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FEASIBILITY REPORT
eGateway India Private Limited
M/s CHENNAI POWER GENERATION PRIVATE LIMITED CHENNAI
1050 MW (2 x 525 MW) MW COMBINED CYCLE POWER PROJECT AT DISTRICT THIRUVALLUR, TAMIL NADU STATE
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
1
CONTENTS
CHAPTE
R NO. PARTICULARS PAGE NO
FEASIBILITY REPORT
I EXECUTIVE SUMMARY 3
II INTRODUCTION OF THE PROJECT / BACKGROUND
INFORMATION 5
III PROJECT DESCRIPTION 9
IV SITE ANALYSIS 31
V PLANNING BRIEF 34
VI PROPOSED INFRASTRUCTURE 35
VII REHABILITATION & RESETTLEMENT (R&R) PLAN 36
VIII PROJECT SCHEDULE & COST ESTIMATES 37
IX ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) 38
LIST OF FIGURES
FIGURE
NO. PARTICULARS PAGE NO
3.1 LOCATION PLAN 10
3.2 SATELLITE IMAGE SHOWING PROJECT BOUNDARY
WITH CO-ORDINATES 11
3.3 PLOT PLAN 18
3.4 WATER BALANE DIAGRAM 28
3.5 INDEX PLAN 30
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
2
LIST OF ANNEXURES
ANNEXURES
NO. PARTICULARS PAGE NO
1 PREVIOUS TERMS OF REFERENCE APPROVED BY
MOEF FOR IMPORTED COAL BASED POWER PLANT 39
2 HEADS OF AGREEMENT BETWEEN IOC AND
CHENNAI POWER GENERATION 47
3 MOU BETWEEN IOC AND CHENNAI POWER
GENERATION 56
4 LAND SURVEY NUMBERS DETAILS FOR PROJECT
SITE 60
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
3
CHAPTER – I
EXECUTIVE SUMMARY
Sl.No
1 Title of The Project
1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M /S. Chennai Power Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu .
2 Name & Address of The Project Proponent
M/s Chennai Power Generation Limited 10, First Street, Gopalapuram Chennai 600 086 Justinpaul2@rediffmail.com Phone Nos. 28117004, 28117005
3 Site Where Proposed Plant Will Be Located
Tamil Nadu / Thiruvallur District. /Ponneri Taluk/ Kattupalli & Kalanji Villages
4 Survey of India Topo sheet No
66 C/7
5 Latitude & Longitude 13⁰19’8.55” to 13⁰20’06.48”North 80⁰19’36.30”- 80⁰20’04.33” East
6 Project Area Out of 175.08 acres of land 153.08 acres is proposed for the Main Plant and 22 acres of (Part of 22 acres falls in CRZ area Zone III) is proposed for Pipe Corridor Area.
7 Approach Road, Railway
The Proposed Site is well connected by road approach. Road connecting Kalanji village with North Chennai Thermal Power Station Road is passing East of the project area which is connected to Minjur. Rail: Existing broad-gauge railway line connecting Athipattu Railway Station to North Chennai Thermal Power Station of TNEB is about 8 km from site.
8 Distance from Nearest Town/City
Minjur, 10 kms (By Road) from Plant site.
9 Notified Archaeologically important places, Monuments
Nil within 10km radius
10 Local Places of Historical and Tourism Interest
Nil within 10km radius
11 Environmental sensitive areas, Protected areas as per Wildlife Protection Act, 1972 (Tiger reserve, Elephant reserve, Biospheres, National parks, Wildlife sanctuaries, community reserves and conservation reserves)
Nil within 10km radius. Pulicat Sanctuary – 12 km - North
12 Reserved / Protected Forests
Nil within 10km radius.
13 Capacity of the Project Under Consideration
1050 MW (Nominal)
14 Power Plant Size Two modules of CCPP (Combined Cycle Power Plant) each comprising 1 GTG of 359 MW capacity (Gas Turbine Generator) +1 HRSG (Heat Recovery Steam Generator) + 1 STG of 166 MW capacity (Steam
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
4
Turbine Generator) totaling 2 x 525 MW = 1050 MW shall be installed.
15 Source of Fuel
The Gas for proposed 1050 MW Gas Fired CCPP shall be supplied by Indian Oil Corporation Limited (IOCL) to site from their proposed Regassified Liquefied Natural Gas (RLNG) terminal at Ennore Port (6 Kms). CPGL has signed Heads of Agreement with IOCL for supply of Regassified Liquefied Natural Gas (RLNG)
15
Water:
Source of Water
Sea water from Bay of Bengal will be brought to the Plant through intake well construction of offshore booster pump house and intake pipeline.
Average Daily Quantity of Water Required
Approx. 48 MCM water per annum required (1,30,800 mm3/ day.)
Type of Cooling System Quantity and Expected Characteristic of Waste Water Discharged
Induced Draft Cooling Towers As per MoEF Guideline
16 Distance from Water Source The Sea water from Bay of Bengal will be brought to the Plant through construction of onshore sea water intake pump house and pipe line for a distance of 1.5 Km.
17 Air Emissions Main Stack. Bypass Stack
18 Transmission Corridors and Power Evacuation System
Power generated from the proposed Plant units will be evacuated through 400 KV outdoor switchyard which will be connected by 400 KV double circuit transmission line to the proposed pooling station of National Grid Substation of Power Grid Corporation Limited (PGCIL) located at Sriperumbudur).
19 Green Belt Proposals Trees for formation of green belt around 50-meter-wide around the plant site will be suitably chosen. Special landscaping shall be made around the technical buildings, main entrance of Power House and Administrative building. Plantation of green belt shall commence at appropriate time, so that green belt is sufficiently developed during the time of commissioning of the project.
20 Rehabilitation and Resettlement plan (R&R plan)
No Home oustees. However Private Land Acquisition is involved.
21 Project Schedule for Commissioning
Commissioning of 1st Module: 24 Months Commissioning of complete plant in combined cycle mode (Both Modules): 30 Months
22 Project schedule and Cost Estimates
The Project Cost is estimated at US $ 825.16 million (Rs. 53635.4 Million @ Rs 65 Per $ ),
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
5
CHAPTER – II
INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION
2.0 GENERAL:
M/s General Mediterranean Holding through its subsidiary M/s Chennai Power
Generation Limited (CPGL), is proposing to setup a 1050 MW Gas Based combined cycle
power plant in Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil
Nadu state. The complete project will be executed on EPC basis.
2.1 BACK GROUND OF THE PROJECT:
The location was selected by TNEB and the Project conceived by TNEB as a 1050
MW Gas based project was allotted through the MOU route and was signed with TNEB by
the Company in year 1998. The PPA was also negotiated with RLNG as Fuel and initialed
by TNEB.
Land is reserved vide GO No 47 dated 5-2-1998 for setting up of this power plant.
Availability of sufficient vacant land in the area, location selected by TNEB.
Environmental Clearance from MOEF&CC was obtained vide letter No. J
13011/11/96-1A11 (T) dated 19.3.97 using naphtha as fuel.
Various other clearances like NOC from Tamil Nadu Pollution Control Board, District
Forest Officer, Clearance from Airport Authority of India NAAI New Delhi, Clearance from
Ministry of Defence, Clearance from Fisheries department, NOC from Madras Metro-water
and Sewerage Board, In Principle Mega Power Project Status from Ministry of Power, etc.,
were obtained.
TIDCO dropped the proposal to establish the RLNG Terminal. Then the Company
had approached MOEF&CC to give amendment for change of fuel from Naphtha to
Imported coal. (Ltr no 27/12/2008).
MOEF&CC asked for revised EIA/EMP report vide letter no J-13011/11/96-IA-II (7)
dated 18/1/2008 for the proposed coal based thermal power-plant using imported coal.
Subsequent to submission of fresh application to get Environmental Clearance to
MOEF & CC for the project during January 2009, based on the EAC Meeting held during
12th and 13th March 2009 and again on 15th and 16th April 2009, TOR was issued for the
project in letter No. J-1301/11/96 IA II (T) dated 03.06.2009.
During the presentation by the CPGL to the Expert Committee, it was informed that
there is overlapping of lands between our project site and the North Chennai Power
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
6
Company Project site and CPGL requested the Committee to impress upon North Chennai
power company to spare 70 acres of land for the proposed project so that both the projects
can come up in the same area.
M/s North Chennai Power Company refused to spare the land and MOEF&CC gave
Environmental Clearance to North Chennai Power Company ignoring CPGL objections
and also imposed two special conditions in the Terms of Reference namely Clear
ownership of the lands belonging to the company free of all encumbrances and there
should not be any overlapping of the lands belonging to any other company and CPGL
have to get a certificate from Revenue Authorities for the above two conditions.
Even though CPGL had completed studies as per TOR, but could not proceed
further as Pollution Control Board, Tamil Nadu refused to conduct Public Hearing stating
that overlap of land issue was not resolved.
As the project could not proceed further and in order to get remedy CPGL
approached Hon’ble High Court, Madras in W/.P. No. 25545 of 2010 and 25080 of 2010
for cancellation of environmental clearance issued to M/s North Chennai Power Company.
In the counter filed by MOEF&CC., they had stated that they had no objection for the
two Power projects co-existing in the areas in question with maintenance of environmental
integrity of power project to come up vis-à-vis that of the base line environment. Further,
during the arguments in the Court M/s North Chennai Power Company submitted that they
have no objection for CPGL to acquire lands in the overlapping area and proceed with their
project.
Based on the assurance given by MOEF&CC in the Counter that both projects can
co-exist, the case pending in the High Court of Madras was disposed on 29.11.2011.
During the litigation in the Court, the validity of TOR given to the project on 3.06.2009 had
expired and CPGL gave a representation to MOEF&CC on 13.05 2015 for extension of
validity.
MOEF&CC in their letter NO. F.No. J/13011/11/1996/IAII(T) dated 18.06.2015 had
directed CPGL to apply for fresh TOR. Based on the above direction of MOEF&CC, CPGL
submitted the application for issue of fresh TOR.
During the 43rd Meeting of the Expert Appraisal Committee held on 18th September
2015, the project was taken up for discussion and the Committee suggested that Project
Proponents may amicably resolve with North Chennai Power Company regarding land
overlapping issue and approach for further consideration of TOR.
However, North Chennai Power Company had refused to spare any land and hence
CPGL had prepared alternative proposal avoiding North Chennai Power Company’s land.
Now as per the CEA guidelines CPGL had decided to install the power plant based
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
7
on Supercritical parameters. As the nearest supercritical unit size, available in India is 600
MW, Company decided to change the unit size from 2 x 515 MW to 2 x 660 MW
Supercritical plant based on imported coal. TOR was obtained for imported coal based
power plant for 2 X 660 MW Super critical power plant in letter number J-13012/16/2015-
1A-I(T) dated 10.06.2016 (Annexure 1).
However the company could not proceed further in the project as it could not tie up
for import of coal and tariff was also high
Hence, company has decided to change the fuel from coal based 2 x 660 MW
Supercritical plant to 1050MW gas based combined cycle plant due to availability of RLNG
from IOCL terminal coming up at Ennore which is about 6 km from selected plant site.
CPGL has signed heads of agreement with IOC for supply of RLNG. (Annexure 2).
Further GCGL also signed Gas transportation Agreement with IOCL for transport of RLNG
supply at the plant site.( Annexure – 3)
This Feasibility Report is prepared for the 1050 MW gas based combined cycle
power plant. It is proposed to adopt the latest technology on generation of power at most
economic parameters and competitive rates, meeting the statutory environmental norms
laid out by the Central /State Pollution Control authorities.
Now the company has submitted a fresh proposal for issue of fresh TOR for 1050
MW (2X525MW) RLNG based Combined cycle power plant.
2.2 NEED FOR THE PROJECT:
The utility electricity sector in India had an installed capacity of 314.64 GW as of 31st
January 2017. Renewable Power plants (including Hydro) constituted 29.94% of total
installed capacity and Non-Renewable Power Plants constituted the remaining 70.06%.
India became the world's third largest producer of electricity in the year 2013 with 4.8%
global share in electricity generation surpassing Japan and Russia. Of the 1.4 billion people
in the world who have no access to electricity, India accounts for over 300 million.
The International Energy Agency estimates India will add between 600 GW to 1,200
GW of additional new power generation capacity before 2050. This added new capacity is
equivalent to the 740 GW of total power generation capacity of European Union (EU-27) in
2005.Besides the existing installed capacity of 314.64 GW, GoI has encouraged private
sector participation in power generation. The total power generation in Southern Region is
82,008 MW consisting the states of Tamil Nadu, Andhra Pradesh, Telangana, Karnataka,
Kerala and union territory of Puducherry.
As per Planning Commission, the capacity addition of 88,537 MW has been planned
from conventional sources for the 12th Five Year Plan on an All India basis.
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
8
The long term projected demand for energy is only expected to grow, as per the 18th EPS
of CEA:
From the above table it may be noted that the southern region is having a Surplus of
3.3 % in respect of energy and there is a short fall of 10 % as on 2016-17 as projected by
CEA. In respect of all India bases, the energy is surplus and peak surplus of 2.6 %. Even
though All India Basis there is Surplus both in Energy and Peak demand, the surplus will be
wiped out. If the industrial development in India expand exponentially and India will become
an energy deficient Country. The projects in the pipeline both in All India basis and
Southern region may not meet the respected demand in the future. The non-conventional
energy sources such as wind energy and solar energy may not meet the energy and
demand projection.
Considering the above scenario of power requirement in Tamil Nadu and also on All
India basis and the persisting power shortage in Southern and Western region, the
proposed 1050 MW Thermal Power Project at Thiruvallur District in Tamil Nadu State is well
justified.
2.3 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE
PROJECT:
The requirement of skilled/unskilled persons will be met from nearby villages during
construction phase in addition to some regular employment during the operation of the plant.
The Project will also help in generation of significant indirect employment. This will have
positive socio-economic development in the region. There will be in general upliftment of
standard of living of the people in the region/ neighborhood.
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
9
CHAPTER – III
PROJECT DESCRIPTION
3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT
PROJECTS, IF ANY:
This project pertains to 1050 MW Power plant using RLNG as Fuel. The Gas for
proposed 1050 MW Gas fired CCPP shall be supplied by Indian Oil Corporation Limited
(IOCL) to the site from their proposed RLNG terminal at Ennore port (6 km). The RLNG
shall be brought from the proposed RLNG terminal of IOCL at Ennore Port up to the
proposed power plant through pipelines to be constructed by IOCL.
3.2 SITE DESCRIPTION
3.2.1 LOCATION & COMMUNICATION:
The 1050 MW Power plant is proposed to be located in Kattupalli and Kalanji village
at Ponneri Taluk, Thiruvallur district, Tamil Nadu state. This site is a part of Survey of India
Topo sheet No 66 C/7, lying at Latitude 13o19’8.55” to 13 o20’06.48”North and Longitude
80 o19’36.30”- 80 o20’04.33” East. Out of 175.08 acres of land 153.08 acres is proposed for
the Main Plant and 22 acres (Part of land falls in CRZ Zone III area) is proposed for Pipe
Corridor Area. The site is located 6 km north of Ennore Port, which is 22km north of
Chennai. Chennai Airport is about 40 Km from the site. Athipattu is the nearest railhead.
The area is approachable from the North Chennai Power Plant (NCTP) – Ennore Port road,
which branches off the Chennai – Manali – Minjur road near Vallur village.
The location plan is given in Figure No 3.1 and Map Showing Project Boundary with
Co-ordinates is shown in Figure 3.2
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
10
Figure No 3.1
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
11
Figure No 3.2
SATELLITE IMAGE SHOWING PROJECT BOUNDARY WITH CO ORDINATES
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
12
3.2.2 TOPOGRAPHY & DRAINAGE:
The project area is a typically plain coastal area with sandy soil and sparse
vegetation. The general slope of the area is from Northwest to Southeast. The site elevation
is up to 10m above mean sea level (AMSL). The Bay of Bengal is located at 1.5km – East
of the plant area and Buckingham canal is located at 100m in the West of the plant area.
Proposed site represents a typical sea shore based environment.
3.3 DETAILS OF ALTERNATIVE SITE CONSIDERED AND THE BASIS OF SELECTING
THE PROPOSED SITE, PARTICULARLY THE ENVIRONMENTAL
CONSIDERATIONS:
This location is selected by Tamil Nadu Electricity board for setting up the Power plant
and allotted to CPGL through MOU route. This land is also reserved vide GO No 47 dated
5-2-1998 for setting up of this power plant.
The proposed site has the following advantages:
Proximity to the well developed Ennore Port and L & T Kattupalli Port for
logistical advantages.
Availability of sufficient vacant land in the area.
Proximity to sea and availability of sea water as source of water without putting
constraints on the existing water system of the locality.
Proximity to load centre (i.e Chennai city)
Absence of any ecologically sensitive features in the 10km region.
The location has the advantages of good accessibility for reaching the site,
transport of heavy machinery, Easy availability of sea water by pipelines,
Evacuation of power is by 400 kV Transmission lines. The transmission lines will
be linked to PGCIL 400kV substation at Sriperumpudur.
Availability of RLNG from proposed IOCL terminal coming up at Ennore which is
about 6 km from selected plant site.
3.4 SIZE OR MAGNITUDE OF OPERATION
The proposed 1050 MW Power Plant will be established in the identified 175.08
acres of land which is selected excluding M/S ABAN LLOYD Power Plant site. Out of
175.08 acres of land 153.08 acres is proposed for the Main Plant and 22 acres is proposed
for Pipe Corridor Area (Part of land falls in CRZ Zone III). The area is divided into two
parts comprising main plant area and pipe line corridor area. The sea water pipe line from
the sea will pass through this proposed pipe line corridor and will be connected to the main
plant through buried pipe line in the intervening road side Government land after obtaining
necessary permission. The entire land is private lands.
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
13
3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS
3.5.1 PLANT SIZE AND ASSOCIATED ACTIVITIES:
The layout is based on the following assumptions:
• Two modules of CCPP (Combined Cycle Power Plant) each comprising 1 GTG of 359
MW capacity (Gas Turbine Generator) +1 HRSG (Heat Recovery Steam Generator) + 1
STG of 166 MW capacity (Steam Turbine Generator) totaling 2 x 525 MW = 1050 MW
shall be installed.
• The plant will be operated on RLNG (Regassified Liquified Natural Gas) only.
• Closed recirculation cooling water with cooling tower shall be adopted for STG
Condensers
• Horizontal type HRSG unit shall be installed.
• The layout has been developed on concept in which power block equipment will be
located in one block, housing the combined cycle module consisting of 2 nos Gas
Turbine and 2 nos Steam Turbine and associated auxiliaries. The block will be located in a
Single Turbine Building. The block will have one switchgear and central Control Room
building as annexe to the turbine building for operational advantage.
The Plot Plan has been developed based on 2 nos combined cycle modules. However,
depending upon the final selection of single shaft or combined cycle modules based on the
manufactures proven design, the plot plan shall be optimized.
• Tentative land requirement for the plant will be around 175.08 acres of land in that 153.08
acres is proposed for the Main Plant and 22 acres of (part of this area is in CRZ Zone III) is
proposed for Pipe Corridor Area
3.5.2 TECHNICAL PROFILES:
It is proposed to install 1050 MW Combined Cycle Power unit for this project. This
will also facilitate execution of these projects in a lesser time frame which will go a long way
in mitigating prevailing the power shortages in the country.
The per day requirement of 1050 MW combined Cycle plant shall be 4.8 Million
Metric Standard Cubic Meter Per Day (MMSCMD) considering Gross Calorific Value of gas
as 8000 kcal/SCM and plant heat rate of 1600 kcal/kwh. The daily gas consumption at 85%
PLF is estimated around 4.0 MMSCMD.
3.5.3 MAIN PLANT EQUIPMENT AND SYSTEMS
The Combined Cycle Power Plant (CCPP) will consist of two modules. Each Module
will have one (1) Gas Turbine Generator, one (1) HRSG and one (1) Steam Turbine
Generator.
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
14
3.5.4 Gas Turbine Generator (GTG):
The GTG set shall be heavy-duty industrial type, capable for fuel firing with
Re-gassified Liquefied Natural Gas (RLNG). GTG would have an ISO output of around 359
MW - in open cycle and plant output of around 1050MW (ISO) under combined cycle mode
of operation. The synchronous generator would be hydrogen cooled, 3000 rpm, 50 Hz set.
The GTG set would be self-contained as far as practicable requiring minimum interface with
other plant facilities.
The GTG would be suitable for indoor installation, and capable of continuous
operation at all loads under site conditions in simple cycle mode and combined cycle mode
at base load. The GTG would be provided with individual bypass stack and transition piece
section and a straight / tee piece upstream of the HRSG to enable operation in simple
cycle mode when HRSG is taken out for maintenance. GTG would be skid mounted to the
extent possible along with enclosure and all associated auxiliaries for ease of
transportation, handling and installation.
3.5.5 Gas Turbine Module
The gas turbine Module would consist of the turbine and compressor with
annular combustor installed in between. The main components of the unit will be –
• Rotor with turbine blades and compressor blades supported and guided in two/more
journal bearings and one thrust bearing.
• Compressor casing and turbine casing.
• Variable compressor inlet guide vanes.
• Compressor vanes installed in the compressor casing and the compressor vane carrier.
• Compressor diffuser.
• Turbine vane carrier and turbine vanes.
• Exhaust casing
• Compressor Bleed-off system
• Supports at the turbine end and the compressor end.
3.5.6 Heat Recovery Steam Generator (HRSG) and Auxiliaries
HRSG would be connected to GT exhaust gas duct with supports, transition piece
section, straight / Tee piece and expansion joints.
The HRSG would be of natural circulation type with dual/triple pressure stages with
steam parameters as per the optimum heat cycle design. The HRSG would be of unfired
heat recovery type designed to accept the maximum gas flow and exhaust gas temperature
from the gas turbine when operated under extreme site conditions.
The exhaust gas temperature at the HRSG exhaust would be designed to leave at a
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
15
temperature well above the acid dew point to prevent back end corrosion. The HRSG would
be designed to operate in sliding pressure mode with variation of HP steam pressure with
load being within the acceptable limits of steam turbine.
The HRSG is suitable for outdoor installation. The entire HRSG would be
constructed to form a gas-tight envelope to prevent gas leakage. Any penetration of the
enclosure required for piping, etc. would be designed to retain the pressure-tight integrity of
the enclosure. The HRSG would be designed to meet all the requirements of Indian Boiler
Regulations (IBR), ASME Section-VIII and ANSI B 31.1.
The steam drums would be of fusion welded construction, fabricated from carbon
steel plate and equipped with two (2) manholes, one at each end of the drums. Connections
are provided on the steam drums for steam outlet, feed inlet, riser and down comers,
venting, safety columns, chemical feed, sampling and nitrogen blanketing. The spray-tube
desuperheater would have all necessary internals, control and shut-off valves. The inlet
ductwork would be fabricated as shop assembled panels consisting of carbon steel outer
casing, insulation and internal liner. The ductwork from the HRSG to the stack would be
carbon steel provided with wire mesh stand-offs for personnel protection. The ductwork
would be properly stiffened, reinforced and complete with necessary doors and expansion
joints. The casing would include all necessary backstays, access doors, inspection ports,
etc., and would be designed to withstand a pressure equal to maximum turbine exhaust
static pressure.
3.5.7 Steam Turbine Generator and Auxiliaries
The steam turbine generator unit would be located in the turbine building and would
operate with steam from HRSG in a module. The turbine-generator unit would be a 3000
rpm, double casing, condensing type with a maximum continuous rating (TMCR) to suit the
guarantee Module Output.
Steam Turbine Casing
Separate casing for different sections of turbine or alternatively combine HP/ IP and LP
casing are acceptable provided they meet the proveness of major equipment as specified.
The casings shall be designed to withstand the maximum pressure and temperature to
which they are likely to be subjected. The casings shall be symmetrical in design to
minimise the effects of thermal stresses. The casings shall be keyed to permit free radial
and longitudinal expansion while maintaining the eccentricity of shaft and the casing. LP
casing shall be provided with pressure relief bursting diaphragms for protection against
increased pressure and a self-contained exhaust hood. Spray system to protect against
excessive temperature under different conditions of operation.
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
16
The HP outer casing consists of an upper and a lower half fabricated from cast steel. The
pre-tensioned bolts in the horizontal flange hold the casing halves together, so that no
gaskets would be required to prevent the steam leakage.
The blade carriers would be made of cast steel having material properties suitable for the
steam temperature and pressure conditions. These are split into two halves at the
horizontal joint and bolted together with hydraulic pre-stressed elongation bolts. The gland
seal casings are also fitted within the pressure casings. All condensate collection points
would be connected to the drainage branches to remove the drains.
Low Pressure (LP) Casing
Exhaust steam from HP casing will enter a single flow LP turbine having axial
exhaust. The main components of the low-pressure turbine casing consist of outer casing,
the LP casing, rotor and the shaft sealing.
Steam would be led from the vertical steam admission line via the steam inlet into
the inner casing. The inner casing inlet section together with the radially arranged
stationary blade row would ensure proper flow of steam to the blading’s.
Gland Seals
The shaft seals prevent air ingress into the turbine and steam leakage into the
ambient atmosphere. The design of the sealing segments would be non-contacting type
during normal operation. The shaft seals consist of a lower and an upper part bolted
together. Steam from this system together with air leaking from the outside is led to the
gland steam condenser.
3.5.8 Environmental and Efficiency Considerations
The Power Plant shall be designed for optimum efficiency, availability and reliability
using advanced class Gas turbine of state-of-art technology. Gas Turbine with high open
and combined cycle efficiencies and having proven performance record shall be installed.
Gas Turbine shall be provided with low NOx fuel burners to make the power station
environmentally compliant to local norms.
Triple pressure Heat Recovery Steam Generator with optimum steam parameters
shall be selected to maximise the waste heat utilisation from gas turbine exhaust flue gas.
Steam Turbine Generator from reputed manufacturers will be installed to optimise
the combined cycle efficiency of the module. Separate HP/LP by-pass system for HRSG
capable to by-pass MCR flow of steam from HRSG is envisaged for quick and independent
start-up of HRSG while the steam turbine is in partial load.
Closed cycle circulating cooling water with cooling towers for STG condensers will
be adopted to improve the condenser vacuum and thereby maximise the LP turbine output.
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
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3.5.9 PLANT LAYOUT:
The layout of the main plant along with all the auxiliary systems for 1050 MW
units is shown in Plant layout Figure No 3.3.
The conceptual plant layout has been developed considering the proposed location of
the plant. The layout is based on the following assumptions:
Two nos modules of CCPP each comprising 1 GTG +1 HRSG + 1 STG shall be
installed.
The plant will be operated on RLNG only.
Closed recirculation cooling water with cooling tower shall be adopted for STG
Condensers
Horizontal type HRSG unit shall be installed.
The layout has been developed on concept in which power block equipment will be
located in one block, housing the combined cycle module consisting of 2 nos Gas
Turbine and 2 nos Steam Turbine and associated auxiliaries. The block will be located
in a Single Turbine Building. The block will have one switchgear and central Control
Room building as annexe to the turbine building for operational advantage.
Steam Turbine will be located near the centre of the block keeping adequate
maintenance space around. Condensers will be located on Turbine Hall floor with
C.W. pipe entry and inlet at one side and tube cleaning and removal provision on
other. Condenser hot well will be located in basement.
GTG Inlet air filter is proposed to be located on top of the electric generator in order to
reduce inlet air flow path to GTG. GT Generator will be located in the electrical bay.
Heat cycle equipment for the module comprising de-aerator, BFP’s (Boiler Feed
Pumps) will be located near the HRSG. Balance of Plant facilities (other than heat
cycle equipment) will be located as reflected in the plot plan.
All the outdoor and yard piping shall be taken on pipe racks, except for the fire hydrant
system, which shall be buried. Small local stretches of pipes may be taken in trenches
or just above ground, should the layout warrant at the time of execution. Interplant
cabling shall also be taken on the pipe rack wherever possible.
The Plot Plan has been developed based on 2 nos multi-shift combined cycle
modules. However, depending upon the final selection of single shaft or multi-shift
combined cycle modules based on the manufactures proven design, the plot plan
shall be optimized.
Tentative land requirement for the plant will be around 175.08 acres including green
belt and pipeline corridor.
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk,
Thiruvallur district, Tamil Nadu
18
PLOT PLAN Figure No 3.3
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
19
3.5.10 PLANT WATER SYSTEM
The total water requirement for the power plant is 5450 m³/hr (1,30,800
m³/day) for 1050MW plant. The total annual water requirement will be approximately 48
MCM. The entire water requirement will be met from Sea water.
Sea water after screening is proposed to be used for cooling of steam
turbine condensers, services other than condenser cooling requiring de-mineralised
water will be met by processing sea water. Sea water intake pump house with pipelines
is proposed to deliver total cooling and consumptive water requirement of the power
plant to the pretreatment plant and makeup to the cooling tower basins located in the
plant area. The fire water pumps will be located in a pump house adjacent to the clarified
water reservoir.
The water treatment system comprises of Water Pre-treatment Plant, RO
Plant (Desalination Plant), DM Plant, Electro-chlorination Plant, Condensate Polishing
Plant, CW Treatment Plant.
Consumptive water will primarily consist of de-mineralised (DM) water for
HRSG feed water make-up and NOx control in the GTG (if required), make-up water to
the air-conditioning and ventilation systems, potable water and miscellaneous services
such as plant washing, etc. DM water is envisaged to meet feed cycle make up and make
up requirement of auxiliaries.
Adequate storage of potable water as well as DM water will be provided
inside the CCPP premises. The individual storage capacities will be based on the buffer
requirement at the relevant stages of the process to ensure uninterrupted operation of the
plant. Firewater storage tank sizing will meet the TAC/ NFPA Regulations which will be
met from the clarified water reservoir.
3.5.11 Cooling Water Systems
Sea Water Intake System
Water required for the power station is drawn from the sea which is about
1.5 KM away from the Main plant. Three (3) vertical turbine pumps (2 working + 1
standby) each of suitable capacity with required head will be installed in the raw water
intake pump house for pumping raw water from sea to plant water treatment system and
cooling tower make-up. Suitable gate, trash rack & travelling water screen will be
provided for the intake pump chamber.
Condenser Cooling water system
Closed cycle circulating water system for the condenser is adopted with
Induced draft cooling tower. The makeup cooling water will be drawn from the clarified
water storage tank. The CW system will consist of basin, circulating water (CW) pumps,
pump discharge and condenser inlet/ outlet piping, butterfly valves, expansion joints,
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
20
debris filters, online tube cleaning system of the Condenser etc. To supply the cooling
water requirement of the condenser, 3x50% (2W + 1S) capacity vertical mixed flow
pumps of about 29,120m3/hr capacity each are proposed. The pumps will be located
indoor in the CW Pump House. Pumps shall be self-lubricated type. One EOT crane will
be installed for erection / maintenance of the C. W. pump sets.
The pump discharge lines and condenser inlet / outlet pipes will be of
carbon steel with internal cement mortar lining and external gunniting/other protective
coating. For the purposes of isolation and control, motor-operated / hydraulically
operated/ butterfly valves are proposed on the CW pump discharge lines, and condenser
inlet and outlet pipes. Expansion joints will be provided on the CW pump discharge lines
and condenser inlet and outlet lines to take care of misalignment and thermal expansion
of these pipelines and condenser as well as to facilitate dismantling of the butterfly
valves. Hot water from the condenser will be discharged in concrete conduits which will
lead the water into a hot water distribution header of the cooling tower.
Auxiliary Cooling water system
GTG, STG and HRSG auxiliaries / coolers associated with HP / LP feed
pumps, condensate pumps, station and instrument air compressors, sample coolers etc.
will be provided with a closed cooling system using passivated DM water. The DM water,
in turn, will be cooled in 2x100% plate type heat exchangers using auxiliary cooling water
drawn through three (3) x 50% capacity ACW pumps from CW inlet piping to the
condenser. Two (2 x 100%) closed cooling water (CCW) pumps will circulate the DM
water through the various auxiliaries and the heat exchangers. Hot water from these heat
exchangers will lead to the hot water conduit of the main CW system and will return to
the cooling tower.
3.5.12 Cooling Tower
The cooling tower will be designed for continuous operation. The hot water
distribution system will be designed to ensure equal distribution of heat load and flow all
over the fill area. Wood/timber will not be used as material of construction in any part of
the cooling tower.
It is proposed to install two (2) Induced draft cooling towers, one for each
unit, of capacity 32,000 m3/hr. The cooling water will be collected in a RCC basin. The
cooling tower will be designed for an approach of 5˚C. The design wet bulb temperature
is considered as 27˚C. The design hot and cold-water temperatures of the cooling towers
will be 39˚C and 32˚C respectively. Tower construction will be of RCC with PVC splash
type fill. The total CW flow from three cooling tower basins is proposed to be conveyed
by gravity to the common CW fore bay and CW pump chambers through RC rectangular
open channels. The channels will be designed to accommodate maximum level
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
21
fluctuations expected under transient flow conditions.
The fore bay will be designed to ensure equal distribution of flow to the
CW pumps as well as to limit the entrance velocity at the CW pump chambers. The top
level of the fore bay walls will be fixed on the basis of maximum upsurge expected in the
fore bay, when all the CW pumps trip under normal water level condition. The sump level
of the pumps will be fixed so as to ensure adequate submergence to the CW pumps.
3.5.13 Water Treatment System
The water treatment system comprises of Water Pre-treatment Plant, RO
Plant (Desalination Plant), DM Plant, Electro-chlorination Plant, Condensate Polishing
Plant, CW Treatment Plant as described below.
3.5.14 Pre Treatment Plant
Raw water shall be pumped from sea water intake pump house to aerator
(one number). From aerator, water shall flow to stilling chamber (one number) and from
stilling chamber to inlet chamber. Flow-measuring instrument (Parshall flume) shall be
installed for measuring the flow between stilling chamber and inlet channel.
Simultaneously raw sea water through a branch off pipeline will be supplied to the CW
makeup system. Bypass channel shall be provided for bypassing the clarifier of
respective system. Chemical dosing shall be done in the clarifier. Chlorine shall be dosed
in stilling chamber.
From clarifier System, water shall flow to clarified water storage tank. This
water shall be used as influent to Gravity filters. Two (2) numbers of air blowers shall be
provided for air scouring of gravity filters. Sludge from the clarifier shall be discharged
into a sludge sump, from where it shall be pumped by means of 2 x 100% capacity
sludge disposal pumps to sludge thickeners for disposal of sludge cakes by trucks.
Gravity filters shall be backwashed by filtered water. Filtered water shall be
stored in an overhead tank to be used as potable water through pumps. The filtered
water will be fed to Reverse Osmosis (RO) Plant comprising RO stage – 1 and RO stage
– 2. The desalinated water of RO stage -1 will be used for fire protection system and
service water system and potable water after hypo chlorination treatment. 2nd stage
desalination water will be used for potable water after hypochlorisation and as influent for
the DM plant.
3.5.15 Demineralization (DM) Plant
The DM plant will be designed for a total productive output of about 60 m3/
hr of DM water based on 3% makeup for HRSG plus steam injection for NOx control in
the GTG if applicable. The DM plant will have three stream each of 30 𝑚𝑚3/ hr capacity
(2W+1S) streams with two working and one standby each consisting of three (3) Nos
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
22
activated carbon filters, three (3) Nos cation units (SAC + WAC (depending upon water
quality)), Three (3) Nos anion units (SBA + WBA (depending upon water quality)), and
Three (3) Nos mixed bed units. Three (3) Nos Degassers comprising 3 nos Degasser
Towers and degassed Water storage tank with all accessories. The use of ultrafiltration
process will be considered if necessary depending upon the Sea water analysis to
achieve desired quality of DM water. The DM water from DM plant will be stored in two
numbers of DM water tanks capable to meet 7 days’ plant requirement at full load. The
operation of the plant will be automatic based on programmable logic control (PLC) and
data-link with the plant DCS.
3.5.16 Electro Chlorination Plant
Electro chlorination plant is envisaged to avoid growth of algae and bacteria in
the sea water intake at the seashore and CW system. This is accomplished by sodium
hypo chlorination dosing in sea water intake and CW fore bay. This will also be used in
pre-treatment area for potable water. The chlorination system shall comprise 2x100%
(1W+1S). Hypochlorite generator with 2x100% booster pumps associated transformer
rectifiers etc. for generation of sodium hypochlorite 2x100% dosing pumps shall
employed for each dosing point.
3.5.17 Service & Potable Water System
The service water system supplies water required for the miscellaneous water
requirements such as for plant washing, toilets, gardening etc. The service water
requirement of the plant will be met by two (1 working + 1standby) service water pumps
each of suitable capacity which will be intermittently operated to pump the water to 2 nos
overhead tanks located at a point 30 m elevation. Water will be distributed through
various small overhead tanks located on top of plant buildings.
This system caters to the drinking water requirements of the plant personnel,
water to the wash basins in toilets and canteen. The potable water requirement of the
plant will be met by two nos (1 working + 1standby) potable water pumps. Plant potable
water pumps take suction from the RO-stage 1 permeate storage tank filtration unit of
DM plant and supply to 2 nos overhead tanks located at 30m elevation for further
distribution through individual overhead tanks to various consumer points by gravity.
3.5.18 OTHER SYSTEMS:
In addition to above facilities, other systems such as compressed air, air
conditioning ventilation, communication, control and instrumentation, etc. will be provided
commensurate with statutory requirements, with latest modern technological features
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
23
3.5.19 FIRE PROTECTION SYSTEM:
Fire protection system is envisaged as common facility for both Modules of
the CCPP. The design of the system shall be as per TAC/ NFPA and other applicable
standards for equipment design.
The following systems are proposed to protect the plant:
Hydrant system for exterior as well as internal protection of various buildings /
areas of the plant
High velocity water spray (HVWS) system for the protection of generator
transformers, turbine oil tanks, lube oil system equipment, unit auxiliary
transformers
Medium velocity water spray system for cable galleries etc.
Trolley mounted CO2 cylinders for control room protection or flooding system
using Halon – substitutes
Portable extinguishers and hand appliances for extinguishing small fires in
different areas of the plant.
Carbon dioxide flooding system for GTG.
Two independent motor-driven pumps each of 410 m3/hr capacities at 88 m head
have been envisaged for the proposed hydrant system. One motor-driven pump of
similar rating will be provided for the spray water systems. Two standby pumps of
410 m3/hr capacity driven by diesel engine will be provided. In addition, two
motors driven jockey pumps each of 30 m3/hr capacities will be provided to keep
the fire water mains at the desired pressure.
The fire water pumps will be located in the fire water pump house and take suction
from the RO stage-1 permeate storage tank. Starting of the pumps is automatic
and stopping of the pumps is manual except the jockey pumps which stop
automatically when the mains pressure is restored.
Hydrant System
Adequate number of fire hydrants will be provided at various locations in and
around the buildings and other plant areas. The hydrants will be provided on a
network of hydrant mains drawing water from the hydrant pump, which will start
automatically due to drop in pressure in the event of opening of the hydrant
valves.
Transformers and Turbine Lube Oil Tank Protection
Automatic high velocity water spray (HVWS) system is proposed for the
generator, transformer, station and unit auxiliary transformer. The system will
consist of a number of high velocity projectors mounted on a pipe network around
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
24
the transformers. Water supply from main to this pipe network will be through
deluge valves. Quartzoid bulb detectors mounted around the transformers will get
fused in the event of a fire at the rated (high) temperature which will cause the
deluge valve to open and the resulting pressure drop in the water mains will be
sensed by a pressure switch through which the spray water pump will be started
automatically and the spray of water will take place. Provision will also be made
for remote manual operation. Remote manual HVWS system will be provided for
turbine lube oil tanks.
Cable Vaults Protection
Medium velocity water spray (MVWS) protection is proposed for the cable
galleries.
The system is automatic with facilities for remote manual operation. To limit the
demand of water and reduce water damage, the cable galleries are divided into a
number of zones and with the help of a suitable alarm and detection system and
control logic, only the zone on fire and two adjacent zones on either side would be
sprayed with water.
Gas Turbine Protection
Gas turbine Generator is provided with automatic carbon dioxide (CO2) flooding
type of protection and this system is supplied along with the GTG package.
Control room protection is by means of large capacity (22.5 kg/45 kg) trolley
mounted CO2 extinguishers. Flooding with a suitable Halon substitute can also be
employed in lieu of CO2 extinguishers.
Portable Extinguishers
Adequate number and suitable type of hand appliances and trolley mounted fire
extinguishers will be provided in the various plant buildings for quenching small
fires in their incipient stage.
3.5.20 COMPRESSED AIR SYSTEM
Compressed air requirement is envisaged mainly for the following services:
For various control systems and power actuators – instrument quality, dry
compressed air at 7-8 kg/cm2 pressure.
For pulse cleaning of gas turbine inlet air filters – instrument quality, dry
compressed air at 7-8 kg/cm2 pressure.
For miscellaneous plant services – ordinary plant quality air at 7-8 kg/cm2
pressure.
For the complete plant, an integrated service and instrument air system is
proposed with a priority valve, which will cut the plant service air supply in case of
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
25
instrument air shortage thus giving the priority to the instrument air. The compressed air
requirement shall be met by 2x100% Instrument Air Compressor and 2x100% Service Air
Compressor for the complete plant compressor shall be oil free tube of suitable capacity
provided along with air receivers and other accessories and Two (2) x 100% capacity
heatless purge type air dryers for supply of instrument quality of air to control and
instrumentation (C&I) system. Normally, pulse cleaning air, if required for inlet filter will be
provided from GT compressor. Alternatively, it can be supplied from air supply system.
Capacity of the air compressors shall be guided by the air requirement of the EPC
contractor based on equipment selection.
3.5.21 AIR CONDITIONING SYSTEM
Properly designed ventilation and air-conditioning systems will be provided to
cater various areas of the plant. The system will be designed in line with the guidelines
and recommendations of ASHRAE and will follow acceptable industry practices.
Wherever practicable, relevant Indian Standards or other international standards will be
adhered to.
3.5.22 VENTILATION SYSTEM
All ventilation areas will be designed such that the difference between indoor and
outdoor temperatures will be within permissible limits. Pressurized ventilation system will
be provided for the turbine building and switchgear & MCC rooms of various plant
buildings CW pump house, etc. The system for each of the areas will be provided with
fresh filtered air supply arrangement consisting of bird screen louvers, filters and supply
air fan complete with ducts. Location and sizing of duct outlets will be done in accordance
with the guidelines of ASHRAE for effective air distribution.
The system will be designed such that positive pressure is maintained inside the
room to avoid ingress of dust, etc. Ventilated air will be exhausted through roof
extractors/back draft dampers.
3.5.23 ENVIRONMENTAL PROTECTION FEATURES OF THE PROPOSED PLANT:
The following environmental management measures are inbuilt in the plant design
itself: which will help in reducing emissions and effluents:
The Power Plant will be designed for optimum efficiency, availability and reliability
using advanced class Gas turbine of state-of-art technology. Gas Turbine with
high open and combined cycle efficiencies and having proven performance record
shall be installed. Gas Turbine shall be provided with low NOx fuel burners to
make the power station environmentally compliant to local norms.
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
26
Triple pressure Heat Recovery Steam Generator with optimum steam parameters
shall be selected to maximize the waste heat utilization from gas turbine exhaust
flue gas.
Steam Turbine Generator from reputed manufacturers will be installed to optimise
the combined cycle efficiency of the module. Separate HP/LP by-pass system for
HRSG capable to by-pass MCR flow of steam from HRSG is envisaged for quick
and independent start-up of HRSG while the steam turbine is in partial load.
Closed cycle circulating cooling water with cooling towers for STG condensers will
be adopted to improve the condenser vacuum and thereby maximize the LP
turbine output.
3.6 FUEL REQUIREMENT:
Regassified Liquefied Natural Gas (RLNG) will be used as fuel. The Gas for
proposed 1050 MW Gas fired CCPP shall be supplied by Indian Oil Corporation Limited
(IOCL) to the site from their proposed RLNG terminal at Ennore port (6 km). The RLNG
shall be brought from the proposed RLNG terminal of IOCL at Ennore Port up to the
proposed power plant through pipelines to be constructed by IOCL.
The per day requirement of 1050 MW combined Cycle plant shall be 4.8 Million
Metric Standard Cubic Meter Per Day (MMSCMD) considering Gross Calorific Value of
gas as 8000 kcal/SCM and plant heat rate of 1600 kcal/kw hr. The daily gas
consumption at 85% PLF is estimated around 4.0 MMSCMD.
3.7 RESOURCE OPTIMIZATION/RECYCLING:
Optimization/Recycling and Reuse is planned in the proposed plant.
3.8 OTHER SOURCES LIKE WATER, POWER/ENERGY REQUIREMENT:
3.8.1 WATER REQUIREMENT:
Water will be required for condenser cooling, cycle make-up and other
consumptive water requirements after doing appropriate treatment. The total estimated
make up sea water requirement for the cooling water system and other consumptive
requirement is 5,450 m³/hr (1, 30, 800 m³/day) for 1050MW plant. The total annual water
requirement will be approximately 48 MCM. The Sea water from Bay of Bengal will be
brought to the Plant through construction of onshore intake pump house and pipe line.
The discharge water pipeline shall be returned to Sea. The water balance diagram is
shown in Figure No 3.4. Water requirement during the construction period will be meet
from Ground Water or other sources
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
27
3.8.2 POWER REQUIREMENT:
The power required for operating the power plant will be met from the Power
generated in the plant itself. The auxiliary power consumption will be within the range of 3
to 3.5% of the Power plant capacity. During the construction period, temporary supply of
power from TNEB at 11 KV and 33 KV power lines to meet power requirement.
3.9. QUANTITY OF WASTE GENERATED (LIQUID & SOLID) AND SCHEME OF
THEIR MANAGEMENT/DISPOSAL:
This being the gas based power plant there will not be any ash disposal. Liquid
Waste will be mainly from the effluents generated from the combined cycle power plant
would be from Cooling tower blow down,DM plant Regeneration plant , Heat recovery
steam generator drum blow down, Sanitary waste, Water from Oil water Separator.
About 4127 m3 / hr of waste is expected to be generated from this plant of which
4045 m3/hr will be from Cooling tower blow down, RO reject and 82 m3/hr is expected to
be from other sources.
Its break up is as follows:
Cooling Tower Blow Down discharge back to sea = 3380 m3/ hr.
RO-1 & RO-2 (DM Plant) process waste discharge back to sea = 665 m3/ hr.
SubTotal = 4045 m3/ hr.
Others:
Heat Recovery Steam Generator Drum Blow Down to CMB = 20 m3/ hr.
Sanitary/ Industrial Waste to CMB = 55 m3/ hr.
Oil/ Water Separator to CMB = 2 m3/ hr.
Neutralization Pit in DM Plant = 5 m3/ hr.
SubTotal = 82 m3/ hr.
The cooling tower blow down and RO rejects (totaling) 4045 m3/hr will be
discharged back in to the sea based on Stimulation Modelling study and in compliance
with regulatory norms in order to keep temperature differential between blow down and
receiving sea water within permissible limits and will be disposed deep in to the sea
through diffuser ports to achieve optimum mixing to attain requisite temperature and
salinity
Other waste Water Collected ( 82m3/hr) will be collected in the Central Monitoring
Basin (CMB) and after treatment shall be utilized for Plantation or other industrial use..
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk,
Thiruvallur district, Tamil Nadu
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Water Balance Diagram Figure No 3.4.
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
29
3.10 SCHEMATIC REPRESENTATION OF THE FEASIBILITY DRAWING WHICH GIVE INFORMATION OF EIA PURPOSE:
The basic process involved in the EIA projects for grant of Environmental
Clearance is given below:
Submission of PFR, Form I, Summary and ToR in
MoEF & CC, New Delhi
Presentation MoEF & CC for grant of ToR
Submission of Draft EIA/EMP Report to TNPCB
Conducting Public Hearing
Preparation of Final EIA/EMP Report Public Hearing
Details
Presentation to MoEF & CC Committees for grant of
EC
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
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INDEX PLAN Figure No – 3.5
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
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CHAPTER – IV
SITE ANALYSIS
4.1 CONNECTIVITY:
The Proposed Site is well connected by road approach. Road connecting Kalanji
village with North Chennai Thermal Power Station Road is passing East of the project
area which is connected to Minjur.
4.2 LAND FORM, LAND USE AND LAND OWNERSHIP:
Land is reserved vide GO No. 47 dated 5.2.98 by Government of Tamil Nadu for setting
up the power plant. Land is mostly sea side waste lands only. No agricultural land is
involved. However, lots of industrial activities are happening in the area and there is good
demand for the land. 56 Acres of land have already been acquired by CPGL, out of the
total land requirement of 175.08 Acres of land. The balance land will be acquired from
private land owners.
4.3 TOPOGRAPHY (ALONG WITH MAP):
The project area is a typically plain coastal area with general slope of the area is
from Northwest to Southeast. The site elevation is up to 10m above mean sea level
(AMSL).. The ground level will be maintained above high flood level of the area.
4.4 EXISTING LAND USE PATTERN (AGRICULTURE, NON-AGRICULTURE, FOREST,
WATER BODIES (INCLUDING AREA UNDER CRZ), SHORTEST DISTANCES FROM
THE PERIPHERY OF THE PROJECT TO PERIPHERY OF THE FORESTS, NATIONAL
PARK, WILD LIFE SANCTUARY, ECO SENSITIVE AREAS, WATER BODIES
(DISTANCE FROM THE HFL OF THE RIVER), CRZ. IN CASE OF NOTIFIED
INDUSTRIAL AREA, A COPY OF THE GAZETTE NOTIFICATION SHOULD BE GIVEN:
There are no declared biospheres, wild life sanctuaries, or tiger sanctuary or migrating
corridor or Coastal zone in the core zone and 10 km buffer zone. Pulicat Sanctuary – 12
km, North.
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
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In the 10km buffer zone, the following features are observed:
S.No Particulars Details
1 Nearest villages Kattupalli, Kalanji, etc
2 Nearest Major water bodies Buckingham canal – 100 m West
Bay of Bengal - 1.5 Km East from the Main
Power Plant
3 Notified Archaeologically important
places, Monuments
Nil within 10km radius
4 Local Places of Historical and
Tourism Interest
Nil within 10km radius
5 Environmental sensitive areas,
Protected areas as per Wildlife
Protection Act, 1972 (Tiger reserve,
Elephant reserve, Biospheres,
National parks, Wildlife sanctuaries,
community reserves and conservation
reserves)
Pulicat Sanctuary – 12km - North
6 Reserved / Protected Forests Nil within 10km radius
7 Defence Installations Nil within 10km radius
8 Seismic Zone Zone – II (Least Active)
9 Other Industries in the area North Chennai TPS, Vallur TPS, Ennore port,
L & T ship yard, L & T Port, Chettinad Coal
Terminal, Chennai Metro Desalination plant,
etc
Index plan showing the features within 10km radius is given as Figure No – 3.5
4.5 EXISTING INFRASTRUCTURE:
Better Infrastructure are avalable in the area. All necessarry infrastructures for this
plant will be created.
4.6 SOIL CLASSIFICATION:
The project area is a typically plain coastal area with sandy soil and sparse
vegetation.
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
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4.7 CLIMATIC DATA FROM SECONDARY SOURCES:
Based on the meteorological data, the design ambient dry bulb temperature has
been considered as 28 ºC, RH of 79%, and cooling water temperature of 34 ºC. Climate
of the region can be considered as subtropical without any extreme variation in
temperature profile. Average annual rainfall is 1330 mm, out of which the maximum
precipitation is during the North-East monsoon period of October to December, when
nearly 70% of the annual rainfall occurs. Maximum rainfall invariably is in the month of
November and minimum in the month of March. The hottest months of the year are May
to July, when the monthly average temperature ranges from 35ºC to 37ºC. Individual day
maximum temperature during the summer months may go up to 40ºC.
4.8 SOCIAL INFRASTRUCTURE AVAILABLE:
Good social infrastructure facilities are available in nearby Minjur Town which is
located 8.2 KM from power plant site and Chennai city is located about 25 KM from the
Site
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
34
CHAPTER – V
PLANNING BRIEF
5.1 PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES, TRANSPORTATION ETC) TOWN AND COUNTRY PLANNING/ DEVELOPMENT AUTHORITY CLASSIFICATION:
The site has been chosen considering the availability of land, proximity of water,
evacuation of power through PGCIL, feasibility of gas linkage from upcoming RLNG
terminal of IOCL at Ennore Port and availability of other infrastructure facilities in the
vicinity of proposed plant.
5.2 POPULATION PROJECTIONS: The populations in nearby villages are given below: NAME DISTANCE AND DIRECTION POPULATION
(AS PER CENSUS OF INDIA 2011)
Kalanji 0.1 KM – N 260
Kattupalli 2.0 KM – SW 1911
Karungali 3.5 KM – N 203
Minjur Town 8.2 KM – SW 28337
5.3 LAND USE PLANNING (BREAKUP ALONG WITH GREENBELT ETC):
The details of land use planning for the project have been furnished in chapter -
III. Landscaping of the entire plant area shall be done. Trees for formation of green belt
around 50-meter-wide around the plant site will be suitably chosen. Special landscaping
shall be made around the technical buildings, main entrance of Power House and
Administrative building. Plantation of green belt shall commence at appropriate time, so
that green belt is sufficiently developed during the time of commissioning of the project.
5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL): Power evacuation from the plant will be through double circuit 400 KV lines for a distance
of 32 KM to link with power grid substation at Sriperumbudur.
RLNG pipe line from IOCL LNG terminal at Ennore port to the plant site for a distance of
6.0 Km will be laid by IOCL.
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
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CHAPTER – VI
PROPOSED INFRASTRUCTURE
6.1 Industrial area: Lots of industrial activities are happening in the area and there is good demand
for the land.
6.2 Residential area (Non-Processing area):
No residential area is proposed within the Power Plant Area.
6.3 Green belt:
Landscaping of the entire plant area shall be done. Trees for formation of green
belt around 50-meter-wide around the plant site will be suitably chosen. Special and
scaping shall be made around the technical buildings, main entrance of Power House
and Administrative building. Plantation of green belt shall commence at appropriate time,
so that green belt is sufficiently developed during the time of commissioning of the project.
About 53 Acres of land is proposed for green belt in the power plant area.
6.4 Social Infrastructure:
The availability of land, proximity of water, evacuation of power through PGCIL,
feasibility of gas linkage from upcoming RLNG terminal of IOCL at Ennore Port and
availability of other infrastructure facilities in the vicinity of proposed plant.
6.6 Drinking water Management (Source & Supply of water):
Already given in Chapter 3, para number 3.5.17
6.7 Sewerage sytem: A permanent sewage treatment plant will be provided to cater to the sewage
discharge of the plant area. The treatment plant shall be so designed as to meet the
requirements of applicable local bye-laws / pollution standards and conditions as
stipulated by the State / Central agencies while according environmental clearance to the
project.
6.8 Industrial Waste Management:
Already given in Chapter 3, para number 3.9
6.9 Solid waste Management:
Already given in Chapter 3, para number 3.9
6.10 Power Requirement & Supply / Source: The power required for operating the power plant will be met from the Power
generated in the plant itself. The auxiliary power consumption will be within the range of 3
to 3.5% of the plant capacity.
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
36
CHAPTER – VII
REHABILITATION AND RESETTLEMENT PLAN (R&R PLAN)
7.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT OUSTEES, LAND OUSTEES AND LANDLESS LABORERS (A BRIEF OUTLINE TO BE GIVEN) The plant is proposed to be located in a total extent of 175.08 acres of land in that
153.08 acres is proposed for the Main Plant and 22 acres of (Part of land in CRZ area III)
is proposed for Pipe Corridor Area. Out of total plant area of 175.08 acres of land, in that
56 acres of land are owned by proponent.
The entire lease area is a non-forest private land without any habitation. As such
no home oustees are involved.
Land is mostly sea side waste lands only. No agricultural land is involved. However,
since lot of industrial activities are happening in the area, there is good demand & market
for the land.
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
37
CHAPTER – VIII
PROJECT SCHEDULE AND COST ESTIMATES
8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION (TIME SCHEDULE FOR THE PROJECT TO BE GIVEN)
The Developer has conducted Plant Location studies, had initial discussions with
equipment manufacturers, suppliers, vendors, contractors, power purchasers and
industry professionals. The supply, erection, testing and commissioning will be contracted
out to the EPC Contractor.
The stages of implementation include:
Pre-construction phase
Construction Phase
Operation & Maintenance Phase
Project and Site Management
PROJECT SCHEDULE:
The construction period has been estimated as 30 months from the zero date
reckoned as the date of financial closure and Notice to Proceed (NTP):
Pre-construction and approvals – 10 months prior to NTP
Notice to Proceed – 0 month
Commissioning of 1st Module – 24 Months
Commissioning of complete plant in combined cycle mode (Both Modules) – 30
Months
8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE PROJECT:
The Project Cost is estimated at US $ 825.16 million (Rs. 53635.4 Million @ Rs 65
Per $),, indicating a per MW all-in cost of about US $0.83 million for a 1050 MW Plant.
The Project is proposed to be financed at a debt to equity ratio of 70:30, corresponding to
US $ 247.55 million in equity and US $ 577.61 million in debt
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
38
CHAPTER – IX
ANALYSIS OF PROPOSAL
(FINAL RECOMMENDATIONS)
9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE LOCAL PEOPLE INCLUDING TRIBAL POPULATION, IF ANY, IN THE AREA: Social and Financial benefits:
The requirement of skilled/unskilled persons will be met from nearby villages during
construction phase in addition to some regular employment during the operation of the
plant. The Project will also help in generation of significant indirect employment. This will
have positive socio-economic development in the region. There will be in general
upliftment of standard of living of the people in the region/ neighbourhood.
Conclusion:
The proposal for setting up a 1050 MW Combined Cycle power plant in Thiruvallur
by M/s Chennai Power Generation Limited is an effort to tide over the power shortage in
the Tamil Nadu State. Combined Cycle Power Plant (CCPP) Power Plants with short
gestation periods are significant contributors to bridge the demand – supply gap. Within
30 months, full-fledged operation in combined cycle mode shall be achieved. Hence, the
proposal to install a Combined Cycle Power Plant (CCPP) Power Plant having an output
1050 MW at Thiruvallur in Tamil Nadu is viable and well justified.
.* * * * * * * *
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
39
Annexure 1
Previous Terms of Reference approved by MOEF for imported coal based
power plant
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
40
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
41
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
42
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
43
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
44
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
45
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
46
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
47
Annexure 2
Heads of Agreement Between IOCL and Chennai Power Generation LTD
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
48
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
49
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
50
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
51
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
52
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
53
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
54
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
55
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
56
Annexure 3
MOU signed Between IOCL and Chennai Power Generation LTD
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
57
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
58
Feasibility Report for 1050 MW ( 2 x 525 MW) Combined Cycle Power Project of M/S. Chennai Power
Generation Limited at Kattupalli and Kalanji villages at Ponneri Taluk, Thiruvallur district, Tamil Nadu
59
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