked for future
expansion on the pipe rack/ sleeper. The future space on each tier of the rack/ sleeper
throughout the length of pipe rack/sleeper shall be maintained and shall be 1500mm
minimum on each tier of the pipe rack.
Maximum width of the T-post shall be restricted to 2.5M. The width of main pipe rack
shall be 6M/ 8M/ 10M/ 12M/ 16M/ 20M as per requirement having 4 tiers maximum. The
span of the pipe rack shall be 6M/ 8M.
No cantilever shall be provided in the pipe rack for meeting present as well as
future extra space requirement.
Requirement of intermediate beams for width/span of pipe rack shall be established

during detailed engineering on the basis of support requirement of small bore piping.
Piping shall run at different elevations for North-South & East-West directions and
change elevation at change in direction.
Total rack shall be designed for densest/ heaviest section. Rack shall be designed to
meet specific requirements of P&ID, like, free draining, no pocket etc.
Weld seam of pipe shall be kept such that it is always in the upper quadrant.
Cable tray-laying shall take care of necessary clearance for fire proofing of structure.
Instruments on piping to be planned in such a way, meeting P&ID requirements, that

access for all instruments on piping & vessel is provided. Flow instruments in pipe-rack
also to be located in such a way that these are approachable by platforms/ladder.
4.4.5 Pipe Spacing / Pipe Span
Actual line spacing shall take care of thermal expansion of adjoining lines during
operation as well as pre-commissioning/start up conditions. The spacing of pipelines in
the transverse direction across the pipe rack should take into consideration the
longitudinal expansion of the pipe along the pipe rack.
4.4.6 Nozzle Loading
Piping shall be so routed and supported, to limit nozzle loadings and moments on
equipment and machinery within allowable limits when furnished by respective vendors.
In the absence of vendor data relevant codes like API 610, API 621, NEMA SM23,
API560, API661 etc. or any other approved proven international code/ practices may be
followed in case of equipments conforming to these standards.

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4.4.7 Utility Hose Station
Utility hose stations shall be provided for steam, Air, Water, etc. as indicated in the
P&IDs. Number of Hose Stations, if shown in P&IDs, have indicative importance only
and adequate number of hose stations shall be provided so that every area at Grade, in
structure, buildings etc. can be reached from at least one hose station.
Each hose station shall be furnished with 1" dia., 15 meter long hose, and one for steam,
one for Air and one for Water. All piping connections at the hose stations shall be
flanged for steam and shall have quick coupling for Air and Water. Free end of hoses
shall be provided with nozzle, with insulated holder for steam hose.
Hose Stations for Nitrogen and any other service shall be provided as per the
requirements of P&IDs. Hose station for nitrogen shall be provided with inbuilt non return
valve in the quick coupling at pipe side connection.
The sequence of lines in hose station shall be steam, air and water from left to right
when looking from front.
Care shall be taken, while installing utility stations under Pipe-rack, to ensure that they
do not foul with electrical /instrument junction box. If necessary, these may be
staggered.
Hose stations, with numbers, are to be marked on the Equipment Layout during detailed
engineering.
4.4.8 Steam Piping
Steam piping under the purview of IBR shall meet the requirement of Indian Boiler
Regulation (IBR). Latest IBR shall be followed for execution.
4.4.9 Flare Piping
Flare header shall be sloped towards flare knock-out drum. Expansion loop shall be
provided in horizontal plane as per requirement to accommodate thermal expansion.
The desired slope shall be ensured throughout including flat loop. Flare header shall be
supported on shoe of height ranging from 100mm to 300mm.
Proper thermal analysis temperature shall be established including the possibility of

temperature gradient along the line before providing expansion loops. Efforts shall be
made to minimise the number of loops.
Flare line between knock out drum and water seal drum shall be designed for pressure
fluctuations and adequately supported to avoid vibrations.

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4.4.10 Heat Traced Piping
A condensate collection system shall be designed to collect condensate from traps and
steam supply/return manifolds.
Steam supply manifolds for steam tracing shall not be located at grade. These shall be
located above on the pipe rack and shall be accessible by continuous platform. This
continuous platform shall be approachable from grade by monkey ladder at every 50
meters.
4.4.11 Stress Analysis
Piping arrangement shall provide for flexibility of lines to take care of the thermal
expansion, contraction and equipment settlement. Large reactions or moments at
equipment connections shall be avoided.
Expansion computation and Stress Analysis shall be done on the basis of a base
temperature of 21.1ºC (70ºF) and shall cover (+ve or -ve) design temperature(s) as
shown in line schedule as well as start-up, shutdown and variable operating conditions.
Analysis shall be done considering the actual fluid densities in the line.
i. Flexibility analysis shall meet the requirements of Code ASME B-31.3 (latest
edition). Analysis shall consider stress intensification factors as per ASME B-
31.3.
ii. Flexibility Analysis of lines shall be carried out using simplified methods or a
comprehensive computer program. Comprehensive computer analysis shall be
carried out for piping as per sub clause (vii) below for lines connected to
equipments like vessels, pumps, turbine, filters, furnaces or other strain-sensitive
equipments. The result of the analysis must satisfy the allowable loading on
nozzles of such equipments.
iii. Piping shall be adequately supported for weight of piping, water full, attached
unsupported components, wind, seismic, dynamic loads, insulation and any other
applicable forces. Care should be taken that these supports are adequate to
prevent excessive stress, loads or moments in either the piping or terminal
nozzles of the equipment to which it is connected. The supports shall be
indicated in the piping isometrics.
Adequacy of supporting of lines having heavy valves shall be checked. Adequacy

check of the supports for imposed loads shall also be carried out. Adequacy of
nozzles shall be checked to bear hydro-test loads, otherwise suitable precaution
to be taken at nozzle points.

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For design of supports, due consideration shall be given for all load cases
including hydro-test. Load generated due to wind and seismic effects shall be
considered for design of supports. Pressure thrust shall be considered for all
lines.
iv. Safety valve manifolds and piping downstream of control valves shall be
adequately supported to avoid vibrations.
v. Flange joints shall be checked for leakage for total equivalent pressure at flange
joints due to combined effect of imposed forces and bending moments and
internal pressure. Flange leakage checks shall be performed for the above
lines as per ASME Section VIII Div. 1 or Div. 2.
vi. The following factors/limits shall be considered in the stress analysis:
Friction factor:
STEEL to STEEL = 0.3
STEEL to PTFE = 0.1
STEEL to GRAPHITE = 0.15
With and without Corrosion Allowance
Initial thermal displacement of nozzles
Transverse deflections due to sustained loading = 25mm (maximum)
Vertical deflections in piping system between two adjacent supports
due to sustained loading =15 mm (max) for all lines except steam and
flare lines. For steam lines the above deflection limit shall be 3mm
max and for flare line it shall be such that slope is maintained in the
flare line.
Stress Analysis report shall contain corresponding nodes to
demonstrate that the above limit of vertical deflection is not exceeded.
Longitudinal expansion/contraction = 200mm (maximum)
Special care to be taken to check for expansion loops and shoe
support lengths shall be finalized accordingly.
4.4.12 Dynamic Analysis
Dynamic analysis shall be performed during detailed engineering for all two phase lines
having slug flow and transfer lines in the plant, in order to ensure that such lines are
provided with proper supports and there shall be no vibrations in the line during normal
operation as well as during start up or any upset conditions.

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Dynamic analysis to be performed at design temperature and operating temperature.

Actual densities shall be considered while carrying out static analysis.
The fundamental frequency of the piping system is to be checked to avoid resonance.

The minimum acceptable frequency can be considered as 7 Hz for Transfer lines and 6
Hz for other lines. Contractor shall submit mode shape plots up to 15Hz. Model
displacement output shall be submitted.
Boundary condition and other parameter used in dynamic analysis shall also be part of
dynamic analysis report.
4.4.13 Piping Supports
All piping shall be adequately supported, guided or anchored so as to prevent undue

vibration, deflection/expansion or loads on connected equipment and piping and leakage
at joints.
Piping at valves and equipments such as heat exchangers and pumps, requiring periodic
maintenance, shall be supported in such a way so that the valves and Equipments can
be removed with a minimum necessity of installing temporary pipe supports.
The first solid support for pump suction and discharge lines shall be adjustable type to
facilitate pump alignment. Pedestal for pipe supports for outdoor installation shall be
150mm above HPP.
Long trunnion type supports are to be avoided. In case long trunnion type supports are
unavoidable in straight length of pipe, it is to be provided with reinforcement pad on the
pipe.
For insulated lines on pipe rack shoe support shall be provided. Shoe height shall be
based on insulation thickness. Minimum shoe length shall be 300mm and shall be
suitably increased to suit thermal movement of line.
Shoe shall be sufficient height such that temperature of the contact point on pipe rack/
support location shall not exceed a temperature of 120deg.C on concrete or 350deg.C
on structural steel.
All the supports in a piping system shall be checked for their correctness & adequacy
after complete installation by the designer.
The pump piping from vessels in technological building/columns may require cantilever
supports to be taken from the pipe rack or from the technological building to maintain the
basic spans.

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T-supports from pavement shall be minimized. Anchor fasteners for T supports shall not
be used.
Spring supports shall have Teflon pad on top slide plate of spring for temperature up to
200 C and graphite pad or roller bearing for higher temperatures.
Spring supports should be unlocked and cold set prior to commissioning of the system,
by Contractor as per the instructions of the spring manufacturer.
For lines on pipe rack/sleeper, resting support on every grid of pipe rack/sleeper shall be
provided.

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4.5 CIVIL & INFRASTRUCTURE
The Site is almost flat. Existing facilities is already there. Some of these facilities are
required to be dismantled to accommodate the new unit. North side road and the
culverts need to be widened and strengthen to enable construction of new GT HRSG
unit. The existing control room need to be extended to accommodate new electrical and
instrumentation facility.
4.5.1 Plant Layout
The layout of main plant along with all auxiliary systems is shown in, Annexure-1. In
laying out the various facilities, consideration has been given to the following general
principles:
I. Power and steam Generation facility

II. Fuel gas facilities
III. DM plant facility
Emphasise have been given to minimise the facility/ building footprint on the
lay out and multi storied facility is adopted where possible such as in switch
gear room.
4.5.2 Site Topography and Graded Level
The proposed power plant area is found to be flat. There are existing facilities which will
be dismantled. During detail engineering to finalize the finished grade level of the site
existing plant grade level of the adjacent GT HRSGs to be considered.
4.5.3 Foundations
For moderate to heavily loaded columns, for all major and important structures such as
GT, HRSG & stack etc. deep foundations in the form of piles will be finalised based on
soil load bearing capacity. Pile foundations are also required to support high dynamic
loads. Open shallow foundations can be provided for lightly loaded structures such as
boundary wall, pipe supporting structures etc.
4.5.4 Main Power House Buildings
The main power block comprises of gas turbine generator building planned to suite
functional requirement. After finalisation of Gas turbine model during award of tender, all
effort shall be made to accommodate the proposed gas turbine to be accommodated in
a shed which will be the extension of the existing GT hall shed.

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4.5.5 Design
Dead and live loads will be considered as per relevant IS codes and standard
engineering practices. The basic wind speed would be considered for design of
buildings/ structures as per IS code. Accordingly to seismic zone seismic forces would
be considered for the design of structures / buildings. The buildings / structures are
designed for wind or seismic loads whichever governs. All designs would be carried out
in SI units and would be as per relevant IS codes.
4.5.6 Materials
All civil construction materials used would confirm to relevant IS standards.

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4.6 CONTROL AND INSTRUMENTATION
4.6.1 Totally new Instrumentation and control systems both at field and control room are
envisaged for the Additional Co-generation unit, including the following.
Gas turbine control system

Distributed Control system
Programmable Logic Controllers
Analyzer systems
4.6.2 The new control system will need to be integrated with the existing control systems
details of which are as given below
Existing DCS- Honeywell make

GT-I control system- Mark V
GT-II control system- Mark II being upgraded to Mark VI E
GT-III control system- Mark V
4.6.3 It has been envisaged to engineer control room for Gas turbine generator-IV, HRSG-IV,
new DM plant and all related/associated /auxiliary units. The man-machine
interface/consoles for all new control systems including those required for new Gas
Turbine Controls, new Burner Management Systems (BMS) shall be located in the
existing control room building. The existing control room building will need to be
modified/ extended to accommodate the above.
4.6.4 Adequacy of the existing UPS and HVAC systems of the control room needs to be
assessed during detailed engineering.
4.6.5 The new control system rack/panels along with its new UPS are envisaged to be located
in new GT-4 switch gear building.
4.6.6 Existing analyzer room located adjacent to the Thermax boiler needs to be relocated and
the new analyzer systems will also be installed in this relocated analyzer room.

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SECTION 5.0
PROJECT DESCRIPTION (DM PLANT)

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5.0 PROJECT DESCRIPTION (DM PLANT)
ONGC’s upcoming process units (APU) are designed to use DM water and for this
purpose, one DM water plant is being installed along with APU. As per current industry
practices, only DM water is used instead of DA water since it provides benefit of better
(lesser) corrosion and deposition characteristics to the equipments and piping. So,
ONGC intended to shift to DM water system entirely, instead of present DA & DM
combined system for better performance of its existing facilities.
The existing DA/DM plant is very old and highly corroded. Further this existing DA/DM
plant need to be dismantled for creation of space for new additional Gas Turbine -IV and
HRSG. Thus this DA/DM plant needs replacement and a new DM plant needs to be
installed.
For uninterrupted DM water supply the new DM plant will be installed before dismantling
of existing DM plant.
The new DM water plant shall be with double chain each with a capacity of 75 m3/hr.
The purpose of the DM Plant will be to demineralise the feed water to the required
quality.
DM Plant shall consist of PSF-SAC-SBA-MB and a degasser tower for producing DM

water. Degasser Tower will be designed for the gross flow of SAC exchanger.
For regeneration of cation exchange resins (of SAC and MB exchangers) Hydrochloric
acid will be used. Two Nos. each (1W+1S) of Acid measuring tanks (which can be
interchangeably used) will be provided separately for SAC exchanger and MB
exchanger respectively. For regeneration of anion exchange resins (of SBA and MB
exchangers) Caustic lye will be used. Two Nos. each (1W+1S) of Alkali Measuring /
dilution tanks (which can be interchangeably used) will be provided separately for SBA
exchanger and MB exchanger respectively. Each tank will be provided with an agitator.
Each tank will be provided with hydraulic ejectors.
One neutralisation pit for collection and neutralisation of effluent from all exchangers will
be provided. The pit having acid/alkali proof ‘Fibre Reinforced Epoxy Screed’ lining
inside will be sized to hold the total regeneration effluent of DM Plant and neutralisation
of effluent. One acid/alkali dilution tank (10% concentration) along with agitator will be
provided for neutralisation purposes.

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5.1 PROCESS DESIGN BASIS
Number of Chains - Two (2)

Capacity of each Chain - 75 m3/ hr
Chain structure - PSF-SAC-SBA-MB
Capacity of Degasser Tower - Gross flow capacity of SAC
5.1.1 Design Characteristics of Feed Water
Table 5-1 Feed water system design characteristics
SL. NO PARAMETER UNIT VALUE

1. Ph 7.6
2. Turbidity NTU 5.9
3. Total Suspended Solids mg/l 5
4. Total Dissolved Solids mg/l 150
5. Electrical Conductivity 20 Deg C Micro-Siemens/cm 210
6. Calcium as CaCO3 mg/l 45
7. Magnesium as CaCO3 mg/l 35
8. Sodium as Na mg/l -
9. Potassium as K mg/l -
10. Chloride as Cl mg/l 15
11. Sulphate as SO4 mg/l 15
12. Iron as Fe mg/l 0.3
13. Silica (Reactive) as SiO mg/l 17
14. M - Alkalinity as CaCO3 mg/l 80
15. Total Copper as Cu mg/l -
16. Organic Matter as KMnO4 value 100 DegC mg/l -
5.1.2 Resins to be used
SAC - Indion / Tulsion/ Rohm & Hass make

SBA - Type I of Indion / Tulsion/ Rohm & Hass make
5.1.3 Regeneration Mode adopted
For SAC exchanger - Counter Current (hold down by water)

For SBA exchanger - Counter Current (hold down by water)

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5.1.4 Regenerant Chemical to be used
Hydrochloric acid - 30 % w/w as per IS-265 (Technical grade)

Caustic lye (NaOH) 45 % by w/w as per IS-252 (Rayon Grade)
5.2 OPERATION OF THE DM PLANT
Operation of the DM Plant shall be PLC based microprocessor control with a selector
switch for manual operation. The operating sequence of regeneration will be controlled
by programmable logic controller. The regeneration will initiate from the DM Plant
Control Room by a push button, on receipt of conductivity/ silica high alarm from the
exchangers and the same will be put back to service by initiation of push button from the
DM Plant Control Room. The initiation of PSF backwash shall be on exceeding the
specified limit of pressure drop with alarm in DM Plant Control Room or end of cycle time
whichever is earlier. DM Plant will have provision to trip in case any one of the
parameters pH, Conductivity, silica is off spec.
5.3 ENGINEERING DESIGN DATA
5.3.1 Tanks& Vessels
The Pressure Sand Filter, priming chamber and ion exchanger vessels, shall be
designed and constructed of boiler quality plate. Vessel shall be designed to contain
filter media, supporting media, ion exchange resins, under drains and distribution system
(corrosion resistant construction), all interconnecting piping with pipe supports and
valves. All internal support beams shall be bolted or clamped in position. Supports rings
may be welded to the shell. The exchanger vessels and priming chamber shall be
completely rubber lined on the insides with 4.5 mm thick (minimum) rubber as per IS -
4682 Part-I latest edition, with rubber lining extending up to the full face of all the nozzle
flanges on the vessel. Priming chamber shall be designed as pressure vessel for both
condition of full vacuum and full liquid. The Pressure Sand Filter shall be epoxy lined on
all internal surfaces.
HCl/ NaOH bulk storage tank and Acid/ Alkali measuring tanks shall be of FRP (with UV
protection). PSF back wash tank and DM Water storage tank shall be epoxy painted on
all internal surfaces.
PSF and Ion exchange vessels shall be furnished with manholes, handholes, sight
glasses, inlet, outlet, vent and drain, instrument nozzles, regeneration nozzles, etc, with
flanged connections for the piping system and structural steel leg supports.
Wastewater from ion exchangers shall be drained to neutralisation pit. Waste water
shall be drained to Fibre Reinforced Epoxy Screed lined regeneration control sump with
orifice boards from where it shall be taken through U-PVC pipes housed in acid/alkali
proof epoxy lined RCC drains and drain covered with precast RCC slabs.

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All tanks with Soda lime breather shall be suitably designed for the maximum positive
pressure as well as vacuum condition.
5.3.2 Piping and Valves
Each PSF and ion exchanger unit shall be provided with a group of individual
pneumatically operated valves designed as required for semi-automatic control with
provision of manual operation. Hand wheel shall be provided for all valves. Also all
other pneumatically operated ON-OFF valves shall be provided with hand-wheels to
facilitate manual operation in the field. Besides the pneumatically operated valves, on
each PSF, ion-exchanger and PSF back wash tank, manually operated isolation valves
at inlet and outlet of each PSF, ion-exchanger and PSF back wash tank, shall also be
provided.
Isolation valves shall be provided at suction of each pump and on discharge of each
pump and blower. Check valve shall be provided on discharge of each pump and lobe
type blowers. Dampers shall be provided on discharge of each turbo blower. Valves
shall be provided at inlet, outlet and drain on each tank and elsewhere in the total
system as required for making it operational and safe.
All pumps shall have permanent strainers on the suction side.
5.3.3 Painting
Primer and finish painting of all piping, vessels, tanks, equipments, structural supports,
etc. shall be as per Corrosive Industrial Environment specifications.
5.3.4 Civil and Structural Works
I. Proper slopes should be provided in the DM Plant area for storm water drainage.
II. Acid /Alkali proof brick (75mm thick) flooring inside the dykes/ kerb walls around
the HCl bulk storage and measuring tanks, NaOH bulk storage, and dilution
tanks, acid /alkali unloading and transfer pumps, brine preparation and dosing
tank, degassed water storage tank, degassed water pumps, effluent pumps and
wherever required shall be provided. Acid /Alkali storage area shall be dyked to
hold total volume of the largest storage tank.
III. All RCC drains inside the battery limit of the DM Plant (lined as well as unlined)
along with precast RCC covers (Removable type) top of cover shall be raised
above pavement level (provided with champering) to avoid rain ingress.
IV. Acid / alkali proof epoxy lined RCC effluent drains with precast RCC covers.

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V. Fibre Reinforced Epoxy Screed lining in neutralisation pits and in regeneration

control sumps shall be provided.
VI. Acid / alkali proof bitumastic lining over bitumen primer on RCC foundations in
acid/alkali handling areas.
VII. Handrailing shall be provided all round the neutralisation pit.
VIII. 150 mm high kerbs of RCC construction shall be provided around all measuring /
dilution tanks, acid/alkali unloading and transfer pumps, effluent transfer pumps,
degassed water tanks and pumps, safety shower and eyewash facilities, hose
stations, and as required / shown..
IX. RCC Platform, with stairs and handrailing (for degasser platform and acid/ alkali
bulk storage tanks), steel platform with handrailing and ladders (for all ion
exchangers and PSF), steel stairs with handrailing and platform (for degassed
water tank, DM water storage tank, PSF back wash tank, wherever
specified/required.
5.4 COST ANALYSIS
The cost details of DM water plant are carried separately and attached as per Annexure-5.

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SECTION 6.0
SAFETY AND ENVIRONMENTAL ASPECTS

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6.0 SAFETY AND ENVIRONMENTAL ASPECTS
6.1 INTRODUCTION
Industrial development is essential for growth and betterment of the living conditions of
the society. Industrial development, however, is endemic with its effect on the
environment. It is essential that even while the industrial development is spurred for
growth, the environment is conserved and protected.
The proposed Cogeneration Cycle Power Plant is a step in the direction of spurring
industrial activity. Notwithstanding this fact, it has been considered essential to adopt
environmental protection measures and adhere to legislations such that the ecology and
the habitat of the area are not disturbed.
Various pollution control measures required to meet the prevailing environmental

standards are planned at the different stages of execution of the project, viz., design,
construction and operational phases.
6.2 INDIAN ENVIRONMENTAL LEGISLATION
Government of India has made many legislations/rules for the protection and
improvement of environment in India. Various environmental legislations/rules are
tabulated in Table 6 -1.
Table 6-1Indian Environmental Legislation
S. NO. LEGISLATION
1 The Environment (Protection) Rules, 1986
2 Environment (Protection) Third Amendment Rules, 2002
3 Coastal Regulation Zone-Notification dated May 21, 2002
4 The Public Liability Insurance Act, 1991
5 The Public Liability Insurance Rules, 1991
The Water (Prevention and Control of Pollution) Act, 1974, and its
6
subsequent notifications.
The Water (Prevention and Control of Pollution) Cess Rules 1977 and its
7

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The Air (Prevention and Control of Pollution) Act 1981 and its subsequent
8
notifications.
Hazardous Wastes (Management and Handling) Rules, 1989, and its
9
Manufacture, Storage and Import of Hazardous Chemical Rules, 1989 and
10
its subsequent notifications.
Noise Pollution (Regulation and Control) Rules, 2000 and its subsequent
11
notifications.
The proposed project shall be designed taking into account the above-referred
legislations/rules.
A brief description of the environmental protection measures proposed to be adopted in

the project with respect to the various components of the environment like air, water,
noise, land, etc., is given in the subsequent sections.
6.3 POLLUTION CONTROL MEASURES
In order to minimize the impact of the project on the environment, due attention is being
given for implementing effective pollution control measures. The design stage
endeavours to mitigate the problems related to health, safety and environment at the
process technology/source level itself.
The design basis for all process units lays special emphasis on measures to minimize
the effluent generation at source.
During the operation of the plant, the major areas of concern will be stack emissions
from the power generation unit along with disposal of treated effluent.
The specific control measures related to gaseous emissions, liquid effluent

treatment/discharges, noise generation, etc., along with relevant stipulated standards
are described below;
6.3.1 Air Environment
The gaseous emissions from the proposed project will be controlled to meet all the
relevant standards stipulated by the regulatory authorities. Standards applicable to this
project are classified into these categories;
Ambient Air Standards

Emission Standards

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6.3.1.1 Ambient Air Standards
The ambient air quality around the premises will be limited to those limits as per National
Ambient Air Quality Standards, which are given below in Table 6 -2.
Table 6-2 National Ambient Air Quality Standards 2009
CONCENTRATION IN AMBIENT AIR

ECOLOGICALLY
S. TIME WEIGHTED INDUSTRIAL, SENSITIVE
POLLUTANTS RESIDENTIAL, AREAS
NO. AVERAGE
RURAL AND (NOTIFIED BY
OTHER AREA CENTRAL
GOVERNMENT)
1. Sulphur Dioxide (SO2), Annual Average* 50 20

µg/m3 24 hours** 80 80
2. Oxides of Nitrogen as Annual Average* 40 30

NO2, µg/m3 24 hours** 80 80
Particulate Matter (size Annual Average* 60 60
3.
less than 10 µm) or
PM10 µg/m3 24 hours** 100 100
Particulate Matter (size Annual Average* 40 40
4.
less than 2.5 µm) or
PM2.5 µg/m3 24 hours** 60 60
5. 8 hours** 100 100

Ozone (O3), µg/m3
1 hour** 180 180
6. Annual Average* 0.5 0.5

Lead (Pb), µg/m3
24 hours** 1 1
7. Carbon Monoxide (CO) 8 hours** 2.0 2.0

mg/m3 1 hour** 4.0 4.0
8. Annual Average* 100 100

Ammonia (NH3), µg/m3
24 hours** 400 400
9.
Benzene (C6H6), µg/m3 Annual Average* 5 5
Benzo (α) Pyrene (bap),

10.
Particulate Phase Only Annual Average* 1 1
ng/m3

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11.
Arsenic (As), ng/m3 Annual Average* 6 6
12.
Nickel (Ni), ng/m3 Annual Average* 20 20
* Annual Arithmetic mean of minimum 104 measurements in a year at a particular

site taken twice a week 24 hourly at uniform intervals.
** 24 hourly or 8 hourly or 1 hourly monitored values, as applicable shall be complied

with 98% of the time in a year. 2% of the time, it may exceed the limits but not on
two consecutive days of monitoring.
6.3.1.2 Emission Standards
The Standard in the context of the proposed project, are given below;
Table 6-3 Emission Standards
GENERATION CAPACITY POLLUTANT EMISSION LIMIT

Generation capacity 210
Particulate matter 150 mg/ Nm3
MW or more
Generation capacity less
Particulate matter 300 mg/ Nm3
than 210 MW
Note:
Depending upon the requirement of local situation, such as protected area, the State
Pollution Control Boards and other implementing agencies under the Environment
(Protection) Act, 1986, may prescribe a limit of 150 mg/Nm3, irrespective of generation
capacity of the plant.
General Notes:
1. Emission monitoring shall be carried out as per the Emission Regulations – Part
III, published by Central Pollution Control Board.
2. Following methods may be used for measurement of pollutant concentrations in
the emissions:

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Table 6-4 Method of Measurement of Emissions
S.
PARAMETER METHOD OF MEASUREMENT
NO.
1 Sulphur Dioxide(SO2) USEPA CFR – 40 Part 60 Appendix A Method 6
Oxides of Nitrogen
2 USEPA CFR – 40 Part 60 Appendix A Method 7
(NOx)
Particulate Matter
3 USEPA CFR – 40 Part 60 Appendix A Method 5
(PM)
USEPA CFR – 40 Part 60 Appendix A Method IOA /
Carbon Monoxide
4 Combustion analyser with electro chemical detector /
(CO)
NDIR detector
6.3.2 Noise Environment
Ambient Standards for Noise, specified by CPCB is given below in Table 6-5.
Table 6-5 Ambient Air Quality Standards in respect of Noise
S. LIMIT IN dB (A) LEG

AREA CODE CATEGORY OF AREA
NO. DAY TIME NIGHT TIME
1 A Industrial area 75 70
2 B Commercial area 65 55
3 C Residential area 55 45
4 D Silence zone 50 40
Notes:
Daytime is reckoned in between 6 am and 9 pm

Night time is reckoned in between 9 pm and 6 am
Silence zone is defined as areas up to 100 meters around such premises as
hospitals, educational institutions and courts. The Silence zones are to be
declared by the competent authority.
Mixed categories of areas should be as "one of the four above Mentioned
categories" by the competent authority and the Corresponding standard shall
apply.

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Comprehensive measures for noise control will be followed at the design stage in terms
of
Noise level specification of various rotating equipment as per Occupational

Safety and Health Association (OSHA) standards.
Equipment layout considering segregation of high noise generating sources.
Erecting suitable enclosures, if required, to minimize the impact of high noise
generating sources.
6.3.3 Water Environment
Effluents (if any) generated from the proposed project shall be treated conforming the
guidelines of CPCB and the treated effluent shall be disposed-off suitably.
Table 6-6 General Standards for discharge of Environmental Pollutants
INLAND
S. PUBLIC LAND FOR MARINE/COASTAL
PARAMETER SURFACE
NO. SEWERS IRRIGATION AREAS
WATER
. . (a) (b) (c) (d)
(a) For process
waste water
(b) For cooling
1. Suspended
100 600 200 water effluent 10
solids mg/l, max.
per cent above total
suspended matter
of influent.
(a) Floatable solids,
Shall pass solids max. 3 mm
Particle size of
2. 850 micron - - (b) Settleable
suspended solids
IS Sieve solids, max 856
microns
3. pH value 5.5 to 9.0 5.5 to 9.0 5.5 to 9.0 5.5 to 9.0
Shall not
exceed 5°C Shall not exceed
above the 5°C above the
4. Temperature
receiving receiving water
water temperature
temperature
Oil and grease,
5. 10 20 10 20
mg/l max,

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Total residual
6. chlorine, mg/l 1.0 - - 1.0
max
Ammonical
7. nitrogen (as N), 50 50 - 50
mg/l, max.
Total
Kjeldahlnitrogen
8. 100 - - 100
(as N); mg/l,
max.
Free ammonia
9. (as NH3), mg/l 5.0 - - 5.0
max.
Biochemical
oxygen demand
10. 30 350 100 100
(3 days at 27°C),
mg/l, max.
Chemical oxygen
11. demand, mg/l, 250 - - 250
max.
12. Arsenic (as As). 0.2 0.2 0.2 0.2
Mercury (As Hg),
13. 0.01 0.01 - 0.01
mg/l, max.
Lead (as Pb)
14. 0.1 1.0 - 2.0
mg/l, max
Cadmium (as
15. 2.0 1.0 - 2.0
Cd) mg/l, max
Hexavalent
16. chromium (as Cr 0.1 2.0 - 1.0
+ 6), mg/l, max.
Total chromium
17. (as Cr) mg/l, 2.0 2.0 - 2.0
max.
Copper (as Cu)
18. 3.0 3.0 - 3.0
mg/l, max.
Zinc (as Zn)
19. 5.0 15 - 15
mg/l, max.
20. Selenium (as Se) 0.05 0.05 - 0.05
Nickel (as Ni)
21. 3.0 3.0 - 5.0
mg/l, max.

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Cyanide (as CN)

22. 0.2 2.0 0.2 0.2
mg/l, max.
Fluoride (as F)
23. 2.0 15 - 15
mg/l, max.
Dissolved
24. phosphates (as 5.0 - - -
P), mg/l, max.
Sulphide (as S)
25. 2.0 - - 5.0
mg/l, max.
Phenolic
compounds (as
26. 1.0 5.0 - 5.0
C6H5OH) mg/l,
max.
Radioactive
materials:
(a) Alpha 10 -7 10 -7 10 -8 10 -7
27. emitters micro
curie mg/l, max.
(b)Beta emitters 10 -6 10 -6 10 -7 10 -6
micro curie mg/l
90% 90% 90%
survival of survival of survival of
90% survival of fish
fish after 96 fish after 96 fish after 96
28. Bio-assay test after 96 hours in
hours in hours in hours in
100% effluent
100% 100% 100%
effluent effluent effluent
29. Manganese 2 mg/l 2 mg/l - 2 mg/l
30. Iron (as Fe) 3mg/l 3mg/l - 3mg/l
31. Vanadium (as V) 0.2mg/l 0.2mg/l - 0.2mg/l
32. Nitrate Nitrogen 10 mg/l - - 20 mg/l
These standards shall be applicable for industries, operations or processes other than
those industries, operations or process for which standards have been specified in
Schedule of the Environment Protection Rules, 1989.

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6.4 PERMISSIONS AND CLEARANCES
Various Approvals and Clearances required for implementation of Power Projects shall
be as below;
Table 6-7 List of Approvals and Clearances required for implementation of Power Projects
RESPONSIBLE
S. NO. RELEVANT APPROVAL & CLEARANCE
GOVERNMENT ENTITY
Clearance from Environment / Pollution

1 State pollution Board
board
Clearances from the Gol (Civil Aviation

Gol (Civil Aviation
Department) and the Director, National
2 Department) / National
Airports Authority in connection with the
Airports Authority
height of any chimneys.
Clearance of the Ministry of Environment

and Forests following consideration of the
Environment Impact Assessment and
Environment Management Plan pursuant to Ministry of Environment and
3
Sections 3(1) and 3(2) (v) of the Forests
Environment (Projection) Act, 1985 and
Rules 5(3)(a) of the Environment
(Protection) Rules, 1986
Approval of the Chief Engineer Inspector for

4 Commissioner of Electricity
the Power Station
Permission from the Director General of Directorate General of

Foreign Trade for the various imports Technical Development/
5
pursuant to the Foreign Trade (Development Director General of Foreign
and Regulation) Act 1992. Trade
Consent under the Factories Act 1948

6 Government of Maharashtra
relating to fire-fighting capability
Consent of the Controller of Explosives to

Controller of Explosive,
7 the possession and use of explosives for the
Government of Maharashtra
purpose of blasting
Permission from the Director General of Directorate General of

8 Foreign Trade for the import of spares Technical Developments /
pursuant to the Foreign Trade Development Director General of the

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and Regulation Act 1992 Foreign Trade
Municipal Byelaws of Urban Development

9 Authority of State Government for Buildings Municipal Corporation
in Township.
The selected contractor during detailed engineering and construction shall take into
account and comply with various local statutory requirements, standards and codes, as
applicable including but not be limited to the following:
OISD (Oil Industry safety Directorate) Guidelines (for Insurance purposes)

Requirement of Chief Controller of Explosives (CCE), Nagpur, in case of liquid
fuel storage only India.
On completion of project, intimation about the plant is to be given to CEA also.
6.5 OTHER BENEFITS FROM PROJECT
The proposed power plant uses natural gas as the fuel for power generation at highly
efficient power plant. The natural gas is considered as ‘cleaner source’ of thermal
energy, having low carbon intensity as compared to coal due to the following primary
reasons;
Substantial amount of heat is generated from combustion of Hydrogen in natural

gas as compared to coal, forming water as combustion product, which is not
harmful to environment.
The atomization of fuel is better during combustion as compared to coal, as the

gas molecules get rigorously mixed with air molecules providing oxygen for
combustion. This helps in reduction of ‘excess air quantity, in combustion and
thereby increasing the ‘flame temperature’ and reducing flue gas losses.
The incombustibles (e.g. Ash) in natural gas are negligible as compared to coal.
The emission factors of Lignite and Natural Gas as per the International Panel for
Climate Change (IPCC) are 0.1012 and 0.0561 (kilo tonnes CO2/Trillion Joules)
respectively. It is evident that coal is 80% higher CO2 emitting source than natural gas
for the generation of equivalent amount of energy. This gap further widens due to better
efficiency factor of the proposed plant. The average efficiency of coal-fired conventional
power plants is 30%, as against over 65% efficiency of the proposed gas based power
plant. This facilitates 35% less usage of input energy of natural gas as compared to input
energy in conventional coal based power plant for the power production of equivalent
amount.

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The plant shall operate at a PLF of 91 %.
No transmission and distribution losses are considered since the project will mainly cater
to the additional power requirement of the plant and will export only a small surplus
power to the nearby existing grid.
Without the proposed project activity, the same energy load would have been taken up
from the GRID to compensate the increased demand due to additional LPG-III, GSU-III
CFU-III & CHU-IV which would have resulted in higher GRID connectivity. Thus the
proposed project will help in reduction of cost and dependency on the grid.
This power plant operating on cleaner fuel like Natural Gas will lead to lower Carbon
Dioxide (GHG) emissions for producing equivalent amount of power as compared to the
other power plants operating on other fuels like coal/ oil/ naphtha.
The project will also increase the installed electricity generating capacity of the plant
making the plant self sufficient in Normal operation condition.
The project is a clean fuel power project, which will use Natural Gas as a fuel for power
generation. Since the Carbon Dioxide (CO2) emission due to combustion of Natural Gas
is substantially less as compared to combustion of coal or Naphtha, the project helps in
reducing GHG emission.
Further this project is based on natural gas; it will positively contribute towards the
reduction in (demand) use of coal and increasing its availability to other places where
natural gas is not available.
ONGC’s contribution will be towards providing employment opportunities during

construction stage and operation stage, thereby improving the quality of the life of
people in surrounding habitations.

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SECTION 7.0
STATUTORY APPROVALS AND
CLEARANCES

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7.0 STATUTORY APPROVALS AND CLEARANCES
In order to control and regulate the development of Power Projects by State / Private
Sector, a legal framework has been developed by Government of India. Accordingly,
several clearances and approvals shall have to be obtained from different Government
and Statutory Agencies at various stages of the project. An Indicative list of approvals /
clearances to be obtained from Govt. Authorities for this project is presented below;
Table 7-1 Statutory Approvals and Clearances
S. RELEVANT APPROVAL &

RESPONSIBLEGOVERNMENTENTITY
NO. CLEARANCE
Clearance from Environment /
1. State Pollution Control Board & CPCB
Pollution board
(State Govt. / Central Water
2. Water availability and use
Commission (CWC)
Clearance of the Ministry of
Environment and Forests following
consideration of the Environment
Impact Assessment and Environment
3. Management Plan pursuant to Ministry of Environment and Forests
Sections 3(1) and 3(2) (v) of the
Environment (Projection) Act, 1985
and Rules 5(3)(a) of the Environment
(Protection) Rules, 1986
Clearances from the Gol (Civil
Aviation Department) and the Director,
Gol (Civil Aviation Department) /
4. National Airports Authority in
National Airports Authority
connection with the height of any
chimneys.
5. Boiler pressure parts Chief inspector of Boilers
Approval of the Chief Engineer Commissioner of Electricity, Govt. of

6.
Inspector for the Power Station Maharashtra
Permission from the Director General
of Foreign Trade for the various Directorate General of Technical
7. imports pursuant to the Foreign Trade Development/ Director General of
(Development and Regulation) Act Foreign Trade
1992.
Consent under the Factories Act 1948
8. Government of Maharashtra
relating to fire-fighting capability

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Consent of the Controller of

Explosives to the possession and use Controller of Explosive, Government of
9.
of explosives for the purpose of Maharashtra
blasting
Clearance for handling & storage of
10. Chief Controller Of Explosives (CCOE)
Fuel
Permission from the Director General
Directorate General of Technical
of Foreign Trade for the import of
11. Developments / Director General of the
spares pursuant to the Foreign Trade
Foreign Trade
Development and Regulation Act 1992

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SECTION 8.0
PROJECT COST ESTIMATE

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8.0 PROJECT COST ESTIMATE
8.1 CAPITAL COST ESTIMATE & FINANCIAL ANALYSIS
Capital cost estimate & financial analysis for DFR has been worked out and summarized
below:
Table 8-1 Cost Estimate of the Project
DESCRIPTION COST IN ` CRORES
Power Plant
Major Items 102.03
Bulks, Spares & Chemicals 20.82
Construction Cost 42.48
Plant Buildings 8.40
Indirect Cost 34.90
Contingency 10.42
PMC Charges &TPI 8.00
Dismantling/Scrap Materials Sales -1.00
DMW 23.62
TOTAL 249.69
The basic assumptions made for working out the cost estimate are as under:
Cost estimate is based on present day price level as of 3rd quarter’ 2012. No
provision has been made for any future escalation.
Cost estimate is targeted to have an accuracy of + 20%.
It has been assumed that the project would be implemented on “EPC” mode of
execution under one package.
The battery limit cost estimate for the identified scope of work is presented as Annexure-
5.

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8.2 BASIS OF COST ESTIMATE
The basis of cost estimate for power block is as under:
Cost estimate has been prepared based on configurations supplemented with in-
house engineering inputs for cost estimation.
Cost estimate is based on cost information available from in-house cost database
which is a repository for storing cost data from ongoing jobs. In-house cost data
has been analyzed and adopted for estimation after incorporating the project
conditions. Cost data has been updated to prevailing price level using relevant
economic indices.
8.3 PLANT & MACHINERY
8.3.1 Supply Costs
The cost estimates have been prepared based on specifications and in - house cost data
for similar type of equipment. Sourcing of equipment and material has been made as per
in-house information on previous executed projects.
Cost estimate for Gas Turbine Generator (GTG), and HRSG is based on in-house cost
data for similar items, updated for required specifications and time escalation. Cost
estimate for Balance of Plant (BOP) such as Gas conditioning skid, Cooling tower with
pumps and Stack is based on in-house cost data.
Cost for supply of piping, electrical items and instrumentation items are based on the
factor of equipment cost. Cost provision for spares has been made on factor basis as
per in-house norms.
Lump-sum cost provision has been made for chemicals.
8.3.2 Construction Costs
Cost provisions towards erection of equipment, piping, electrical and instruments, Civil &
structural works, insulation & painting work have been made on factor basis.
8.3.3 Plant Building
Cost provisions towards plant buildings such control room, sub-station, MCC room is
based on the sizes of the buildings.

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8.4 STATUTORY & INDIRECT COSTS
The cost estimate includes following statutory and indirect costs:
Table 8-2 Statutory and Indirect Costs for the Project
Inland Freight 3% of ex-works cost of indigenously sourced equipment
Excise Duty 12.36% of ex-works cost of indigenously sourced equipment.
2% of ex-works cost of indigenously sourced equipment

Central Sales Tax
including excise duty.
Service Tax 12.36% on subcontracted works
Octroi / State Entry Tax 4.5% of landed cost of supply items
Insurance 0.5% of total cost
8.5 CONTINGENCY
Provision for contingency has been made @ 5%.
8.6 PMC CHARGES & TPI
A lump-sum cost provision for PMC charges (Pre-award & post award) and TPI has
been made in the capital cost estimate based on in-house information.
8.7 DISMANTLING /SCRAP MATERIALS SALES
The cost estimates for Dismantling & Disposal/Sales of Scrap materials have been
prepared based on weight of the scrap.
8.8 EXCLUSIONS
Following costs have been excluded from the cost estimate:-
Site Development
HVAC, Ventilation & Pressurization for plant buildings
Owner’s management expenses
Forward Escalation

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SECTION 9.0
FINANCIAL ANALYSIS

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9.0 FINANCIAL ANALYSIS
9.1 OPERATING COST & FINANCIAL ANALYSIS
Operating cost & financial analysis has been worked out based on following:
Table 9-1 Operating Cost of the Project
S.NO. DESCRIPTION ASSUMPTIONS MADE
1 Natural Gas price Rs 7.72 / SCM

2 Raw water Rs 40.00 / SCM
3 Electricity Duty Rs 0.30 / kWH
4 O & M charges Rs 17.50 lakhs/MW
5 Sale of Power Rs 9.00 / KWH
6 Demand charges Rs 190 / kVA
4 Construction Period 28 months
5 Project Life in Years 15
6 Debt/ Equity Ratio 100% Equity
7 Working capital Excluded
P& M - @ 5.28% SLM , @ 15% WDV ; @
8 Depreciation
5% Salvage value
1st 6 months - 10%
2nd 6 months - 20%
9 Capital Phasing (half yearly) 3rd 6 months 25%
4th 6 months 35%
Last 4 months 10%
10 Capacity Build-up 1st year onwards - 100%
11 Operating hours (Annual) 330 days
12 Exportable power 19.5 MW
13 Corporate Tax Rate Basic 30% + 5% + 3% = 32.45%
14 MAT (%) Basic 18.5% + 5% + 3% = 20.01%
Yearly variable operating cost comprising of cost for Natural Gas, Raw Water and
Electricity duty has been escalated @ 8% pa as per ONGC input. Yearly fixed operating
cost has been considered to take care of Salary & wages, Repair and maintenance,
General administrative expenses and Insurance @ Rs 17.50 lakh / MWH in 1st year of
operation. Yearly fixed operating cost has been escalated @ 5.72% pa (CERC guide
lines) 2nd year onward over the life of the plant. Annual Sales revenue has been

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calculated considering saving in energy import, saving in demand charges and saving in
gas consumption by HRSG-4. No escalation has been considered in the yearly revenue
over the life of the plant as suggested by ONGC as per their norms. Capital cost has
been escalated by 6% as per ONGC norms for financial analysis.
Based on above assumptions, Operating cost, sales revenue, Cash flow, NPV, Internal
rate of return and Payback period has been worked out for the project and are
summarized below:
Table 9-2 Financial Analysis of the Project
SL.NO DESCRIPTION VALUES

CAPITAL COST (Rs. LAKH) FOR IRR, PAY BACK
1 PERIOD CALCULATIONS USING 6% ESCALATION 26466
AS PER ONGC NORMS
2 TOTAL OPERATING COST (Rs. LAKH) 5771
3 ANNUAL REVENUE (Rs. LAKH) 16878
4 IRR (%) ON TOTAL CAPITAL
BEFORE TAX 19.66%
AFTER TAX 15.07%
5 PAY BACK PERIOD (YEARS) ON TOTAL CAPITAL
BEFORE TAX 2.9
AFTER TAX 3.7

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SECTION 10.0
PROJECT IMPLEMANTATION AND
SCHEDULE

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10.0 PROJECT IMPLEMANTATION AND SCHEDULE
10.1 PROJECT IMPLEMENTATION METHODOLOGY
Single Engineering Procurement and Construction (EPC) Contract including the

complete Technical Requirements and scope under this Contract for Design,
Engineering, procurement, Supply, Fabrication, Construction, Inspection, Testing, Pre-
Commissioning, Commissioning and Performance Guarantee Test Run to be carried out
by the CONTRACTOR is proposed for the Project in order to execute project on time.
This will cover following major works
Clearing NGL loading area to accommodate DM plant

Construction of new DM plant
Dismantling and disposal of existing DA/DM plant/ Thermax Boiler/ IAEC Boiler
House and other facilities
Re-routing of existing pipelines catering to GT/ HRSG 1,2 & 3
Construction and Installation of GT/ HRSG and associated facilities
If multiple CONTRACTORS for different jobs are deployed, delay in finalizing any one of
the contracts, default of any one contractor or delayed due to any interface issues will
lead to abnormal delay in overall completion of the project.
Lump Sum Turnkey Contract (LSTK) / Engineering, Procurement and Construction

contract (EPC)
Under this mode of operation, owner awards the implementation of the project to a
contractor with turnkey responsibility. The award of the contract is based on a tender
comprising of technical requirements (specified in FEED) and commercial conditions. In
this case, LSTK / EPC contractor takes full responsibility to complete the project as per
the scheduled completion date specified in the contract. The delay in completion invites
heavy penalties which range from 5% to 10% of total project cost under LSTK / EPC
contractor’s scope. Since the liabilities are high, the LSTK / EPC contractor generally
loads his liabilities to the quoted price thus owner has to spend high capital cost.
Therefore even though LSTK / EPC mode of operation minimizes the risk of delayed
completion to some extent however this is at the cost of high capital expenditure.
The mandatory requirement to successful completion of LSTK / EPC contract is;
a) to ensure a perfect FEED document with necessary detailing and minimum

contradictions

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b) To engage a competent PMC consultant to manage the contract. In most of

the cases, FEED is also generated by PMC consultant.
The main advantages of LSTK mode are;
Minimal project schedule risk

Micro level Project Monitoring not required
No interface requirements between various packages
Performance guarantees of the complete system.
It is envisaged that entire project shall be executed as above on single responsibility

under one contract with fixed contract price and time schedule with provision of
liquidated damages. The plant is scheduled to be setup within 28 months from date of
order to EPC. The Project Implementation Schedule has been detailed in Annexure-7.
However site grading and any area clearance/dismantling/shifting work have to be

executed separately and prior to main plant contract, as above.
To ensure timely completion, the Contractor shall establish and maintain an effective
Planning, Scheduling, Monitoring and Control system, including mobilization of required
number of professionally qualified and experienced Planning Engineers for design office
and construction site. The system shall be capable of accurate and timely prediction of
trend, evolution of adequate preventive actions for likely slippages, and formulation of
suitable catch-up schedule for delays, if any, that have occurred.
Schedules, reports and documents to be prepared and submitted by the contractor for
review of Client/ Project Management Consultant (PMC) at various stages and details of
meetings to be held are described here.
10.2 AFTER AWARD OF WORK THE CONTRACTOR SHALL COMPLY WITH:
10.2.1 90 Days Front End Schedule
The Contractor shall prepare and submit a detailed 90 days front-end schedule within
two weeks of award. Pending finalization of functional schedules, this schedule shall be
the basis of monitoring of front-end activities. The schedule shall cover all activities to
be carried out during initial 90 days period of the contract. The schedule shall be
reviewed in the kick-off meeting.
10.2.2 Kick off Meeting
A Kick off Meeting shall be organized within two weeks of award of contract. The
meeting shall be attended by Client’s and PMC’s representatives. During the meeting

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the following with respect to Planning, Scheduling, Monitoring and Control system shall
be discussed and finalized,
1. Planning deliverables required for Project Monitoring and Control.

2. Work Breakdown Structure for Project Schedules, organization and level of
detailing for Overall Project Schedule and Functional Schedules.
3. Procedure for Project Planning, Scheduling, Monitoring and Control including
all reporting formats.
4. Progress Measurement Methodology and Unit, Function, Discipline, and
Deliverable wise weight age breakdown.
5. List of engineering deliverables with indicative schedule for submission.
6. List of unit wise milestones to be included in the network, in addition to
milestones specified in the Contract, if any (the number of milestones shall be
at least 2 to 3 per unit per month).
7. List of critical equipment and materials for the fortnightly expediting report to
be issued by the Contractor.
8. Procedure for Bulk material control.
9. Cut off dates, distribution list with number of copies and Project calendar
indicating submission of various planning documents and revisions.
10. ANY OTHER DOCUMENT AS REQUIRED.
10.3 PROGRESS MEASUREMENT METHODOLOGY
The Contractor shall submit during Kick off Meeting, the detailed methodology of
progress measurement of Residual Basic Engineering, Detailed Engineering, Ordering,
Manufacturing & Delivery, Sub-contracting, Construction and Commissioning for review
by Client/PMC. Contractor shall also furnish the methodology of progress measurement
for sub-contracted packages, if any and integration of the same with the overall
progress.
During the Kick Off meeting, Client/PMC shall specify weighted values to be used for the
following:
Unit wise within the package, if applicable.

Function wise within each unit.
Milestone weight age within each deliverable.

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Effort based weighted values for the following, along with the basis of their derivation,
shall be submitted by Contractor for review by Client/PMC, and the comments if any
shall be incorporated by Contractor before submission of functional schedules that use
these weighted values as the basis:
Discipline wise within each function.

Deliverable level weight age Percentage.
Progress figures at Unit / Function / Discipline level shall be summarized from

deliverable level and indicated in the functional schedules

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SECTION 11.0
RISKS AND MITIGATIONS

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11.0 RISKS AND MITIGATIONS
As projects are exposed to a wide variety of risks in the various stages of project
evolution, risks associated with the development and commissioning of the project were
identified, categorized and measures for risk mitigation defined as far as feasible.
Main categories of risks are
Design risks
Project related
Construction related
Operations related
Revenue risks
Financial risks
Force majeure risks
Insurance risks
Environmental risks
The proposed mitigation measures shall be a basis for development of adequate

strategies in the contractual framework of the tendering documents and later in the
contracts with the construction contractors, subcontractors and in the O&M contractual
documents.
The results of the preliminary assessment listed according to the type of risk are shown
below;
Table 11-1 Preliminary assessment listed according to the type of risk
RISK TYPE RISK EVENT RISK MITIGATION
Sound supervision at EPC stage

with provision for remedy and
Design
Design risk/ faulty design liquidated damages from EPC
Related
contractors for curing the risk along
with coverage from insurance
Delay/non receipt of Proactive consultation and
Project
environmental and other statutory negotiation with authorities and
Related
approvals other stakeholders
Project Project target cost estimate Open book approach, proactive
Related inadequate (PTC) activity with contractors
Project Delay caused by governmental Efforts to proactively act to acquire
Related action or inaction / Force Majeure required approvals

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Sound pre-selection process for the

award of the project development
contracts to contractors with
Construction experience, reputation and track
Contractor Capability
Related record. Additional contractual
safeguards like liquidated damages
for non-performance, performance
security, defects liability clause etc.
Field investigation studies to
Construction establish suitability. Land to be
Suitability and availability of land
Related made available as condition
precedent.
Provide for reasonable cost overrun
in fixed lump sum price in the
Construction
Cost overrun construction contract. Any overrun
Related
on account of contractors to be
absorbed by EPC contractors
Safety clauses in EPC contract
including liquidated damages from
Construction
Delay in construction the contractor (sufficient to cover
Related
interest due to lenders and fixed
operating costs)
Failure to meet performance
Operations criteria at completion tests due to Include planned redundancy in
Related quality shortfall and defects in process design
construction
Require liquidated damages
Failure of plant to meet
Operations
performance criteria at Payable by the construction
related
completion tests consortium, supplemented by
insurance.
Establish sound industrial relations
Industrial action such as strike,
Operations and also put in place insurance
lockouts, work-troubles
related cover for loss or physical damage
blockades, go-slow actions
as well as for business interruption
Sound pre-selection process for the
award of the operator contracts to
contractors with experience,
Operations reputation and track record.
Operator failure.
related Additional contractual safeguards
like liquidated damages for non-
performance, performance security,
defects liability clause etc.
Fixed capacity charge on take or
pay principle to cover fixed costs
Revenue Risk Low off-take
like maintenance cost, debt
servicing etc.

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Long term fuel supply agreement /

Revenue Risk Rising fuel and other input costs input cost recovery on actual for
quantity delivered
Judicious mix of Rupee and Forex
Exchange rate variation. debts to optimize on interest cost.
Revenue Risk Devaluation of local currency, Protection against adverse
fluctuations in foreign currencies. currency movement by exchange
cover, swapping of rupee debt etc.
Same as above (for hedging
Revenue Risk Fluctuations in interest rates facilities against exchange rate
risks).
Insurance cover for loss or physical
Force
Flood, earthquake, riot, strike damage as well as business
majeure risk
interruption
Changes in tax law, customs
Force Timely approvals/certification by
practices, environmental
majeure risk statutory authorities
standards
Uninsured loss or damage to

Insurance risk Insure against all the main risks
project facilities
Environmental Environmental incidents due to Require indemnity from the

risk Operator's fault operator

Consultancy service on the emission aspect of acid gas
disposal at Oil and Natural Gas Corporation Plant,
Uran, Navi Mumbai
Sponsor
M/s Oil and Natural Gas Corporation Limited, Uran
CSIR-National Environmental Engineering Research Institute (NEERI),

Nehru Marg, Nagpur - 440 020 (India)
October 2015
PROJECT PERSONNEL
ONGC, Uran, Mumbai

S. K. Pandey GGM (Head of operations)
K Giridhar Rao DGM (P) (I/C Technical services)
Mr. Rajat Sinha (EE (P))
Mr. Asish (Environmental Engineer)
CSIR-NEERI, Nagpur
Er. B. Padma S. Rao (Head, Air Pollution Control Division)

Er. K. V. George (Principle Scientist)
Dr. (Mrs.) Anjali Srivastava (Chief Scientist & Head, DZL)
Dr. V. V. Khaparde (Scientist)
Er. Shivangi Nigam (Quick Hire Scientist)
Er. Harsha vardhan (Project Assistant)
Ms. Amruta Anjikar (Project Assistant)
Ms. Priyanka Bajaj (Project Assistant)
Er. M. N. V. Anil (Trainee Scientist)
Project Leaders
Er. Padma S. Rao Er. K. V. George
Project Coordinator
Dr. S R. Wate
Director
Content
S. No. Title Page no.
1.0 Introduction 1
1.1 Objective 1
1.2 Scope of work 1
1.3 Deliverables 2
2.0 Operations at ONGC Uran 2
3.0 Study approach 9
3.1 Study area 10
3.1.1 Ambient Air Quality (AAQ) Monitoring and Real Time Monitoring 10
(RTM) Data provided by ONGC
3.1.2 AAQ Real Time Monitoring (RTM) Data 15
3.2 Enhanced reactive oxidation and scrubbing techniques 21
3.3 Source dispersion modeling 25
4.0 Recommendations 30
List of Tables
1 Phase-wise development of Uran plant 3
2 Composition of Sour Gas fed to GSU 7
3 Specification of product generated from GSU 8
4 Composition of Product Gases at the outlet of GSU 8
5 Composition of Acid Gas considered for treatment system 9
6 Ambient air quality status of H2S in Plant premises 13
7 AAQ RTM 3 and RTM4 percentile Distribution Data 16
8 International Standards for Ambient H2S Exposure and its Toxic 19
Effects
9 Emission of SO2 from different stack of ONGC, Uran 20
10 Stack Details of ONGC, Uran : Input for Dispersion Modelling 26
List of Figures

1 Location of O&G platform and Uran plant (Schematic). 3
2 Separate processing of Crude Oil & Gas at Uran plant (Schematic). 4
3 Overall Natural Gas processing at ONGC Uran (Schematic). 5
4 Input and output of Gas Sweetening Unit at Uran (Schematic) 6
5 Study Area Landuse Map -10 km radius 11
6 Land use pattern in 2 km radius around ONGC Uran 12
7 Instantaneous data obtained through Portable Monitor 14
8 Distribution of pollutants monitored at RTM3 inside ONGC premises 15
9 Distribution of pollutants monitored at RTM4 inside ONGC premises 16
10 Distribution of ambient air SO2 at RTM3 and RTM4 inside ONGC 17
premises, Uran (H2S converted to SO2).
11 Pictorial view of a wet scrubber 23
12 Proposed acid gas treatment scheme at ONGC Uran. 24
13 GLC of SO2 due to emission of untreated SO2 (without scrubber). 27
14 GLC of SO2 with scrubber efficiency at 90% (5 g/s SO2 emission). 29
List of Annexures
1 Material safety data sheet AX1
2 Occupational Safety & Health Administration Guidelines for Industry AX9
3 HYDROGEN SULPHIDE: H2S (wet chemical method) AX10
4 CPCB, National Ambient Air Quality Standards, 2009 AX14

Dispersion Modelling of Acid Gas Disposal at Uran, Navi Mumbai
1.0 Introduction
Oil and Natural Gas Corporation (ONGC) having one of its on-shore installation at
Uran, Navi Mumbai. the oil and natural gas received from Bombay High offshore oil field
and adjoining basin and pre-treats it before supplying to downside chemical refining and
processing units (like HPCL,) at different locations near Mumbai. Natural Gas i.e. Sour gas
consisting H2S & CO2 is cleaned in gas sweetening unit (GSU) for the removal of H2S &
CO2 results in, a separate stream of acid gas, which is currently vented off through a stack.
The dispersion of acid gas without any treatment is resulting in higher ground level
concentration of pollutant (H2S), which is corrosive in nature. It is perceived that in due
course of time, the Natural Gas and Oil received from adjoining basins may have high
sulphur content, resulting in further increase of ambient air concentration of H2S. This may
damage the metallic structure of the plant and therefore, there is a need to look into the
present scenario of sulphur emission and take appropriate steps for its control by treating acid
gas before its disposal. ONGC, Uran has approached NEERI, Nagpur with a proposal for
recommending the needful for acid gas treatment. The project has following components:
1.1 Objective
To provide consultancy services on the emission aspects of acid gas and its release.
1.2 Scope of Work

 Study the applicable regulation and recommend emission norms / Standards for
acid gas disposal, including study of emissions for domestic refineries and
international norms / standards / emissions.
 Carry out stoichiometric computation for various scenarios and find out
emission loads of various pollutants.
 Carry out dispersion modeling and predict the ground level concentration of
pollutant and verify compliance.
 Compare toxicity and tolerance of H2S and SO2 for health and safety point of
view.
1
1.3 Deliverables
 Study the applicable regulations/guidelines and recommend emission norms /

standards for acid gas disposal, including study of emissions for domestic
refineries and international norms/ standards / emissions.
 Short term baseline and spatial AAQ monitoring results for H2S in and around
the plant premises.
 Carry out stoichiometric computation for various scenarios and find out
emission loads of various pollutants.
 Carry out dispersion modeling and predict the ground level concentration of
pollutant and verify compliance.
 Compare toxicity and tolerance of H2S and SO2 for health and safety point of
view.
2.0 Operations at ONGC, Uran
Uran receives Oil & Gas mainly from Heera and Bombay High platforms and
adjoining basins located at 203 km away from Uran through different pipes of 4.0 m diameter
namely Heera Uran Trunk (HUT) line and Mumbai Uran Trunk (MUT) line. Presently, there
are six incoming trunk lines at Uran from Offshore platforms.
The trunk line follows the sea bed topography at a depth of 2km below water level
and rises at 40km from the shore. Fig. 1 shows the schematic of O&G transport from High
seas to Uran plant. At Uran Terminal, facilities are provided to stabilize the crude oil and
recover LPG, Naphtha and C2C3 from these gases. These facilities have been expanded in a
phased manner as shown in Table 1.
2
Fig. 1: Location of O&G platform and Uran plant (Schematic).
Table 1: Phase-wise development of Uran plant.
Year Plant / Unit Commissioned

1978 Crude Oil & Gas Terminal
1981 Crude Stabilization Unit 1 (CSU-I), LPG Plant-I & Satellite Earth Station.
1983 Crude Stabilization Unit 2(CSU-II).
1984 LPG Plant-II & Co-generation Plant (GT-I & II)
Condensate Fractionation Unit 1 (CFU-I), Gas Sweetening Units (GSU-12 & 13),
1989
Ethane Propane Recovery Unit (EPRU).
Condensate Fractionation Unit 2 (CFU-II), Expansion of Additional Gas Handling
1994 System (AGHAS) & Effluent Treatment Plant comply with MINAS (Minimum
National Standards).
1997 Modified Gas Processing (MOGAP)
2000 GT-III
2003 Flare Gas Recovery Unit (FGRU)
2005 Mumbai High - Uran Terminal (MUT) Oil & Gas Trunk Pipeline.
3
At Uran, Oil and Natural gas are processed separately and supplied to the downstream
users. The off gases of Crude Oil Stabilization unit are mixed with gas processing units. Fig.
2 shows the major separation of Oil and Gas processing.
Slug Catcher
Gas
Processing
Gas
Oil Off
Gases
Crude Oil Storage
Crude Oil
Stabilization
ETP
Wastewater
Treatment
Fig. 2: Separate processing of Crude Oil & Gas at Uran plant (Schematic).
Oil Processing Facilities
The crude oil received from offshore (Mumbai High and Satellite fields) is stabilized
in Crude Stabilization Unit (CSU) through three stage separation with a view to optimize the
liquid recovery. The liberated gas from CSU is compressed and mixed with offshore gas and
fed to gas processing unit. The stabilized oil is stored in floating roof tanks and transferred
through pipelines to the refineries (HPCL)
Gas and Condensate Processing Facilities

The gas from Mumbai High and Satellite fields is first separated from the liquid in it
by condensation in slug catcher. There are two separate slug catchers namely Phase-II
(capacity 11.5 MMSCMD) & Phase-III (capacity 5.2 MMSCMD). In this, the liquid
condensate generated during sub-sea en-route is separated out in respective slug catchers.
Condensate, separated in two slug catchers are sent to condensate fractionating unit (CFU)
4
with fall back provision for stabilization and injection in crude oil. Total 16.2 MMSM3/d of
gas is handled at Uran plant. Of this, only 11.5 MMSM3 /d of gas is processed and the
remaining gas is supplied to consumer through Plant bypass loop. Separated Natural Gas
called sour gas as it contains CO2 & H2S. in Gas Sweetening Unit (GSU). Two GSU units of
5.75 MMSM3/d capacity each receives the MUT and HUT gas mixture along with CSU off
gas and CFU off gas. The combined sour gas is sweetened to contain less than 50 ppm CO2
and 4 ppm of H2S. Overall gas processing is shown in Fig. 3.
Acid Gas
Gas to Consumer
Gas
Sweetening
C2C3
C2C3
Plant
Storage
Sweet
Gas
Sour Gas
LPG Plant
Slug Catcher
Condensate LPG
Fractionating
Storage
Naphtha
Storage
Fig. 3: Overall Natural Gas processing at ONGC Uran (Schematic).
5
Gas Sweetening Unit (GSU)

Gas from Slug Catcher unit and off gas from Crude Fractionating Unit (CFU) and
Crude Stabilization Unit (CSU) contains acid gases like H2S & CO2 called sour gas, which
needs to be removed before its processing or onward transportation. Gas sweetening units
(GSU) perform the function of removing acid gases in two identical trains, unit-12 & 13.
11.5 MMSCM/d of sour gas is treated in GSU and 11.2 MMSCM/d of sweet gas is
produced along with 0.04 MMSCM/d of fuel gas and 0.3 MMSCM/d of acid gas. The GSU
operates throughout the year and the partitioning of different product from GSU is shown in
Fig. 4.
0.3 MMSCM/d
Acid Gas
11.5 MMSCM/d Gas Sweetening

0.04 MMSCM/d
Unit
Sour Gas Fuel Gas
Sweet Gas
11.2 MMSCM/d
Fig. 4: Input and output of Gas Sweetening Unit at Uran (Schematic).
A typical composition of sour gas is given in Table 2. It can be seen that the
molecular weight (20.34) is lower than that of air (29) and therefore is lighter gas. The
treatment of sour gas is carried out by absorption of acid gas in amine solution. When amine
solution is regenerated for re-use/re-circulation, low pressure acid gas containing hydrogen
sulphide, carbon di-oxide and a little quantity of hydrocarbons is generated as a separate
stream. Specification of product generated from GSU is given in Table 3. It can be seen that
the acid gas available for treatment is at an absolute pressure of 1.3 kg/cm2 and 50oC. The
temperature and pressure needs to be considered while designing the subsequent units. The
6
composition of product gas is shown in Table 4. Acid gas containing H2S is currently
discharged off without any treatment and is proposed to be treated and then disposed by
atmospheric dilution through tall stack. For the purpose of acid gas treatment, properties of
acid gas mentioned in Table 5 are considered. At present the liberated acid gas is vented into
the atmosphere through a 0.4 m diameter stack at a height of 50 m. Over time, the quality of
crude oil and natural gas in the off shore is changing and its sulfur content is gradually
increasing. In addition, ONGC also wishes to prepare itself for future expansion if at all
happens. This necessitates exploring technology for safe disposal of acid gas.
Table 2: Composition of Sour Gas fed to GSU.
Components Source
(% mole) BUT/MUT HUT CSU off gas CFU off gas Composite
C1 83.91 77.88 69.87 60.20 82.35
C2 7.15 8.94 10.37 20.24 7.75
C3 4.37 7.03 11.98 10.59 5.05
i-C4 0.94 1.38 2.55 2.36 1.06
n-C4 1.12 1.61 2.91 2.76 1.16
i-C5 0.28 0.34 0.53 0.60 0.28
n-C5 0.26 0.31 0.39 0.50 0.25
C6 + 0.10 0.11 0.17 0.15 0.09
CO2 1.51 2.03 0.85 2.24 1.63
N2 0.36 0.37 0.38 0.36 0.38
H2S (ppm) 40 160 200 250 65
Total 100.00 100.00 100.00 100.00 100.00
Physical properties
Mol. Wt. 19.98 21.58 24.07 25.40 20.34

Net CV 9490 10097 11448 11761 9626
(kcal/sm3)
Gross CV 10480 11128 12580 12911 10625
(kcal/sm3)
7
Table 3: Specification of product generated from GSU.
Product Parameters Value

Sweet gas Temperature(0C) 40 (max)
Pressure (kg/cm2 Abs) 47.7 (min)
CO2 content (ppm) Max. 50 (vol.) dry basis
H2S content (ppm) Max. 4 (vol.) dry basis
Moisture (0C) Saturated at 40 max.
Acid gas Temperature(0C) 50
Pressure (kg/cm2 Abs) 1.3
Treated Fuel gas Temperature(0C) 38
Pressure (kg/cm2 Abs) 6.0
H2S Content (ppm) Max. 20 (vol.) dry basis
Table 4: Composition of Product Gases at the outlet of GSU.
Components (% mole) Sweet Gas Acid Gas Treated fuel Gas
C1 83.31 2.15 76.60

C2 7.98 0.63 10.21
C3 5.23 0.68 7.58
i-C4 1.15 0.11 1.61
n-C4 1.29 0.21 1.96
i-C5 0.29 0.00 0.52
n-C5 0.26 0.00 0.43
C6 + 0.10 0.00 0.17
CO2 0.00 95.83 0.54
N2 0.39 0.39 0.38
H2S (ppm) Nil 2200 100
Total 100.00 100.00 100.00
Physical Properties
Mol. Wt. 20.08 43.30 21.95

Net CV (kcal/sm3) 9843 491 10567
Gross CV (kcal/sm3) 10863 538 11637
8
Table 5: Composition of Acid Gas considered for treatment system.
Flow rate 3, 00, 000 NM3/d

Temperature 35O C
Pressure 3 – 4 psig
Composition
CO2 98.0 %
H2S 0.5 %
Hydrocarbons 1.5 % (CH4)
Volumetric Flow (Nm3/d) 300000 200000

Volumetric Flow (Nm3/s) 3.4722 2.3148
H2S (%) 0.5 0.5
H2S (ppm) 5000 5000
Volume of H2S (Nm3/s) 0.0174 0.0116
Molecular Weight of H2S 34 34
1 gram mole occupies (m3) 0.022414 0.022414
34 gram H2S occupies (m3) 0.022414 0.022414
Emission of H2S (g/s) 26.34 17.56
Molecular Weight of SO2 64 64
Emission Rate of SO2 (g/s) 49.57 33.05
3.0 Study Approach

 Existing Baseline Status Study of H2S and its Impact
o Identification of Study Area
o H2S Emission Characterization Details- from ONGC
o Temporal (one year) AAQ Data of H2S- from ONGC
o Spatial Variation of H2S both implant as well as outside the plant in the
region- NEERI study
 Collation of National and International standards of H2S
o H2S Emission Standards- India for Boilers/SRU
o H2S Emission Standards- USEPA for Oil and Gas units
o H2S Emission Standards- WB/OSHA/NIOSH for Oil and Gas units
o H2S Ambient Standards- WB/OSHA/NIOSH for 24 hourly/ 30 mins.
 Dispersion modeling for proposed SO2 generation from enhanced oxidation of acid
gas from vent and its compliance to standards.
 Recommendation for management of impact
9
3.1 Study Area

ONGC Uran plant is situated on the western part of India in Navi Mumabi area. The
plant is on the coastal side with hill on the south-eastern side. The nearest airport is upcoming
Navi Mumbai airport. Presently the plant can be reached from Mumbai or Pune by road. Fig.
5 shows the land use pattern around 10 km radius of the plant. For a closure view, a 2 km
radius area is shown in Fig. 6. It is observed that there is no habitation on the hill adjacent to
ONGC boundary in 2km radius study area.
3.1.1 Ambient Air Quality (AAQ) Monitoring and Real Time Monitoring (RTM)
Data provided by ONGC
In order to further obtain spatio-temporal variation of H2S inside the plant premises
after its release from acid gas vent, a comprehensive ambient air quality monitoring (inside
the plant premises ) for H2S is undertaken by NEERI Team in a study area of radius 5 km is
during September/October 2015. About 4 stations were operated simultaneously on 24 hourly
basis round the clock for three days. The monitoring protocol followed is based on
Methylene blue method (CPCB/NAAQM), Annexure 3 by using portable handy samplers.
The instantaneous levels were also detected through portable gas monitor (Infitron make).
The results of the continuous as well as instantaneous levels of ambient air quality of H2S are
given in Table 6 and Figure 7 respectively. It is observed from Table 6, that H2S
concentration ranged from 0.66-17.73 ppb. Variations are observed in the continuous
monitored data during the time of the day which may be due to change in meteorological
parameters. The instantaneous data shows H2S concentration ranged from 10-20 ppm.
10
Fig. 5: Study Area Landuse Map -10 km radius
11
Fig. 6: Land use pattern in 2 km radius around ONGC Uran
12
Table 6: Ambient air quality status of H2S in Plant premises
No. Date Location Conc. , ppb Comparison with Conc. , Comparison

around the 24 hourly WHO guidelines Instantaneous with WHO
plant average (10ppb) 24hrly levels ppm guidelines
avg, 30 min avg (0.005 ppm)
30 min avg.
1 29/9/15 GSU III 29 Exceeding the 20 Exceeding the
limits limits
2 30/9/15 GSU III 22 Exceeding the 20 Exceeding the
limits limits
3 30/9/15 APU- 10 Within the limits 15 Exceeding the
substation limits
4 1/10/2015 APU- 20 Exceeding the 8 Exceeding the
substation limits limits
5 29/9/15 C-3, C-2 12 Exceeding the 10 Exceeding the
Storage Tank limits limits
6 30/9/15 C-3, C-2 21 Exceeding the 12 Exceeding the
Storage Tank limits limits
7 1/10/2015 C-3, C-2 9 Within the limits 10 Exceeding the

Storage Tank limits
8 29/9/15 Near control 10 Within the limits 20 Exceeding the
room limits
9 30/9/15 Near control 14 Exceeding the 19 Exceeding the
room limits limits
10 1/10/2015 Near control 11 Exceeding the 13 Exceeding the
room limits limits
Note: NEERI Study: Sept-Oct 2015
The concentrations of H2S both inside and outside the plant premises were found to
be highly fluctuating and dependent on meteorological parameters. The levels outside 2-3
kms of the plant premises were observed to be in the range 1- 15ppb with one time high value
exceeding 20 ppb in some places.
There is no standard available for H2S in ambient air in India. The international
standards/ guidelines were hence referred for compliance status. The levels of H2S in ambient
air exceeded the international regulations/ exposure guidelines and hence it is suggested to
control these emissions from the plant. An advanced reactive oxidation treatment followed by
scrubber is recommended to reduce this impact on the surrounding exposed population.
13
Figure 7: Instantaneous data obtained through Portable Monitor
14
3.1.2 AAQ Real Time Monitoring (RTM) Data

ONGC, Uran operates four Real Time Monitoring (RTM) station for observing
ambient air quality and meteorological data. During the field visit, air quality data from
RTM3 and RTM4 was made available as the equipment were in operation. The data gathered
consist of six air quality parameters which are NOx, H2S, SO2, O3, PM10 and PM2.5, which is
plotted for analyzing its distribution using box-whisker plot and is shown in Figure 8 and
Figure 9 and the percentile distribution summarized in Table 7. It can be seen that outliers of
SO2 reaches up to 100 g/m3. Similarly the outliers of H2S reaches up to 100 g/m3. H2S in
terms of equivalent SO2 is its double value (64/34) and therefore if H2S is converted to
equivalent SO2, the total SO2 concentration may exceed 300 g/m3.
Figure 8: Distribution of pollutants monitored at RTM3 inside ONGC premises,

Uran.
15
Figure 9: Distribution of pollutants monitored at RTM4 inside ONGC premises,

Uran.
Table 7: AAQ RTM 3 and RTM4 percentile Distribution Data
Mass Concentration (µg/m3)

RTM 3
Min 25% 50% Mean 75% Max
NOx 1.010 3.440 5.360 6.806 9.380 153.50
SO2 1.01 5.61 19.90 31.52 46.58 250.00
H2S 1.043 1.738 5.444 10.85 11.17 323.90
PM10 3.00 35.00 47.00 53.98 63.00 232.00
PM2.5 2.00 23.00 31.00 35.31 41.00 140.00
Total SO2 1.065 3.246 9.887 30.560 29.190 859.70
Mass Concentration (µg/m3)
RTM 4
Min 25% 50% Mean 75% Max
NOx 1.50 10.10 10.80 12.58 11.60 302.0
SO2 1.70 10.00 13.80 26.09 27.78 669.0
H2S 1.10 7.625 11.15 40.58 21.95 786.5
O3 1.40 5.30 7.70 8.838 9.80 306.0
PM10 19.50 45.05 54.50 55.52 61.75 669.0
PM2.5 4.59 10.26 13.80 19.13 20.71 669.0
Total SO2 5.382 24.10 35.260 74.920 69.020 1501.0
16
Currently, H2S is emitted at a rate of 27 g/s, the max dispersion of this load is
observed at RTM3 and RTM4. To analyze the ground level concentration of SO2 of this
scenario, the monitored H2S values at RTM3 and RTM4 is converted to SO2 and then linearly
added to monitored SO2 values. The total SO2 thus obtained is then plotted using box-whisker
for two RTM stations and is shown in Fig. 10. It can be seen that the extreme value of SO2
approaches 500g/m3. This suggests that the emission rate of SO2 needs to be reduced
significantly.
Fig. 10: Distribution of ambient air SO2 at RTM3 and RTM4 inside ONGC
premises, Uran (H2S converted to SO2).
17
Comparison with International Guidelines

The ambient air quality is compared with International standard for H2S. The
international standards for H2S in the ambient air are given in Table 8. Several countries
including USEPA have promulgated ambient standards for H2S. These are based on varying
time periods ranging from 30 minutes, 1 hour, 24 hours and 1 year. Comparing the
monitored data with these standards, it is observed that the continuous as well as
instantaneous data were found mostly above the international guidelines.
The ambient air quality data given by ONGC also shows that H2S present in the
atmosphere is more than the standard by WHO guidelines. Hence, proper
reduction/mitigation strategy for H2S may be planned; there are several techniques for
mitigating H2S in stack. The different standard given by the different country is given below.
Within the United States, there is no federal ambient air quality standard for
hydrogen sulfide, but more than 30 states have chosen to independently regulate hydrogen
sulfide levels to protect the public from adverse effects related to hydrogen sulfide exposure.
Some states have standards based on short-term hydrogen sulfide levels (averaged over 15
minutes), while others use an average over a much longer period of time (extending up to
one-year). The table, below, includes information for states that have ambient air quality
standards (or guidelines) for hydrogen sulfide.
• H2S Emission Standards- India for Boilers/SRU : 150/10 mg/Nm3

• H2S Emission Standards- USEPA for Oil and Gas units: 7.6mg/Nm3
• H2S Emission Standards- WB/OSHA/NIOSH for Oil and Gas units: 5-
15mg/Nm3
• H2S Ambient Standards- WB/OSHA/NIOSH for 24 hourly/30 min:
10ppb/0.005ppm resp.
18
Table 8: International Standards for Ambient H2S Exposure and its Toxic Effects
WHO guide lines
Concentration Time period Effect
150 µg/m3 (10.6 ppb) 24-hour based on the avoidance of eye irritation
Should not exceed 0.005 ppm 30-minutes To avoid substantial complaints about odor
(5 ppb; 7 µg/m3)
New Mexico, New York and Kentucky
Greater than 10 ppb one hour The effects may be health-related or the odors
may create a nuisance for the citizens.
Massachusetts
Greater than 0.65 ppb 24-hour Adverse health effect
Oklahoma
Greater than 200 ppb 24-hour Adverse health effect
Cal EPA,1999
30ppb(42 µg/m3) 30-minute Headaches and nausea in normal subjects
USEPA,2003
1ppb(2 µg/m3) 1-year
Nasal inflammation / lesions in sub chronic
mouse and rat studies
Alberta occupational health and safety (OHS) legislation
10 ppm 8 hour -
Occupational
Exposure Limit
(OEL)
15 ppm Ceiling OEL -
Regulatory Aspect for discharge of Acid Gas and Dispersion Modeling of SO2
At present in our country there are no Central or State rules that identify air emission
standards specifically for H2S from stack for Oil and Natural Gas processing. Standards exist
in terms of concentration of SO2 in emission and in ambient air. Further, State Pollution
Control Boards while giving consent to operate fixes the daily emission of SO2 in terms of
mass i.e. say 50 kg per day. These values are fixed based on the health effect they have on the
man, environment and surrounding. Information on the effect of hydrogen sulfide on TLV
and STEL and IDLH exposure is available in MSDS data sheet (Annexure I). Also OSHA
has fixed standards for H2S for outdoor Air Quality (Annexure II).
In order to meet the regulatory compliance, daily emission standard limit is considered
first and the guidelines for control system are designed. This is followed by conducting
dispersion simulation exercise using CALPUFF model. The ground level concentration
obtained by simulation help in deciding the appropriateness of emission rate and height of
release above ground level.
19
Emission Inventory of SO2 (kg/d)
Emission inventory for the entire ONGC plant at Uran is estimated for assessing the
impact present regulatory compliance in terms of SO2 emission rate (kg/d). There are nine
stacks that may emit SO2. Based on the data given in Table 6, emission of H2S from Acid
Gas Stack is estimated to be 27 g/s, which is equivalent to 50 g/s of SO2 emission after
oxidation. All the values are converted to kg/d and is given in Table 9.
Table 9: Emission of SO2 from different stack of ONGC, Uran

No. Stack SO2 Emission (g/s) SO2 Emission (kg/d)
1. Acid Gas Vent (27 g/s H2S) 50 4320
2. HRSG I 0.07 6.048
3. HRSG II 0.15 12.96
4. HRSG III 0.1 8.64
5. LPG I 0.1 8.64
6. LPG II 0.1 8.64
7. LPG III 0.1 8.64
8. Old Thermax 0.01 0.864
9. New Thermax 0.01 0.864
Total 50.64 4375
Source: ONGC, Uran, Navi Mumbai
The existing consent of 50 kg/day of SO2 was only for sweetened gas. However, in
view of proposed advanced reactive oxidation of H2S to SO2 this consent may be further
reviewed. This will reduce the impact on H2S on the surrounding further reducing the load in
the atmosphere.
Proposed Acid Gas Emission Treatment – Enhanced reactive oxidation technique
Presently acid gas vent releases H2S directly into the atmosphere. H2S gas is toxic to
human and environmental health and in reduced state has the tendency to corrode the
materials by oxidation. Therefore, it is proposed to oxidize H2S to SO2 before releasing it into
the atmosphere. An enhanced reactive oxidation technique followed by a scrubber is hence
recommended. The proposed enhanced reactive oxidation process followed by scrubber for
mitigating the H2S probably is the best alternative in the present scenario at ONGC, Uran
where the quantity of acid gas is very less relative to other similar industries in India.
20
3.2 Enhanced reactive oxidation and Scrubbing Technique

Acid gas containing H2S can be treated in an enhanced reactive oxidation by using
dilution air to get effective oxidation of H2S to SO2. SO2 thus generated needs scrubbing with
solid or liquid alkaline absorbents, typically lime or magnesium hydroxide is used.
Neutralization of SO2 in the flue gas can be carried out using wet slurry or dry powder in the
scrubber.
Following emission scenarios are used for modeling studies.
 Oxidation of 27 g/s of H2S will generate 50 g/s (or 4320 kg/d) of SO2.
 Emission of SO2 from all the stacks except acid gas vent totals 0.6g/s (or 55 kg/d).
 The ground level concentration (GLC) of SO2 due to emission after oxidation needs to
be estimated using source dispersion model. If the GLC of SO2 is found to be very
high compared to the regulatory standard (80 g/m3), the SO2 emission needs to be
reduced by gas desulphurization technique.
Flue Gas Desulphurization (FGD)
There are three scrubbing (wet or dry) control technologies which have major application
in the field of Sulphur di Oxide control.
1. Adsorption.
2. Catalytic Oxidation / reduction.
3. Absorption.
Adsorption is a control technology for control of SO2 from stack gases. Different adsorbent
is used to control the SO2 emission like lime, sodium carbonate, sodium bicarbonate, calcium
hydroxide and mixture of fly ash with lime (at high temperature) etc . The following issues
to be addressed:
 Higher energy requirements.
 Penetration of SO2 in the granule is difficult.
 Highly active absorbent surfaces cause oxidation of SO2 to SO3 which react with
moisture in flue gases to form acid.
 Regeneration techniques are costlier.
 Required large storage area for storing the by-product.
21
Catalytically oxidation / reduction is a dry scrubbing technology for controlling SO2 from
stack emissions. The following issues to be addressed:
 Higher energy requirements
 Large equipment size.
 Catalysts (Zeolite based adsorbent) are expensive.
 Regeneration and disposal of catalysts.
 Contact design is complex.
Absorption is a wet flue gas desulphurization (FGD) technology for controlling SO2 from
stack emissions, which is widely practiced. An important design consideration associated
with wet FGD systems is that the exhaust gas generated from the absorber is saturated with
water and still contains some SO2. These gases are highly corrosive to any downstream
equipment such as fans, ducts and stacks. The following issues to be addressed:
 Reheating the gases to above their dew point for mist elimination.
 Using materials of construction and designs that allow equipment to withstand the
corrosive conditions.
However these problems can be easily managed with proper engineering design used.
Besides this less operator’s intensiveness, less cost and ease of handling of liquid sorbent
makes it an attractive option. It is one of the most widely used control technology used for the
removal of SO2. Usually solid or liquid alkaline absorbents like lime or magnesium
hydroxide is used for SO2 removal from gas stream in a scrubber.
A. The reaction taking place in dry scrubbing using a CaCO3 (limestone)

produces CaSO3 (calcium sulfite) and can be expressed as:
CaCO3 (solid) + SO2 (gas) → CaSO3 (solid) + CO2 (gas)
B. When wet scrubbing with a Mg(OH)2 (magnesium hydroxide) slurry, the reaction
produces MgSO3 (magnesium sulfite) and can be expressed as:
Mg(OH)2 (solid) + SO2 (gas) → MgSO3 (solid) + H2O (liquid)
C. When wet scrubbing (pl. see Fig. 11) with a Ca(OH)2 (lime) slurry, the reaction produces
CaSO3 (calcium sulfite) and can be expressed as:
Ca(OH)2 (slurry) + SO2 (gas) → CaSO3 (solid) + H2O (liquid)
22
Fig. 11: Pictorial view of a wet scrubber.
D. A natural alkaline medium used to absorb SO2 is seawater. The SO2 is absorbed in the
water, and when oxygen is added reacts to form sulfate ions SO4- and free H+. The
surplus of H+ is offset by the carbonates in seawater pushing the carbonate equilibrium to
release CO2 gas:
SO2 (gas) + H2O (liquid) + ½O2 (gas) → SO42− (solid) + 2H+
HCO3− + H+ → H2O (liquid) + CO2 (gas)
E. In industry a solution of caustic (NaOH) is often used to scrub SO2, producing sodium
sulfite:
2NaOH (aq) + SO2 (gas) → Na2SO3 (aq) + H2O (liquid)
Fig. 12 shows the schematic of acid gas treatment system. For 90% efficient wet
scrubber, the emission of SO2 would be 5 g/s. It is recommended that the effluent from
scrubber to be diluted with existing treated effluent from ETP, finally to be discharged into
sea (complying the MINAS standards of sulphide)
23
WetScrubber
Fuel Gas
27 g/s 50 g/s
5 g/s
Gas (H2S) H2S (SO2) 90% (SO2) Stack
Sweetening Oxidation
Sour Gas
Sweet gas to ETP

LPG Plant Wastewater
Fig. 12: Proposed acid gas treatment scheme at ONGC Uran.
Usually the efficiency of dry scrubber is lesser than that of wet scrubber. Lime and
Magnesium hydroxide is used when large amount of flue gas needs to be desulphurized as in
the case of coal fired thermal power plant. For industrial level, like ONGC, where the gas
amount is relatively less compared to a thermal power plant, a stronger neutralizer like NaOH
should be preferred for scrubbing of SO2. Wet scrubbing using NaOH solution results in
generation of wastewater which is alkaline in nature. Wet scrubbing reduces SO2 emission;
however, the wastewater treatment remains an additional responsibility. The generated
wastewater is inorganic in nature and should not be mixed with other wastewater stream
containing organic matter and is being treated by biological methods. Wastewater from
Scrubber can be disposed through pipeline for the sea disposal. Since ONGC Uran plant is on
sea shore, the wastewater from scrubber can be joined to the existing treated effluent
discharge line, disposing deep in the sea, complying with the Existing standards of sulphide
(MINAS). In case of any buyer of sodium sulphite approaches ONGC at later stage, the
product can also be sold.
Use of Sodium Sulphite

 Pulp and paper: In the production of pulp by sulphite semi-chemical process and
chemi-thermo mechanical means.
 Water treatment: As an antichlor Boiler water.
 As an oxygen scavenger: Chemicals and drugs
24
 A moderate reducing agent in the manufacture of sodium thiosulphate, sulphonated

chemicals, sulphomethylation, and acetaminophen
 Natural latex rubber: As a preservative
 Photography: As a preservative
 Food industry: As an antioxidant, enzyme inhibitor and antimicrobial Agent
 Fibre industry: As a solvent for raw materials, an additive for precipitation baths, for
bleaching and for desulphurising bobbins
 Chlor-alkali: To destroy chlorine in return brine
 Leather industry: In the sulphitisation of tanning extract
 Explosives: In the production of trinitrotoluene (TNT)
 Minerals: Oil well floatation as an oxygen scavenger
 Detergents: In the manufacture of sulphosuccinates and shampoo
In order to evaluate the compliance of SO2 dispersed from the proposed enhanced
oxidation Unit for acid gas treatment with and without scrubber, the source dispersion
modeling using state of art CALPUFF model (USEPA Approved) is used.
3.3 Source Dispersion Modeling
CALPUFF is an advanced non-steady-state meteorological and air quality modeling

system developed by Exponent scientists. It is maintained by the model developers and
distributed by Exponent. The model has been adopted by the U.S. Environmental Protection
Agency (USEPA) in its Guideline on Air Quality Models as the preferred model for assessing
long range transport of pollutants and on a case-by-case basis for certain near-field
applications involving complex meteorological conditions. The modeling system consists of
three main components and a set of preprocessing and post processing programs. The main
components of the modeling system are CALMET (a diagnostic 3-dimensional
meteorological model), CALPUFF (an air quality dispersion model), and CALPOST (a post
processing package). Each of these programs has a graphical user interface (GUI). In addition
to these components, there are numerous other processors that may be used to prepare
geophysical (land use and terrain) data in many standard formats, meteorological data
(surface, upper air, precipitation, and buoy data), and interfaces to other models such as the
Penn State/NCAR Mesoscale Model (MM5), the National Centers for Environmental
25
Prediction (NCEP) Eta/NAM and RUC models, the Weather Research and Forecasting
(WRF) model.
Table 10: Stack Details of ONGC, Uran: Input for Dispersion Modelling
No. Stack Height Diameter Exit Gas Emission Emission

(m) (m) Velocity Rate SO2 Rate SO2
(m/s) (g/s) (kg/d)
1. Acid Gas Vent 50 0.4 22 50 (equivalent) 4320
2. HRSG I 15 3.15 15 0.07 6.05
3. HRSG II 15 3.15 15 0.15 12.96
4. HRSG III 32 3.15 15 0.1 8.64
5. LPG I 45 1.3 15 0.1 8.64
6. LPG II 45 1.3 15 0.1 8.64
7. LPG III 45 1.3 15 0.1 8.64
8. Old Thermax 20 2.04 9 0.01 0.864
9. New Thermax 35 2.1 12.5 0.01 0.864
Total 50.64 4375
Source: ONGC, Uran, Navi Mumbai
CALPUFF model is considered for source dispersion modeling. Emissions from nine
stacks are considered for baseline simulation. Table 10 shows the emission details considered
in the baseline scenario. Initially study domain of 48 km x 48km with a grid size of 1km x
1km is considered for meteorological data. ONGC, Uran plant is located in the south-west
part of the study area and therefore, a small area around ONGC (2km x 2km) is used for
showing the results of dispersion modeling.
Two scenarios were considered for dispersion modeling of SO2 from the proposed
enhanced reactive oxidation followed by scrubbing unit to predict it’s Impact in and around
the plant through CALPUFF dispersion model. Predictions are undertaken considering the
proposed unit to be installed adjacent to the existing acid gas vent.
Scenario 1
The first scenario with only enhanced reactive oxidation without scrubber generates
50 g/s of SO2 and the predicted ground level concentration (GLC) contours in and around the
plant (2km radius) for 24 hourly average peaked up to 790 µg/m3 on the hill slope, which is
much higher than the regulatory value. The GLS of SO2 under this scenario is given in
Figure 13.
26
Fig. 13: GLC of SO2 due to emission of untreated SO2 (without scrubber)
27
Scenario 2:
The Second Scenario with enhanced reactive oxidation followed by scrubbing (90%
efficiency) generates 5 g/s of SO2 and the predicted ground level concentration (GLC)
contours in and around the plant (2km radius) for 24 hourly average peaked up to 75 µg/m3,
on the hill slope, which is also not habitated and the GLC value is below the below the
regulatory levels. The prediction of SO2 impact on the surroundings through dispersion model
and its output under this scenario is given in Figure 14.
28
Fig. 14: GLC of SO2 with scrubber efficiency at 90% (5 g/s SO2 emission).
29
4.0 Recommendations
 H2S present in acid gas stream to the tune of 27g/s is released in the atmosphere
creating high levels of H2S in and around the plant. There is no standard available for
H2S in ambient air in India. The international standards/ guidelines were hence
referred for impact assessment purpose. The levels of H2S in ambient air exceeded the
international regulations/ exposure guidelines and hence it is suggested to control
these emissions. An enhanced reactive oxidation technique followed by a scrubber is
hence recommended.
 The proposed advanced reactive oxidation process followed by scrubber for
mitigating the H2S probably is the best alternative where the quantity of acid gas is
very less relative to other similar industries in India. This may also reduce the impact
on the surrounding exposed population.
 Two scenarios were considered for dispersion modeling of SO2 from the proposed
enhanced reactive oxidation followed by scrubbing unit to predict it’s Impact in and
around the plant through CALPUFF dispersion model. Predictions are undertaken
considering the proposed unit to be installed adjacent to the existing acid gas vent.
 The first scenario with only enhanced reactive oxidation generates 50 g/s of SO2
and the predicted ground level concentration (GLC) contours in and around the
plant (2km radius) for 24 hourly average peaking to 790 µg/m3, on the adjacent
hill slopes.
 The Second Scenario with enhanced reactive oxidation followed by scrubbing

(90% efficiency) generates 5 g/s of SO2 and the predicted ground level
concentration (GLC) contours in and around the plant (2km radius) for 24
hourly average peaking to 75 µg/m3, on the adjacent hill slopes.
 If high efficiency of scrubber is maintained more than 90%, then the outlet emission
of SO2 will be less than 5 g/s. The maximum GLC of SO2 under this scenario would
further reduce.
 It is recommended that the effluent from scrubber, is to be diluted by mixing it with
existing treated effluent from ETP, finally to be discharged into sea, while complying
the MINAS standards.
30
 The existing consent of 50kg/day of SO2 was only for sweetened gas. However in
view of enhanced reactive oxidation followed by scrubbing of H2S to SO2, this
consent may be further reviewed. The implementation of oxidation of H2S and
desulphurization of resulting SO2 will reduce the impact on surrounding environment.
It would also reduce the total emission load on the atmosphere.
-----------------------------------------------------------------------------------------------------
31
Annexure 1
Source: http://avogadro.chem.iastate.edu/MSDS/hydrogen_sulfide.pdf
AX1
AX2
AX3
AX4
AX5
AX6
National & International Regulations for H2S and SO2 gas release from oil and gas
processing unit, Petroleum Refineries and Other Industries, India and Other Countries
Sr. Country / Limits for H2S /SO2 Reference /Source

No. institution /
organization
H2S Emission Regulation for Oil and Gas Processing Units, Petroleum Refineries and Other Industries, India
and Other Countries
H2S Emission Factors for Other Industries, India
1 Emission standard Limiting Concentration in flue gas Emission Standard
furnace/boiler/captive 150mg/Nm3, unless stated Furnace/Boiler/Captive
power plant, Petroleum Power Plant, Petroleum
Refinery, Refinery, CPCB, India
CPCB, India
2. Emission standard Limiting Concentration in flue gas Emission Standard
New Sulphur Recovery For Sulphur Recovery, 5-20 TPD: Furnace/Boiler/Captive
Unit, Petroleum 10 mg/Nm3 Power Plant, Petroleum
Refinery, Refinery, CPCB, India
CPCB, India
3. Emission standard Emission/concentrations as per regulation Emission standard
For Pesticide H2S: 5 mg/Nm3 For Pesticide
Manufacturing Manufacturing
and Formulation and Formulation
Industry, CPCB, India Industry, CPCB, India
H2S Emission Regulation for Oil and Gas Processing Units, Petroleum Refineries and Other Industries,
International
1 IFC, World Bank, 2007 Emission/concentrations as per General Environmental, Health, and
EHS Guidelines Safety Guidelines
H2S: 5 mg/Nm3 ONSHORE OIL AND GAS
DEVELOPMENT, IFC,
World Bank, 2007
2 OSHA,1992 For H2S, the threshold quantity regulated OSHA issues its final
is 1500 pounds. This means that facilities process safety standards on
with 1500 lbs or greater H2S on-site would February 24.1992
be subjected to the process safety
management standards.
3 NIOSH NIOSH suggests no employee be exposed NIOSH,US federal agency
to H2S as ceiling concentration greater
than 15 mg/m3 (1 x104ppb) for upto a 10
hr work/ week. Evacuation is required
with the concentration equals or excess 70
mg/m3 (5 x102 ppb)
4 Mineral & management Applies to significant emission of H2S Mineral & management
services, OSHA, PSD from new sources emitting greater than services The PSD permit
permit program 250 tons per year (or 100 tons per year for program i.e. major PSD
certain source categories)of any regulated sources
pollutant. . It also applies to modifications
of existing facilities if the net emission
increases of H2S from the modification are
significant. In either case, the significant
emission rate for H2S is 10 tonnes per
year. Also, permits do not require
monitoring if the average concentration is
AX7
below 0.014 ppb(0.02µg/m3). H2S is also
related under the PSD program for its
resistance odor as a part of a larger group
of Total Reduced sulfur and Reduced
sulfur(significant ≥ 10 tons/yr).
5. USEPA H2S Emission : 7.6 mg/m3 US Environmental Pollution
Control (Air Impurities)
Regulations
SO2 Emission Regulation for Incinerators, India and Other Countries
1. USEPA Limits, 2002 SO2 Emission : 55 ppmv USEPA for New as well as
Existing Units for small,
medium and large units
2. EU Limits SO2 Emission : 25 ppmv (daily) EU Limits
SO2 Emission : 50 ppmv (hourly)
3. AP-42, USEPA, 1995 SO2 Emission : 54.6 ppmv AP-42, USEPA, 1995
4. German Federal SO2 Emission : 50 mg/m3, BImSchV, Seventeenth Ordinance of the

Immission Control Germany German Federal Immission
Control
Act (BMU, 2009), only daily
mean and MSW (M&H)
Rules, 2000
MoEF, GoI
5. MSW, MoEF, 2000, SO2 Emission : 100 mg/m3, MoEF MSW Seventeenth Ordinance of the
India Rules, India, 2000 German Federal Immission
Control
Act (BMU, 2009), only daily
mean and MSW (M&H)
Rules, 2000
MoEF, GoI
6 Emission standard Emission/concentrations as per regulation Emission standard

Common Hazardous SO2: 200 mg/Nm3 Common Hazardous Waste
Waste Incinerator, Incinerator, CPCB, India
CPCB, India
7 WHO No Guideline for Incinerator
*Suitable dimensions of stack and exit velocity may be provided for safe disposal.
AX8
Annexure 2
Occupational Safety & Health Administration Guidelines for Industry
Source: https://www.osha.gov/pls/oshaweb/owadisp.show_document
AX9
Annexure 3
HYDROGEN SULPHIDE: H2S
METHYLENE BLUE
Principle of Method When air is allowed to pass flocks in A.M., H 2S present in air gets combined
with Cadmium Hydroxide and forms Cadmium Sulfide (Yellow color). This
sulfide under suitable conditions combines with N:N Dimethyl P-Phenylene di
amine and ferric chloride solution forming a complex methylene blue color.
Intensity of color measured at 670-nm spectrophotometrically.
Sensitivity This method covers the range from 6 µg/m 3 to 600 µg/m3 or 0.03 µg/ml of
AM
Interference Sulfide & Thio sulfate Removed by adding sufficient amount of Ferric sulfate
solution.
NO2 Removed by adding Sulfamic Acid solution
SO2, Ammonia, Do not interfere at existing levels of concentration.
Ozone
Chemicals (AR Grade)  Cadmium Sulfate CdSO 4
 Sodium Hydroxide NaOH
 Sulfamic Acid NH2HSO3
 N:N Di methyl P- Phynylene Di amine C8H12N2
 Sulfuric Acid H 2SO4
 Ferric Chloride FeCl 3.6H2O
 Distilled water
Reagents:
(1) Absorbing Media Prepared by dissolving 4.3 g. of Cadmium Sulfate 0.3 g. of Sodium Hydroxide in
1 lit. of D.D.W.
(2)Sulfamic Acid solution Prepared by dissolving 1 g. of sulfamic acid in 100 ml of D.D.W.
(3) Amine Acid Solution  Add 1.5 ml of Concentrated Sulfuric acid to 1 ml of D.D.W.
 Cool the solution.
 Add 0.3 g. of di amine salt of dye or 0.7 g. of sulfate salt of dye to this
solution.
 Mix well till it dissolves.
 Prepare 1:1 sulfuric acid solution by dissolving 100 ml sulfuric acid in 100
ml D.D.W.
 Add 100 ml of this 1:1 sulfuric acid solution to above solution.
 Store in refrigerator.
(4) Ferric Chloride Prepare by dissolving 25 g. of Ferric chloride in 25 ml D.D.W.
Solution
AX10
Analysis of Sample  Bring the samples in laboratory.
 Remove the caps and rinse it with little D.D.W.
 Keep the sample open for 20 min if ozone is expected in air.
 Keep one impinger filled with 20 ml AM as BLANK
 5. Add 1 ml of Sulfamic Acid solution ,
 0.5 ml of Amine Sulfuric acid solution
 0.05 ml of Ferric Chloride solution (one drop)
 Shake well after addition of each solution.
 Make up the volume of each upto 25 ml with D.D.W. including blank.
 Keep samples for 30 minute for developing the color completely.
 Warm up the instrument B & L during this time
 Set the wavelength at 670 nm.
 Check 0 of instrument, If not, adjust it with left knob.
 Fill the cuvette with blank solution.
 Put this in B&L and adjust 100 % Transmittance with right knob.
 Keep this blank for checking 100 %T before analysis of each sample.
 Fill up one sample in cuvette and note the % T.
 16. Note % T of each sample as above (One by one).
Calculations  Calculate the total time of sampling in minute from starting and closing
(use Laboratory Data time
Sheet)  Calculate the flow rate of air which is average of all readings for every hr.
of sampling.
 Calculate the µg of H 2S present in each sample from %T reading with help
of calibration curve.
Formula
 H2S (µg / m3) = (Conc. Of H 2S in sample (in µg ) X 1000)
Total volume of air passed ( in lit. )

= Conc. Of H 2S in sample (in µg ) X 1000
Flow rate(in lit/min) X Total time (in min)

Correction for Volume of air passed
Volume of air passed through impinger varies with temperature. Hence the result are reported at
S.T.P.(Standard Temperature and Pressure) .Total volume of air passed through impinger is corrected by
factor calculated as follows.
P1V1 = P2V2
T1 T2
P1 : Standard Atmospheric pressure I.e. 760 mm of mercury
V1 : Corrected volume (require to calculated)
T1 : Absolute temperature (273 + 25)
P2 : Pressure at time of sampling
V2 : Volume of gas collected
T2 : Temperature at time of sampling.(273 + t )
PLOTING OF CALIBRATION CURVE For H 2S
AX11
Chemicals (AR Grade) 1. Potassium Di Chromate K 2Cr2O7
2. Sulfuric Acid 36 N H 2SO4
3. Potassium Iodide KI
4. Starch Soluble
5. Salicylic Acid C6H5(OH)COOH
6. Sodium Thio Sulfate Na 2S2O3.5H2O
7. Chloroform CHCl 3
8. Iodine Resublimed I
9. Sod. Sulfide Na 2S
10. Absorbing media
11. Sulfamic acid solution
12. Amine acid solution
13. Ferric Chloride solution
Reagents:
Sodium sulfide (0.01N) Dissolve 1.21 g. of sodium sulfide Na 2S. 9H2O in small D.D.W. and make up the
volume to 1000 ml with pre – refrigerated D.D.W. This solution will give
sulfide equivalent to 170 to 200 µg of H 2S/ ml
Standardization of Sodium sulfide
Take 100 ml of standard iodine solution (0.025N). Add 25 ml of HCl (0.1N) and
titrate with Sodium thiosulfate solution using starch. Note the titrant reading A. Take
100 ml of distilled water in 250 ml conical flask and add 20 ml of standard iodine
solution (0.025N). Add 25 ml of HCl (0.1N) and 20 ml of sodium sulfide solution
and repeat the titration with Sodium thiosulfate solution. Note the reading B.
Calculate the strength of Sodium sulfide solution in terms of H 2S as follows:
(A-B) x Normality of thio x 17 x 103
H2S µg/ml = -----------------------------------------------------
20
Working std Dilute a portion of the Sodium sulfide solution so that it contains equivalent to 10
Sodium sulfide solution µg/ml of H2S.
CALIBRATION  Arrange about 12 properly cleaned impingers in stand.
CURVE :  Number these from 1 to 12.
 Add 10 ml approximately A.M. to each impinger.
 Add 0.1, 0.3, 0.5, 0.7, 1.0, 1.3, 1.5, 2.0, 2.5, 3.0, 3.5.. ml of working solution in
2 to 12 impingers.
 Impinger No 1 should be treated as Blank.
 Add 1 ml of Salfamic acid solution.
 Add 0.5 ml of Amine acid solution
 Add 0.05 ml of Ferric chloride solution in each sample including blank.
 Shake well after addition of each solution.
 Make up the volume of each to 25 ml with D.W. including blank.
 Keep samples for 30 minute for developing the color completely.
 Warm up the instrument B & L during this time and
 Set the wavelength at 670 nm .
 Check 0 of instrument, If not, adjust it with left knob.
 Fill the cuvette with blank solution.
 Put this in B&L and adjust 100 % Transmittance with right knob.
 Keep this blank for checking 100 % T before analysis of each sample.
 Fill up one sample in cuvette and note the % T
 Note % T of each sample as above.( One by one)
 Draw the curve on log X c.m graph paper taking µg of H 2S on X - axis and % T
on Y - axis, The curve will be straight line following Lambert's and Beer's law.
IMPORTANT NOTES Indicate clearly on calibration chart
A. Name of scientist drawing the curve.
AX12
B. Date
C. Instrument used
D. Reagent added S. Acid : 1 ml , Amin sulfuric acid solution: 0.5
ml, Ferric chloride : 0.05 ml
E. Reference Volume 25 ml
F. Wave length used 670 nm
G. Time for color development 30 min.
For H2S:
Chemical Preparation:
 Absorbing Media (1000ml) : 3.4 gm Cadmium Sulphate + 0.5gm NaOH +1000ml DDW
 Sulphamic Acid (100ml): 0.6gm Sulphamic acid- Volume make up to 100ml with DDW
 Ferric Chloride: Prepare by dissolving 25 g. of Ferric chloride in 25 ml D.D.W.
 Diamine:
a. Add 1.5 ml of Concentrated Sulfuric acid to 1 ml of D.D.W.
b. Cool the solution.
c. Add 0.3 g. of di amine salt of dye or 0.7 g. of sulfate salt of dye to this solution.
d. Mix well till it dissolves.
e. Prepare 1:1 sulfuric acid solution by dissolving 100 ml sulfuric acid in 100 ml D.D.W.
f. Add 100 ml of this 1:1 sulfuric acid solution to above solution.
g. Store in refrigerator.
Analysis Procedure:
 Add 2ml of Sulphamic acid to the given sample + 0.5 ml Diamine Solution + 0.5 ml Ferric Chloride +
volume make upto 25ml by DDW
 Prepare blank and add the following reagent to the blank + volume make upto 25ml by DDW
 Wait for 30 min
 Take Absorbance at 670 nm at Spectrophotometer
AX13
Annexure 4
CENTRAL POLLUTION CONTROL BOARD
[SCHEDULE VII]
[See rule 3(3B)
NATIONAL AMBIENT AIR QUALITY STANDARDS (NAAQS)
S. No. Pollutant Time Industrial, Ecologically Methods of Measurement
Weighted Residential, Sensitive
Average Rural or Area
Other Areas (Notified by
Central
Govt.)
(1) (2) (3) (4) (5) (6)
1 Sulphur Dioxide Annual* 50 20 - Improved West & Gaeke
(SO2), g/m3 24 hrs** 80 80 - Ultraviolet florescence
2 Nitrogen Annual* 40 30 - Modified Jacob & Hochheiser
Dioxide (NO2), 24 hr** 80 80 (Na–Arsenite)
g/m )3
- Chemiluminescence
3 Particulate Annual* 60 60 - Gravimetric
Matter (Size 24 hrs** 100 100 - TEOM
less than 10 m) - Beta attenuation
or PM10, g/m 3
4 Particulate Annual* 40 40 - Gravimetric

Matter (Size 24 hrs** 60 60 - TEOM
less than 2.5 - Beta attenuation
m) or PM2.5,
g/m3
5 Ozone (O3), 8 hrs** 100 100 - UV photometric
g/m3 1 hr** 180 180 - Chemiluminescence
- Chemical method
6 Lead (Pb), Annual* 0.5 0.5 - AAS/ICP method after
g/m 3
24 hrs** 1 1 sampling on EPM 2000 or
equivalent filter paper,
- ED-XRF using Teflon filter
paper
7 Carbon 8 hrs** 02 02 - Non Dispersive Infrared
Monoxide (CO), 1 hr** 04 04 (NDIR) Spectroscopy
mg/m3
8 Ammonia Annual* 100 100 - Chemiluminescence
(NH3), g/m 3
24 hrs** 400 400 - Indophenol blue method
9 Benzene (C2H6), Annual* 05 05 - Gas Chromatography based
g/m 3
continuous analyzer
- Adsorption and Desorption
followed by GC analysis
AX14
S. No. Pollutant Time Industrial, Ecologically Methods of Measurement
Weighted Residential, Sensitive
Average Rural or Area
Other Areas (Notified by
Central
Govt.)
(1) (2) (3) (4) (5) (6)
10 Benzo Annual* 01 01 - Solvent extraction followed by
(O)Pyrene HPLC/GC analysis
(BaP), ng/m3
11 Arsenic (As), Annual* 06 06 - AAS/ICP method after
ng/m3 sampling on EPM 2000 or
equivalent filter paper
12 Nickel (Ni), Annual* 20 20 - AAS/ICP after sampling gon
ng/m3 EPM 2000 or equivalent filter
paper
* Annual Arithmetic mean of minimum 104 measurements in a year at a particular site taken
twice a week 24 hourly at uniform intervals.
** 24 hourly or 8 hourly or 1 hourly monitored values, as applicable, shall be complied with

98% of the time in a year, 2% of the time; they may exceed the limits but not on two
consecutive days of monitoring.
AX15

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DETAILED FEASIBILITY REPORT

OIL AND NATURAL GAS CORPORATION

Doc No.: A333-RP-14-41-0001

SECTION DESCRIPTION PAGE NO.

1.0 EXECUTIVE SUMMARY 5

2.0 EXISTING COGENERATION PLANT 13

2.1 EXISTING CAPTIVE POWER PLANT DESCRIPTION 13

3.0 CONFIGURATION COMPARISON 19

3.1 PROPOSED SYSTEM 19

4.0 PROJECT DESCRIPTION (MAIN PLANT) 27

4.1 DESIGN BASIS 27

5.0 PROJECT DESCRIPTION (DM PLANT) 60

5.1 PROCESS DESIGN BASIS 61

6.0 SAFETY AND ENVIRONMENTAL ASPECTS 66

7.0 STATUTORY APPROVALS AND CLEARANCES 78

8.0 PROJECT COST ESTIMATE 81

8.1 CAPITAL COST ESTIMATE & FINANCIAL ANALYSIS 81

Copyrights EIL – All rights reserved

8.3 PLANT & MACHINERY 82

9.0 FINANCIAL ANALYSIS 85

9.1 OPERATING COST & FINANCIAL ANALYSIS 85

10.0 PROJECT IMPLEMANTATION AND SCHEDULE 88

10.1 PROJECT IMPLEMENTATION METHODOLOGY 88

11.0 RISKS AND MITIGATIONS 93

Annexure-1 : Overall Plot Plan

Copyrights EIL – All rights reserved

Copyrights EIL – All rights reserved

1.0 EXECUTIVE SUMMARY

Crude Stabilization Unit : 05 Trains

The processing complex at ONGC, Uran is of strategic importance as it handles 60% of

The purpose of present study is to prepare a techno-economic Detailed Feasibility study

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system, environmental aspects, estimates of project cost, project implementation

1.3.1 Existing Power & Steam Scenario

1.3.2 Requirement of Power & Steam for upcoming Units

In order to process additional C-series gas from offshore, commissioning of additional

Additional process plant is expected to be in operation in FY 13-14.

Power requirement is approximately 20 MW (Continuous) and 60 TPH Steam from

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1.4 PROJECT HIGHLIGHTS

Table 1-1 Highlights of the project

Nearest Highway Mumbai JNPT Highway

Domestic airport : Mumbai – 58 km

Nearest sea port Jawaharlal Nehru Port at Nhava Sheva – 7 km

Nearest Railway Panvel Railway station

Site : ONGC Uran

5. Fuel, Water and Electricity

Main Fuel Natural Gas

Gas cost with

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Raw Water Rs. 25 /kL

DA/DM Water Rs 40 /kL (Inclusive of Raw water cost)

Electricity Duty Rs 0.3/kWh

Gas Turbine Generator

Unit size Approx. 20 MW GT + 90 TPH HRSG

Unit type Cogeneration cycle

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1.5 PROJECT COST & FINANCIAL HIGHLIGHTS

Table 1-2 Project Cost

DESCRIPTION COST IN ` CRORES

1.5.1 Financial Highlights for the Project

Table 1-3 Operating Cost

S.NO. DESCRIPTION ASSUMPTIONS MADE