2014 9 02 Sep 2014 1520027671660MWCPP-Form1-Projectreport

FORM-I
FOR
660 MW CAPTIVE POWER PLANT
AT JSW STEEL LIMITED,
GEETAPURAM, DOLVI VILLAGE, PEN TALUKA,
RAIGAD DISTRICT, MAHARASHTRA
Submitted to:
Ministry of Environment and Forests

New Delhi
Submitted by:
STEEL LIMITED
DOLVI VILLAGE, PEN TALUK, RAIGAD DISTRICT
MAHARASHTRA
APPLICATION FOR PRIOR ENVIRONMENTAL CLEARANCE
(FORM-1)
(As per Gazette Notification dated 1st December, 2009 only basic information
has to be substituted only.)
(I) BASIC INFORMATION
Name of the Project/s 660 MW CAPTIVE POWER PLANT (Coal

BASED) AT JSW STEEL LIMITED,
GEETAPURAM, DOLVI VILLAGE,
TALUKA - PEN,
RAIGAD DISTRICT,
MAHARASHTRA.
S. No. in the schedule 1 (d)
Proposed capacity / area / length / 660 MW Captive Power Plant (Coal Based)
tonnage to be handled / command
area / lease area / number of wells to
be drilled
New / Expansion / Modernization New
Existing Capacity / Area etc. NA
Category of Project i.e. ‘A’ or ‘ B’ Category ‘A’
Does it attract the general condition? No

If yes, please specify.
Does it attract the specific condition? No

If yes, please specify.
Location The proposed plant facility is located in existing

plant premises at Geetapuram, Dolvi Village, Pen
Taluka, Raigad District, Maharashtra State.
The location of the site and study area map is

shown in Figure-1 & Figure-2.
Plot/Survey /Khasra No. Land is comprises of Dolvi & Wadkhal Villages
Village Wadkhal Village
Tehsil Pen
District Raigad
State Maharashtra
Nearest railway station /airport along Pen is the nearest railway station at about 08 km
with distance in kms. (aerial distance) on the Konkan Railway line
connecting Mumbai-Mangalore along the west
coast of India. The nearest airport is Mumbai
(national and international) located about 80 km
in the north direction from the proposed project
site.
Nearest Town, City, District Alibag 20 Km

Headquarters along with distance in
kms.
Village Panchayat, Zilla Parishad Grampanchayat Wadkhal.

Municipal Corporation, Local body
(complete postal address with
telephone nos.
Name of the applicant JSW Steel Ltd
Registered Address JSW Steel Ltd

JSW Centre
Bandra Kurla Complex
Bandra (East)
Mumbai – 400051
Tel No 022-42861000
Fax 022- 42863000
Address for correspondence JSW Steel Ltd

Geetapuram, Village – Dolvi,
Taluka – Pen,
District – Raigad.
Maharashtra.
Tel 02143 – 277501 to 15

Fax 02143 – 277533 / 42
Name Shri. V. K. Patidar
Designation (Owner / Partner /CEO) Sr. Vice President (Projects, Utilities & Services)
Address JSW Steel Ltd

Taluka – Pen,
District – Raigad.
Maharashtra.
Pin Code 402 107
E-mail vijaykumar.patidar@jsw.in
Telephone No. Phone no: 02143 277501 – 15
Fax No. Fax No. : 02143 – 277533 / 42
Details of Alternative Sites examined, Not Applicable

if any. Location of these sites should
be shown on a topo sheet.
Interlinked Project No
Whether separate application of Not Applicable
interlinked project has been
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submitted?
If yes, date of submission Not Applicable
If no, reason Not Applicable
Whether the proposal involves Not Applicable

approval / clearance under: if Yes,
details of the same and their status to
be given.
(a) Name of the Court
(b) Case No.
(c) Order/ directions of the Court, if
any and its relevance with the
proposal project.
(II) ACTIVITY
1. Construction, operation or decommissioning of the Project involving actions,

which will cause physical changes in the locality (topography, land use,
changes in water bodies, etc.)
Sr. Information/Checklist Yes/ Details thereof (with approximate

No. Confirmation No quantities/ rates, wherever possible)
with source of information data
1.1 Permanent or temporary No The company has already a total of about

change in land use, land 1200 acres of land in its possession for its
cover or topography including existing operating integrated steel plant
increase in intensity of land complex.
use (with respect to local Area required to setup the proposed 660
land use plan) MW Captive Power plant (Coal based) is
150 Acres proposed to be setup near
existing Jetty.
1.2 Clearance of existing land, No There will be clearance of existing land,

vegetation and building? vegetation wherever required. The
proposed area is generally plain area.
1.3 Creation of new land uses No The proposed facility will be constructed
within the existing Industrial area.
1.4 Pre-construction Yes Detailed land survey, topographical

investigations e.g. bore surveys and soil testing / investigation
houses, soil testing? studies has already been carried out
earlier.
1.5 Construction works? Yes Installation of 660 MW power plant (Caol

based) – construction work to be done.
1.6 Demolition Works? No There will not be any demolition works
during the construction of the plant.
1.7 Temporary sites used for Yes Temporary construction offices will be set
3
construction works or housing up during the construction stage, which

of construction workers? will be removed later.
1.8 Above ground buildings, Yes Excavation works will be carried out for
structures or earthworks constructing the civil structures of the
including linear structures, industries. The project may require filling,
cut and fill or excavations leveling and piling works.
1.9 Underground works including No Not applicable
mining or tunnelling?
1.10 Reclamation works? No Not applicable
1.11 Dredging? No Not applicable

1.12 Offshore structures? No Not applicable
1.13 Production and Yes The description of manufacturing process
manufacturing Process? and process flow of 660 MW power plant
is presented in Annexure-I.
1.14 Facilities for storage of goods Yes Storage facilities are planned for raw
or materials? material.
1.15 Facilities for treatment or Yes The wastewater generated from the
disposal of solid waste or indirect cooling circuit would be routed
liquid effluents? through the cooling tower and pressure
filter for recycling purpose.
The plant sanitary waste water will be

treated in sewage treatment plant and the
treated whole water will be used for green
belt
1.16 Facilities for long term No There will not be colony for construction
housing of operational workers.
workers?
1.17 New road, rail or sea traffic Yes Augmentation of port, road and rail
during construction or facilities for receipt of additional
operation? equipments.
1.18 New road, rail, air water or Yes Augmentation of port, road and rail
other transport infrastructure facilities for receipt of additional
including new or altered Equipments.
routes and stations, ports,
airports etc?
1.19 Closure or diversion of No Not envisaged
existing transport routes or
infrastructure leading to
changes in traffic
movements?
1.20 New or diverted transmission No Not envisaged

lines or pipelines?
1.21 Impoundment, damming, The plant drainage network will be
culverting, realignment or No planned and designed in line with the
other changes to the existing topography and systems.
hydrology of watercourses or
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aquifers?
1.22 Stream crossings? No Not envisaged
1.23 Abstraction or transfers of No The total water requirement for 660 MW

water from ground or surface power plant will be
waters? Raw water requirement 400 M3/Hour
Sea water intake 7475 M3/Hour.
At present JSW Steel Ltd., Dolvi Works

has been allocated about 56.0 MLD water
from Amba river, Nagothane,
K.T.Bandhara.
1.25 Transport of personnel or Yes Construction materials, mechanical and

materials for construction, electrical materials will be sourced from
operation or different parts of the state and as well as
decommissioning? various part of country through road and
rail network.
1.26 Long-term dismantling or No Not envisaged.

decommissioning or
restoration works?
1.27 Ongoing activity during No Not envisaged

decommissioning which could
have an impact on the
environment?
1.28 Influx of people to an area in Yes The requirement of total manpower for
either temporarily or power plant will be about 250.
permanently?
1.29 Introduction of alien species? No Not envisaged
1.30 Loss of native species or No Not envisaged

genetic diversity?
1.31 Any other actions? No -
2. Use of Natural resources for construction or operation of Project

(such as land, water, materials or energy, especially any resources
which are non-renewable or in short supply).

2.1 Land specially undeveloped No The additional land is required for the
or agricultural land (ha) proposed project since the plant will be
constructed near the Jetty industrial
complex.
5
2.2 Water (expected source and Yes The total water requirement for 660 MW
competing users) power plant will be
Raw water requirement 400 M3/Hour
Sea water intake 7475 M3/Hour.
At present JSW Steel Ltd., Dolvi Works
has been allocated about 56.0 MLD water
from Amba river, Nagothane,
K.T.Bandhara.
2.3 Minerals (MT) Yes Thermal Coal 30,00,000 Tonnes/Year will

be used as raw material in 660 MW
Captive power plant.
Fuel Oil (HFO) 5782 M3/Year
2.4 Construction material – Yes Cement
stone, aggregates, and/ soil Coarse aggregates
(expected source-MT) Fine aggregates
Reinforcement steel
Structural Steel
2.5 Forests and timber (source- No No timber use is envisaged in the
MT) proposed project.
2.6 Energy including electricity Yes 47.0 MW power will be required and met
and fuels (source, competing by the captive power generated by the
users) Unit: fuel (MT), energy CPP Complex.
(MW)
2.7 Any other natural resources No Not envisaged

(use appropriate standard
units)
3. Use, storage, transport, handling or production of substances or

materials, which could be harmful to human health or the
environment or raise concerns about actual or perceived risks to
human health

3.1 Use of substances or No Some amount of used/spent oil and
materials, which are grease will be generated during
hazardous (as per MSIHC maintenance work, which will be sold to
rules) to human health or the MPCB authorized vendor.
environment (flora, fauna,
and water supplies)
3.2 Changes in occurrence of No Not envisaged
disease or affect disease
vectors (e.g. insect or water
borne diseases)
3.3 Affect the welfare of people Yes Standard of living of the population
e.g. by changing living surrounding the proposed project area is
conditions? likely to be further improved.
6
3.4 Vulnerable groups of people No Not envisaged
who could be affected by the
project e.g. hospital patients,
children, the elderly etc
3.5 Any other causes No -
4. Production of solid wastes during construction or operation or

decommissioning (MT/month)

4.1 Spoil, overburden or mine Yes No major spoil or overburden will be
wastes generated at the project site during land
development. However, the spoil or
earthwork generated during construction
will be reused for construction.
4.2 Municipal waste (domestic Yes All municipal solid waste generated from
and or commercial wastes) the sewage treatment plant will be used
within the plant site for plantation as
manure.
4.3 Hazardous wastes (as per Yes The used oil sludge from the plant area
hazardous waste and used / spent oil & grease removed
management rule-s) from the plant will be sold to authorized
users/recyclers approved by state
pollution control board.
4.4 Other industrial process Yes Coal fines and fly ash will be generated as
wastes solid waste during process, Coal fines will
be recycle in the process and fly ash will
be sold to cement plant, some amount of
bottom ash will be generated which is
used in road filling for road construction
within the plant or sold to outside party.
4.5 Surplus product No Not envisaged
4.6 Sewage sludge or other Yes No Process sludge will be generated from
sludge from effluent the plant.
treatment The sewage sludge from the STP will be
generated and used within the plant
premises as organic manure.
4.7 Construction or demolition Yes Small quantity of metallic scrap waste
wastes expected and the same will be used as
melting scrap in the existing steel making
process.
Construction material will be used
internally for filling and leveling of the
sites within the plant site area.
4.8 Redundant machinery or No Not envisaged
equipment
7
4.9 Contaminated soils or other No Not envisaged

materials
4.10 Agricultural wastes No Not envisaged
4.11 Other solid wastes No Not envisaged
5. Release of pollutants or any hazardous, toxic or noxious

substances to air (kg/hr)
Sr. Information/ Yes/ Details thereof (with approximate

No Checklist Confirmation No quantities/ rates, wherever possible)
5.1 Emissions from combustion of Yes The following air pollutant will be generated
fossil fuels from stationary or from combustion of fossil fuel.
mobile sources
1. Dust particulate from fly ash in flue
gas:
The standard for particulate emission
applicable to this project is 150 mg /
Nm3. The electrostatic precipitators
(ESP) proposed to be installed in this
project would be designed to limit the
emission level of the particulate matter
to this limit 100 mg/N m3
2. Sulphur dioxide (SO2) in flue gas:
One stack (chimney) of height 275 M,

with twin flues for effective dispersal of
SO2 is proposed to be constructed.
3. Nitrogen oxides (NOx) in flue gas:
To reduce NOx emissions, over-fire air

system equipment with air ports would
be installed for the furnace. Further,
the steam generators would be fitted
with advanced low NOx burners. The
NOx emissions would be checked for
ground level concentrations (GLC) as
per the above indicated Indian
Emission Regulations.
5.2 Emission from production Yes Emission from production processes are as
processes follows.
• Dust particulate from fly ash in flue
gas
• Sulphur dioxide (SO2) in flue gas
8
• Nitrogen oxides (NOx) in flue gas
Emission level will be within the prescribed

norms.
5.3 Emissions from materials Yes Coal dust would be generated generally at
handling including storage or the conveyor transfer points. Hence, coal
transport transfer points would be provided with dust
suppression / dust extraction facilities.
Further, in order to arrest the coal dust
generation, all conveyors would be provided
with enclosed galleries. Dust collection
system would also be provided in coal
bunkers to evacuate dust from the coal
bunkers.
Fly Ash:
At the time of unloading fly ash in to the
silo, some ash laden air would get vented
out. In order to restrict the fly ash dust
particles to the limits of 100 mg / Nm3, a
vent filter would be installed on top of the
fly ash silo at the vents. Apart from that
a) To reduce the dust nuisance while

loading the ash into the trucks from fly ash
silo, the fly ash would be conditioned with
water spray.
b) It is proposed to cover the ash in the

open trucks with tarpaulin to prevent flying
of fine ash during transportation.
c) Water sprinking system would be

provided in the ash disposal area to
restrain flying of fine ash due to wind.
d) The Ash disposal area would be lined

with impervious lining to prevent seepage
of rain water from the disposal area into
the ground and pollute ground water.
5.4 Emissions from construction Yes Fugitive Dust.
activities including plant and
equipment
5.5 Dust or odours from handling Yes Dust emissions from construction materials
of materials including are envisaged. Suitable dust suppression
construction materials, methods will be followed.
sewage and waste
There is no possibility of any odour
generation.
5.6 Emissions from incineration No Not envisaged
of waste
5.7 Emissions from burning of No Not envisaged
9
waste in open air (e.g. slash
materials, construction
debris)
5.8 Emissions from any other No Not envisaged

sources
6. Generation of Noise and vibration, and emissions of Light and heat

6.1 From operation of equipment Yes Noise will be generated from the power
e.g. engines, ventilation plant, plant which will not be allowed to exceed 85
crushers dB (A).
Adequate control measures like acoustic
systems will be provided.
6.2 From industrial or similar Yes The expected noise level will not be allowed
processes to exceed 85 dBA (A) or proper noise
protection systems will be used whenever
required.
There will be not be any adverse effect on

the ambient Noise.
6.3 From construction or Yes Yes. This will be in the range of about 65-80
demolition dB(A). Regular maintenance of the
equipment will help in reducing these noise
levels.
6.4 From blasting or piling Yes Some noise <85 dB (A) will be generated.
6.5 From construction or Yes The noise levels are expected to be in the
operational traffic range of about 70-75 dB(A).
6.6 From lighting or cooling No Not envisaged

systems
6.7 From any other sources No Not envisaged
10
7. Risks of contamination of land or water from releases of
pollutants into the ground or into sewers, surface waters,
groundwater, coastal wasters or the sea

7.1 From handling, storage, use No Not envisaged.

or spillage of hazardous
materials
7.2 From discharge of sewage or No The sewage water will be treated and used
other effluents to water or for greenbelt development within the
the land (expected mode and premises. Out side discharge is not
place of discharge) envisaged.
The wastewater from the plant units will be

treated at the individual source of
generation and re-used or re-cycled into the
processes.
There will not be any external discharge of

wastewater, except cooling of sea water.
7.3 By deposition of pollutants No There is no discharge of wastewater outside

emitted to air into the land the plant.
or into water
7.4 From any other sources No Not envisaged
7.5 Is there a risk of long term No Not envisaged

build up of pollutants in the
environment from these
sources?
8. Risk of accidents during construction or operation of the project,

which could affect human health or the environment

8.1 From explosions, spillages, Yes There will not be any possibility of oil spill in
fires etc and from storage, the plant. However, suitable risk
handling, use or production assessment will be carried out and disaster
of hazardous substances management plan will be in place.
8.2 From any other causes No Not envisaged
11
8.3 Could the project be affected No The area is generally flat land. There is no
by natural disasters causing record of occurrence of floods, land slides,
environmental damage (e.g. cloud bursts etc.
floods, earthquakes, slides,
could burst etc) The proposed project site falls in Zone-IV as
per IS-1893 (Part-I):2002.
9. Factors which should be considered (such as consequential

development) which could lead to environmental effects or the
potential for cumulative impacts with other existing or planned
activities in the locality

9.1 Lead to development of Yes Existing and ancillary facilities will improve.
supporting, facilities, ancillary
development or development
stimulated by the project
which could have impact on
the environment
Supporting infrastructure Yes Existing infrastructure facilities will be

(roads, power supply, waste expanded / extended to take care of the
or waste water treatment, project.
etc)
Housing development No Utilises the existing facility
Extractive industries No The proposed facilities are captive to JSW

Steel Ltd.
Supply industries Yes Existing supply chain will improve
Other ---
9.2 Lead to after use of the site, Yes The proposed project will not have impact
which could have an impact on environment. However, these impacts
on the environment will be contained by adopting suitable
mitigation measures.
9.3 Set a precedent for later Yes Ancillary industries will be developed as a
developments consequence.
9.4 Have cumulative effects due Yes The industry is not located in a critical zone.
to proximity to other existing There are not many major industries
or planned projects with operating in this region. Hence, no major
similar effects effects are envisaged.
12
(III) Environmental Sensitivity
Sr. Areas Name Aerial distance (within 15 km)

No. / Proposed project location boundary
Identity
1 Areas protected under No There are no ecological, landscapes,
international conventions, cultural or other related sensitive areas
national or local legislation in 15 –km radius.
for their ecological,
landscape, cultural or other
related value
2 Areas which are important or No There are no national parks, sanctuaries

sensitive of ecological in 15-km radius from proposed project
reasons – wetlands, water site.
courses or other water
bodies, coastal zone,
biospheres, mountains,
forests
3 Areas used by protected, Yes Four reserve forests exists in 15 Km

important or sensitive species radius area as listed below:
of flora or fauna for breeding, • RF near Kharkhara village ( 1-
nesting, foraging, resting, km, E)
over wintering, migration • RF near Katkariwadi village (5.3-
km, NE)
• RF near Turmal village (4.6-km, E)
• RF near Katvira village(5.1- km, SW)
• RF near Dhavte village(8.5-km NE)
Detailed floral and fauna studies will be

conducted and details will be
incorporated in EIA report
4 Inland, coastal, marine or Yes Amba river 2.0 – km, W

underground waters Bhogeswar river 7.8-km, N
5 State, national boundaries No Nil
6 Routes or facilities used by No Not applicable

the public for access to
recreation or other tourist,
pilgrim areas
13
Sr. Areas Name Aerial distance (within 15 km)
No. / Proposed project location boundary
Identity
7 Defence installations No Nil within 10-km radius
8 Densely populated or built-up Yes Pen Taluka is 6.9-km from the plant
area site.
9 Areas occupied by sensitive Yes Pen Taluka has all the facilities such as
man made land uses primary schools, middle schools, high
(hospitals, schools, places of schools, hospitals health centers, public
worship, community facilities) health sub centers, dispensaries and
place of worship.
10 Areas containing important, No No scarce resources are present in 15-

high quality or scarce km radius
resources
(ground water resource,
surface resources, forestry,
agriculture, fisheries,
tourism, minerals)
11 Areas already subjected to No This is not a listed or critically polluted

pollution or environmental area.
damage. (those where
existing legal environmental
standards are exceeded)
12 Areas susceptible to natural No The proposed project site falls in zone-

hazard which could cause the IV as per (As per IS: 1893 (RSM) from
project to present 2002).
environmental problems
(earthquakes, subsidence, No land slides / flooding is envisaged in
landslides, erosion, flooding project area.
or extreme or adverse
climatic conditions)
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(IV) Proposed Terms of Reference for EIA Studies – Annexure – II.
I hereby given undertaking that the data and information given in the
application and enclosure are true to the best of my knowledge and
belief and I am aware that if any part of the data and information
submitted is found to be false or misleading at any stage, the project
will be rejected and Clearance give, if any to be the project will be
revoked at our risk and cost.
Date: 1st April 2014
Place: Dolvi
Mr. V.K. Patidar

Sr. Vice President (Projects, Utilities & Services)
JSW Steel Ltd
Taluka – Pen, District – Raigad
Maharashtra 402107.
15
FIGURE -1
LOCATION MAP
Plant Site
16
FIGURE -2
STUDY AREA MAP
73° 0' 73° 5'
Kalve Johe
Sonkhar Tambatshet Mumbai
98km
N
Bhalpada Tukaramwadi
Kanebachapada
Hamrapur
Kalesri
Varedi
Mothe vadhav Shinole
Sapoli
Div Borze Kane Khar Sapoli Chinchghar

Vadhav
Narvel Antora Ramraj

Benavle Navgharwadi Tarankhop
Vashi
18° Masad Khurd 18°
45' Kaproli Antora RF 45'
Patnoli
Khalapur
PEN Bh Dhavte 27.8km
Dherankhar Dhondapada og Ambeghar
Masad Khurd Pipalpada es
hw
Masad Budruk
Umbarde ar
Pimpalpada
R.
Borgaon
Borve Shirki
Shahapur Vashinaka Ramwadi
Maleghar
Bori Vadgaon
Dhakta Shahapur Uchede
Shinganvat Kandepada
Kolve Kashmire
Rode
Sutarpada Kandale
Vadkhal Indranagar
Lebhi
Am
Khidki KOPAR Wave Katkariwadi

Virani
RESERVED FOREST
ba
Dharamtar Navegaon
R.
Chari
Kurkundi Dolvi
Ghasvadkhar Kamalpada PLANT

Divlang
Bhanghar
Shahabaj RESERVED FOREST Bandhanwadi
Pezari Dadaji
Talanikar Valvade Kharkaravi Turmal
Ambeghar Bangalwadi
Poinad
Ambepur Bhakhwadi Gadab RESERVED FOREST
Dehankoni Khapachiwadi
Tadmalwadi
Vagholi Patharmal Chaphegani
Nagjhari
Dhombi Jirne
18° Navenagar Takachiwadi 18°
Medhekhar
40' Sukatrie Shekatmal RESERVED FOREST 40'
Kachali Mounepale
Katkorwadi Pitkari Bakeghar
Kherpale
Vadvali Shirgaon Katvira Kusambale
Ratalpada Vaghvira Devali RESERVED FOREST
Katvaripada
Hemnagar Anandnagar Kalad
Tadvagle Kharjul
Talashet Pedkyawadi
Kathodipada Chikhali Karanjatep
Burdi Brahmanwadi
Kharoshi RESERVED FOREST Kasu Khadakwadi
Kolghar
Pandapur
Thakurwadi
Ruishet Bhomoli Navakar
Kurdus
Bidbav
Chaura Dattawadipada
Ananwadi
Sutwadi
Sambri Mahabalewsaram
Ruishet 133.7km
Bidwagale Aveti
73° 0' 73° 5'

LEGEND
Plant Site Settlements
Road Forest Boundary
Railway Line Nadi/Nala/Water Body
17
ANNEXURE-I
660 MW CAPTIVE POWER PLANT – PROCESS DESCRIPTION
Process Description
In captive power plants, water is taken to the boiler or steam generator where
coal is burnt. The boiler transfers heat energy to the water in form of latent
heat of vaporization or enthalpy by the chemical reaction of burning coal.
External fans, such as PA fans and FD fans, are provided to give sufficient air
for combustion. The steam generating boiler produces steam at the high
purity, pressure and temperature required for the steam turbine that drives
the electrical generator. The steam generator includes an economizer, a steam
drum, and the furnace with its steam generating tubes, superheater coils and
reheater coils. Necessary safety interlocks, fuel purging systems, safety valves
are installed to ensure safe operation of the boiler.
Steam turbine uses the dynamic pressure generated by expanding steam to
turn its blades. The power so produced by the electric generator which is
coupled with the rotating steam turbine is transmitted to the main distribution
centre (switchyard).
Requirement of Raw Materials
The annual (net and dry) requirements of raw materials for 660 MW Captive
Power Plant (Coal Based) are given in table.
Annual Major Raw Material Requirement (net & dry basis):
Sl. Raw material Quantity

Source
No. (TPA)
Australia / South
1. Thermal Coal 30,00,000 Africa / Indonesia
Thermal Coal
The steam boiler would be designed for coal firing. The steel plant has no
indigenous coal supply linkage. Availability of low ash thermal coal of desired
quality is limited in India. Hence, it has been envisaged that requirement of
thermal coal will be met through imports. The possible sources of supply of
18
thermal coal are Australia, South Africa and Indonesia.
The requirement of thermal coal is about 30,00,000 TPA on Net and Dry basis
considering average GCV value of thermal coal as 5000 kcal/kg and annual
plant load factor (PLF) of 85%. 100% imported thermal Coal is proposed to be
used in the Captive Power Plant. Considering moisture loss of 10%, handling
loss of 5% the annual requirement is about 34,60,000 MT.
The average analysis of thermal coal is expected to be as follows.
Fixed carbon : 54 – 56 %
Volatile matter : 20 – 23 %
Ash : 10 – 12 %
Total moisture : 12 % maximum
CV of coal : 5000 kcal/kg (approx.)
Size of coal : < 100 mm
Fuel Oil
Heavy fuel oil would be used for start-up and flame stabilization at low loads and
LDO would be used for light up and warm up of units.
ANNEXURE-II
PROPOSED TERMS OF REFERENCE
19
Project Implementation:
A detailed description of all elements of the project during the pre-

construction, construction and operational phases will be prepared. The
elements analyzed will include the infrastructures of the project including:
drainage features, roads, waste collection, disposal and management and
utility requirements.
Analysis and assessment of designs to ensure environmental soundness,

sustainability and regulatory compliance of the designs will be studied and
incorporated in the draft and final EIA Report.
Field Assessments:
Field assessments of the physical, ecological, and socioeconomic aspects of
the site and associated environs will be conducted during post-monsoon
season. These assessments will be used to determine the potential impacts, if
any, of the proposed project. A photographic survey of the proposed site and
the nearby environs has been conducted. The survey included a photo-
inventory of the physical and biological features of the site and environs, and
the areas are viewed with respect to the suitability of the proposed facility.
The assessments included:
Physical:
Climate, air quality, geology, topography, groundwater/surface water
hydrology quality, hazard vulnerability, noise levels and land use.
Ecological:
Terrestrial and aquatic communities; presence of rare, threatened and
endangered species.
Socioeconomic:
Demography, regional setting, location assessment, and land uses.
The technical scope of work for carrying out the baseline monitoring has been
as given below. The baseline monitoring will be carried out in 10-km radius
study area around the proposed project site for three months representing
the post - monsoon season.
Sr. Attributes Scope of Work

No.
1 Ambient Air Quality 4 Locations - 2 days/week for 13 weeks (3
months) PM-2.5, SPM, RPM, SO2, NOx, and CO
will be monitored as per CPCB guidelines.
Design of ambient air quality sampling network

with regard to topography, population, sensitive
locations, emission sources, background
concentrations and possible impact zones,
through application of screening air quality
models for assessing the maximum GLC zones
prior to start of baseline study.
2 Meteorological data 1 Location - 90 days
20
No.
Wind speed, direction, temperature, humidity,
cloud cover and rainfall will be monitored.
This is further supported by the meteorological
data for the area of interest from the nearest
meteorological observatory and Trend analysis of
micrometeorological data generated at the site.
3 Water Quality 9 Locations- (Surface and Ground water
samples)
– Once during the EIA study
Parameters as per IS-10500, IS:2296 and EPA

Act as applicable .
The survey also include estimation of water

balance and assessment of impacts on regional
water demand and availability of fresh water due
to drawl of water for plant, recommendations on
water conservation and rain water harvesting
measures based on past experience on similar
projects; and identification of suitable location
and methodology for disposal of waste water
form all sources.
4 Soil Quality 6 Locations once during EIA study. Parameters
related to afforestation, nutrients, pollutants etc.
will be carried out.
5 Noise Levels 8 Locations (Residential, Commercial and
Sensitive areas) once during EIA study.
Readings will be taken for 24-hr duration at each
location
6 Land use Land use as per the district census handbooks as
well as with the help of satellite imagery will be
presented in 10-km radius study area.
7 Solid waste Characterization of all the solid wastes generated
from the plant operations and its disposal
including impacts due to disposal.
8 Socio-Economic and Socio-economic and health aspects are covered
Demography for 10-km radius study area based on the Census
documents and NIC database.
9 Ecological studies Flora and fauna will be studied in 10-km radius
(Terrestrial and study area. These studies will be based on
Aquatic) primary as well as secondary sources.
The survey also includes assessment of the

species diversity, density, abundance etc. in the
study area and formulation of ecological indexes,
assessment of likely changes on flora and fauna
due to the project related activities, suggestions
for conservation and protection of flora and fauna
in the study area and suggestions for
development of new conservation areas locally.
10 Traffic Study Traffic at important points on the approach roads
21
No.
will be surveyed for the existing total daily traffic,
peak hour traffic and traffic composition.
Assessment of the change in traffic composition
and volumes and suggestions for improvement of
traffic flow around the project site and around will
be studied
11 Aesthetic/Cultural Identification of all historical/ archeological
Aspects sites/monuments in the study area.
Detailed qualitative assessments of the physical, ecological, and

socioeconomic conditions associated with the site in the Draft and Final
Report.
Legislation and Regulatory Considerations
Government policies, legislation and regulations relevant to the proposal will
be identified. Local plans and policies will also be evaluated. Project
characteristics will be analyzed to ensure compliance with these policies,
legislation and regulations. Appropriate recommendations will be provided to
ensure regulatory compliance.
The legislation relevant to the project will be summarized and presented in
the EIA Reports.
Environmental Impact Assessment
The guidelines suggested and international practices will be reviewed to

determine the adverse impacts and critical areas.
There are various qualitative as well as quantitative methods of conducting

EIA studies, each having its own merits and demerits. We intend to use the
best logical tool to assess the impact of the project.
The baseline data generated from above studies will be analyzed and
compared with applicable standards for each environmental attribute, so that
the critical environmental areas and also attributes of concern will be
identified. The short term and long-term impacts particularly on sensitive
targets such as endangered species, plants and historically important
monuments will be identified.
The Environmental Impact Assessment of proposed project will be done on

above basis to determine the environmental acceptability of this proposed
project in absence of control measures and after implementation of the
mitigation measures, including worst impact.
A qualitative and quantitative assessment of pollution aspects of proposed

project (air and dust, wastewater, noise pollution, wastewater discharges
etc.) will also be done to identify the adequacy of the proposed control
measures as well as the likely impact on existing critical areas. Mitigation
measures to reduce adverse impacts will be suggested.
Air Impacts:
22
Emission Inventory will be carried out in an area of 10-km around the project
site. A computer based internationally recognized mathematical air quality
model (ISC-ST3) model will be used to predict the concentration of SO2, NOx
and SPM due to the operation of the proposed project. The model would also
take into account other sources of pollution and topographical features of the
area. The emission of relevant pollutant (SO2, NOx, PM2.5, PM10) from
nearby sources shall be used in the model for more accurate estimate of air
quality. The results will be presented for short term (24 hourly)
concentrations over a radius of 10-km around the plant site. The dispersion
model results will be included in the report using isopleths or other graphical
methods, over laying a land use map of the surrounding area. The predicted
air quality will be compared with existing regulations and mitigative
measures, if any, will be identified. The long term and short term impact at all
the monitoring locations shall also be estimated.
Noise Impacts:
Sources of noise and its impact on the environment would be clearly brought
out. The noise level at varying distances for multi-sources will be predicted
using suitable model. A comparison of measured noise (Leq) at monitoring
locations to that of predicted noise levels (Leq) would be made and mitigatory
measures required, if any, will be recommended to conform to regulatory
ambient air noise standards.
We propose to estimate increase in noise levels over the baseline conditions

in different zones like industrial, residential and sensitive areas like hospitals,
wild life habitation etc. The potential noise level exposure will be determined
and evaluated for acceptable limits of exposure.
Environment Management Plan
For each potential negative impact identified, recommendations will be

presented for avoidance, minimization or mitigation of impacts along with
costs associated with potential mitigation.
An EIA/EMP, based on three months baseline study, will be prepared for the
project. The EMP will address the following:
• Identify and summarize all anticipated significant adverse environmental

impacts;
• Identify and summarize all mitigation measures, including the type of
impact to which it relates and the conditions under which it is required;
• Define a set of policies and objectives for environmental performance and
continual enhancement of performance;
• Recommend monitoring measures including the parameters to monitored,
methods to be used, sampling locations, frequency of measurements,
detection limits and definition of thresholds that will signal the need for
corrective actions;
• Recommend monitoring and reporting procedures;
• Recommend capacity development and training requirements for
implementation of EMP;
• Recommend organizational structure for effective implementation of the
EMP; and
• Draw up an implementation and cost schedule for EMP.
23
Environmental Monitoring
An environmental monitoring and management plan will be developed for the

sensitive elements of the environment that may require monitoring during
construction and operations of the facility. Recommendations will be made on
the institutional arrangements that will be necessary to ensure effective
monitoring and management.
A detailed management and monitoring program will be developed to reduce
the effects of potential negative environmental impacts.
Risk Assessment and Disaster Management Plan
Risk Assessment studies comprising sub-activities such as hazard

identification, assessment and quantification of risk for suggesting risk
mitigation measures based on Maximum Credible Accident (MCA) Analysis to
be carried out for the proposed project. Preparation of the Risk Assessment
Report will be followed by Disaster Management Plan (DMP) and Emergency
Preparedness Plan (EPP) based on the quantitative Risk Assessment of the
proposed activity and associated infrastructure for the project.
Occupational Health and Safety
We will review the existing system of safety management and occupational

health surveillance system in the proposed facility plant and recommend for
further appropriate measures in view of the proposed plant.
24
Captive Power Plant
1 x 660 MW
At Dolvi Works, Maharashtra
Project Report
Mumbai
March 2014
JSW Steel Limited
660 MW Captive Power Plant Maharashtra
Project Report
CONTENTS
Chapter No. Title Page Nos.
From To
01 Introduction 1-1 1-2
02 Market Analysis & Power Scenario 2-1 2-4
03 Process Description & Raw Materials 3-1 3-5
04 Proposed Site 4-1 4-4
05 Plant and Equipment 5-1 5-20
06 Services, Utilities & Manpower Requirement 6-1 6-8
07 Environmental Management 7-1 7-8
08 Project Implementation 8-1 8-1
09 Block Capital Cost 9-1 9-1
LIST OF DRAWINGS
Sl. No. Description Drawing No.
1. Location Map JSW/DW/CPP/PR/001
2. Regional Map JSW/DW/CPP/PR/002
3. Road Linkage JSW/DW/CPP/PR/003
4. Rail Linkage JSW/DW/CPP/PR/004
5. Process Flow Sheet JSW/DW/CPP/PR/005
6. General Layout JSW/DW/CPP/PR/006
7. Water Balance Diagram JSW/DW/CPP/PR/007
8. Implementation Schedule JSW/DW/CPP/PR/008
This document is the property of JSW and contains confidential information

and proprietary intellectual property. This is not to be copied or used for
other projects unless expressly permitted by JSW.
JSW TECHNO PROJECTS MANAGEMENT LTD.

JSW Steel Limited
Project Report
01 INTRODUCTION
01.01 Preamble
JSW Group, the biggest steel producer in India is ranked amongst

India’s top business houses in terms of turnover, size and scale.
The Group is a multi-location, multi-product business with interest
spanning across Mining, Carbon Steel, Power Generation &
Distribution and Ports and Infrastructure. “Growth with a social
conscience” is a paradigm the Group lives by. Its strength lies in
its individual companies, with each one committed to consolidate
its core strength and excelling in its field of specialization.
The JSW group owns and operates, a 3.3 Mt/yr Steel plant at
Dolvi, Maharashtra based on BF-DR-CONARC-CSP process route.
It also has cold rolling, galvanizing, colour coating plant,
galvalume and pipe & tube plant at Kalmeshwar, Nagpur in the
state of Maharashtra. The next phase of expansion will take the
capacity of this plant to 5.0 Mt/yr by the year 2015.
It is also proposed to expand the capacity of the integrated steel

plant from 5.0 Mt/yr to 10.0 Mt/yr at Dolvi. At 10 Mtpa capacity
the steel plant would have a power demand of about 900 MW.
The steel plant is presently consuming 300 MW of average power

from MSEB grid, at 220 kV from MSEB grid sub-station located
near the plant site out of which 55 MW is from a Captive Power
Plant.
It is proposed to set up a 660 MW coal based Supercritical Captive

Power Plant (CPP) near Geetapuram Port in Dharamtar, in Pen
Taluka of Raigad District in Maharashtra State. The power
produced from the captive Power Plant will be used in the steel
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plant of JSW Steel Ltd. at Dolvi. Services like supply of water,

power & compressed air etc. will be made available at plant
boundary limit from the existing steel plant of JSW Steel Dolvi
Works.
01.02 Objective of the Report
This project report has been prepared for getting Environmental

Clearance for the proposed 660 MW coal based supercritical
Captive Power Plant in Dolvi, Maharashtra. This power plant will
be used to fulfill the power demand from the various units of the
steel plant.
The power plant will have a capacity of 660 MW and the

investment will be about Rs. 4500 crores.
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02 MARKET ANALYSIS & POWER SCENARIO
02.01 General
India’s continued economic growth has put massive strain on the

country’s existing infrastructure, which has not kept pace with
development. Private participation coupled with government
support will be the key driver for infrastructure construction. With
more than 20% tax-revenue growth over the past four years,
central and state government finances are in better shape, and
improved public-enterprise profitability supports capex plans.
India’s power-generation capacity is likely to double by 2017. It is

expected that the capex will jump from US$48bn in the federal
government’s 10th five-year plan (FY03-07) to US$108bn in the
11th plan (FY08-12) and US$171bn in the 12th plan (FY13-17).
India, which has an installed capacity of around 2.28 lakh MW, is

estimated to have a deficit of nearly 12% during peak hours. The
government has added about 53,000 MW power generation
capacity in the past five years (2007-12), around 9,000 MW short
of the target of 62,000 MW.
The government had earlier set a target of over 78,000 MW for

the 2007-12 period, which was curtailed to 62,000 MW in the
Planning Commission’s mid-term review due to lack of
environment clearance for the coal blocks allotted for the power
projects. The Power Ministry also envisages to add 76,000 MW in
the coming five years (2012-17), even though the Planning
Commission has proposed a target of above 90,000 MW during
the same period.
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NTPC is the largest power producer in the country with an

installed capacity of 42,964 MW capacity, plans to add over
14,000 MW. According to industry experts, India needs
investment of $120-150 billion over the next five years in the
energy sector, and strong private sector participation is required
to complement the public sector.
02.02 Indian Electricity Scenario
The electricity sector in India is predominantly controlled by

Government of India's public sector undertakings (PSUs). Major
PSUs involved in the generation of electricity include National
Thermal Power Corporation (NTPC), National Hydroelectric Power
Corporation (NHPC) and Nuclear Power Corporation of India
(NPCI). Besides PSUs, several state-level corporations, such as
Maharashtra State Electricity Board (MSEB), are also involved in
the generation of electricity. The intra state distribution is
managed by the State Electricity Boards (SEBs) and private
companies. Powergrid Corporation of India is responsible for the
interstate transmission of electricity and the development of
national grid. The sector-wise total installed capacity in India is
presented in table – 02.01 below :
Table – 02.01
Sector-wise Installed Capacity in India
Sector MW %age
State Sector 90,062.14 39.37
Central Sector 65,732.94 28.73
`Private Sector 72,926.66 31.88
Total 228,721.74
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Source : CEA (as on Sept.-2013)
India is world's 4th largest energy consumer, accounting for 4.0%

of global energy consumption. Due to India's economic rise, the
demand for energy has grown at an average of 3.6% per annum
over the past 30 years. More than 50% of India's commercial
energy demand is met through the country's vast coal reserves.
About 68% of the electricity consumed in India is generated by
thermal power plants, 17% by hydroelectric power plants and 2%
by nuclear power plants. The country has also invested heavily in
recent years on renewable sources of energy such as wind
energy. The fuel-wise power generation in India is tabulated in
Table-02.02 below:
Table - 02.02
Fuel MW %age
Thermal 155,968.99 68.19
- Coal 134,388.39 58.75
- Gas 20,380.85 8.91
- Oil 1,199.75 0.52
Hydroelectric 39,788.40 17.39
Nuclear 4,780.00 2.08
Renewable Energy Sources
(include Biomass Gasifier,
Biomass Power, Urban & 28,184.35 12.32
Industrial Waste Power and
Wind Energy)
Total 228,721.74
Source: CEA
In September 2013, the installed power generation capacity of

India stood at 228,721.7 MW while the per capita power
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consumption stood at 917 kWh as per CEA. The country's annual

power production increased from about 190 billion kWh in 1986 to
more than 911 billion kWh in 2012-2013. The total demand for
electricity in India is expected to cross 950,000 MW by 2030.
02.03 The likely power supply position at the end of 2012-13 is

given in the table below.
Table – 02.03
Period Peak Peak Peak Peak Energy Energy Energy Energy

Demand Met Deficit/ Deficit/ Require Avail Deficit/ Deficit/
(MW) (MW) Surplus Surplus ment ability Surplus Surplus
(MW) (%) (MU) (MU) (MU) (%)
2012-13 135,453 123,294 -12,159 -9.0 995,500 908,574 -86,926 -8.7
Despite the sharp increase in capacity addition, India’s power

shortages are likely to remain fairly high in the 11th plan and
demand-supply may reach close to a balance some time in the
12th plan.
02.04 Conclusions
Thus looking at the demand supply scenario and the plans of the
Government to boost the power sector, the proposed captive
capacity addition is expedient and economically viable.
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03 PROCESS DESCRIPTION & RAW MATERIALS
03.01 Process Description
In captive power plants, water is taken to the boiler or steam

generator where coal is burnt. The boiler transfers heat energy to
the water in form of latent heat of vaporization or enthalpy by the
chemical reaction of burning coal. External fans, such as PA fans
and FD fans, are provided to give sufficient air for combustion.
The steam generating boiler produces steam at the high purity,
pressure and temperature required for the steam turbine that
drives the electrical generator. The steam generator includes an
economizer, a steam drum, and the furnace with its steam
generating tubes, superheater coils and reheater coils. Necessary
safety interlocks, fuel purging systems, safety valves are installed
to ensure safe operation of the boiler.
Steam turbine uses the dynamic pressure generated by expanding
steam to turn its blades. The power so produced by the electric
generator which is coupled with the rotating steam turbine is
transmitted to the main distribution centre (switchyard).
The process flow sheet of the proposed process for captive power
plant is given in drawing no. JSW/DW/CPP/PR/005.
The salient features of major equipment of 660 MW coal based
supercritical captive power plant are
• Pulverized coal fired, once through, balanced draft super
critical boilers with BMCR around 2100 Tons per hour,
regenerative type air pre-heater, Bowl/Tube type mills with
one spare under worst coal firing, 2x60% duty ID, FD & PA
fans etc.
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• Tandem, compound, double flow, reheat regenerative &

condensing steam Turbine having HP,IP &LP cylinders with
TMCR around 1970 Tons per hour, with 3 nos. HP Heaters and
4 nos. LP Heaters
• HP&LP Turbine Bypass with capacity 60% TMCR
• Horizontal, double pass, surface type, integral air cooling zone
condenser with temperature rise of cooling water by 9 degrees
at inlet temp.33 degrees C with hot well storage 3 minutes at
Turbine V.W.O condition.
• 3x50% duty Condensate Extraction pumps
• 2x50% duty Turbine driven and 1x30% motor driven Boiler
Feed Pumps
• Spray cum Tray type Deaerator with storage 10 minutes at
V.W.O condition
• Condensate polishing plant of full flow, 3 x 50% duty with
mixed bed trains
• Circulating Water Pumps of 3x50% duty
• Auxiliary Cooling Water pumps of duty 2x100%
• DM Plant of total 2x70 m³/hr capacity to ensure make-up
requirement of heat cycle at the rate of 3% of the BMCR
steam flow
• Coal Handling Plant of1450TPH belts
• Induced Draft Cooling Tower/ Natural Draft Cooling Tower
• Control and Instrumentation system with major components
:Distributed Control System DCS) with Plant wide Data High
way ,Steam Generator Control and Protection System as per
manufacturer’s standard design with interfacing with the Plant
DCS, Turbine Generator Control and Protection System as per
TG manufacturer’s standard design interfacing with the Plant
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DCS, Turbine Supervisory Instrumentation system for TG,

Vibration monitoring system for major plant auxiliaries
including BFP, Master and Slave Clock System, Central Control
Room, Measuring Instruments, Stack Emission Monitoring
System etc.
03.02 Raw Materials
Raw materials availability is becoming critical due to the heavy

demands made and the limited resources. Proper sourcing and
appropriate beneficiation combined with logistics planning has
become vital for the success of any plant operation. Thermal coal
is the major raw material required for the plant. The location and
the regional map of the plant site have been shown in the
drawing no. JSW/DW/CPP/PR/001 & JSW/DW/CPP/PR/002
respectively.
03.03 Requirement of Raw Materials
The annual (net and dry) requirements of raw materials for 660
MW Captive Power Plant are given in table 03.01.
Table-03.01
Annual Major Raw Material Requirement (net & dry

basis):
Sl. Raw material Quantity

Source
No. (t/yr)
Australia / South
1. Thermal Coal 3,000,000 Africa /
Indonesia
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Estimated requirement of raw material have been briefly

described in subsequent paragraphs.
03.03.01 Thermal Coal
The steam boiler would be designed for coal firing. The steel plant
has no indigenous coal supply linkage. Availability of low ash
thermal coal of desired quality is limited in India. Hence, it has
been envisaged that requirement of thermal coal will be met
through imports. The possible sources of supply of thermal coal
are Australia, South Africa and Indonesia.
The requirement of thermal coal is about 3,000,000 t/yr on Net
and Dry basis considering average GCV value of thermal coal as
5000 kcal/kg and annual plant load factor (PLF) of 85%. 100%
imported thermal Coal is proposed to be used in the Captive
Power Plant. Considering moisture loss of 10%, handling loss of
5% the annual requirement is about 3.46 Mt.
The average analysis of thermal coal is expected to be as follows.

Fixed carbon : 54 – 56 %
Volatile matter : 20 – 23 %
Ash : 10 – 12 %
Total moisture : 12 % maximum
CV of coal : 5000 kcal/kg (approx.)
Size of coal : < 100 mm
03.03.02 Fuel Oil
The annual requirement for the proposed 660 MW unit would be

about 5782 m3 based on consumption of 1ml/kWh (CERC
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guidelines) of power generation. The daily average consumption

of HFO would be about 15.84 m3 /day.
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04 PROPOSED SITE
04.01 Proposed Site
The 660 MW coal based Supercritical Captive Power Plant is

proposed to be set up near Geetapuram Port in Dharamtar, in Pen
Taluka of Raigad District in Maharashtra State. The site is at a
distance of 100 km from Mumbai, and about 40 km from Panvel
by Road. The location map and the regional map of the proposed
site have been shown in the drawing no. JSW/DW/CPP/PR/001 &
JSW/DW/CPP/PR/002 respectively.
The indicative coordinates of the proposed site are given below:
Latitudes : 18° 42’ 12.50” N
Longitudes : 73° 01’ 43” E
04.02 Area Requirement
04.02.01 General
The area requirement for the proposed plant has been estimated
based on the following factors:
¾ Area requirements of individual technological and service

facilities
¾ Smooth and uninterrupted flow of incoming and outgoing
materials with minimum counterflow for different technological
facilities.
¾ Logistics in location of technological units as well as services
facilities.
¾ Safety requirements and statutory provisions.
¾ Adequate green belt all around the plant.
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04.02.02 Existing Area
The total area required for the proposed 660MW coal based
Supercritical Captive Power Plant is about 150 acres. The plant
layout will contain facilities like Main power block including area
for future FGD, Balance of Plant including Sea water intake pump
house Cooling Towers, Demineralised Water Plant, Ash mound
area including Ash Plant area, 220 KV Switchyard, Clarified water
storage, Effluent treatment, lay-down area, green belt
development, Coal storage, access roads, etc. The general layout
considering recirculation type sea water Induced Draft Cooling
Tower (IDCT) is shown in dwg. no. JSW/DW/CPP/PR/006.
04.03 Logistics
The entire thermal coal required for the captive power plant will
be sourced from Australia, South Africa & Indonesia.
04.03.01 Road
The National Highway NH-17 (Mumbai-Goa) passes on the east

side of the plant. State Highway also passes on the north side of
the plant. The Mumbai city is located at about 100 km on the
North-West side of the plant.
The Road linkage of the proposed site is shown in Drg.No.
JSW/DW/CPP/PR/003.
04.03.02 Railways
The nearest railway station Pen is about 8 km from the plant site
and is located in the east on the Konkan Railway Mumbai -
Mangalore main line. Rail linkage from plant site has to be
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strengthen. The Rail linkage of the proposed site is shown in

Drg.No. JSW/DW/CPP/PR/004.
04.03.03 Port Connectivity
The Dolvi complex has a captive port located close to it on the

Amba River, which opens into the Arabian Sea. This port can
handle barges and mini-bulk carriers up to 4,000 dry weight
tonnage (DWT). Moreover, a jetty adjoining the complex is
capable of handling cargo of up to 16.2 million tonnes per annum.
Raw materials and finished products, to be exported, are being
handled through these ports. It is proposed to increase the jetty
length to handle the additional raw material.
04.03.04 Air Connectivity
The nearest Mumbai airport is 80 km away from site connected

through major road. The proposed Navi Mumbai International
airport is 40 km away from plant site.
04.04 Water
The make-up raw water requirement is about 400 m3/hour and

sea water intake would be around 7475 m3/hr, consumption is
1275 m3/hr and return back to sea would be about 6200 m3/hr for
the proposed 660 MW Captive Power Plant. At present JSW Steel
Ltd., Dolvi Works has been allocated about 56.0 MLD water from
Amba river, Nagothane, K.T.Bandhara. The water requirement is
proposed to be met from the existing allocation to JSW Steel Ltd.
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04.05 Power
The estimated power requirement for the 660 MW Captive Power

Plant will be about 47 MW. The total power requirement is
proposed to be met by the captive power generated by the CPP
complex.
04.06 Township
A township is being constructed to take care of the

accommodation facilities of the employees of the plant including
the proposed Power Plant.
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05 PLANT & EQUIPMENT
The plant and equipment for coal based supercritical captive

power plant of capacity 660 MW are briefly enumerated below
based on General Layout (Drg. No. JSW/DW/CPP/PR/006).
The Committee appointed by CEA to recommend to adopt units
of 660-1000 MW size in the country as next higher size in its
report of November - 2003. The Committee has examined among
other factors, the important aspects of grid reliability to withstand
outage of unit of large capacity, future grid inter connections,
increase in plant efficiency and reduction in the installation cost
of large size power plants, reduction in consumption of coal,
reduction in effluents and particulate matter to outside, established
reliability of large size units world-wide and environment benefits.
For the proposed 660 MW supercritical power project following
parameters are selected.
Main steam pressure 242.2 bar (a)
Main steam temperature 565°C
Reheat temperature 593°C
05.01 Steam Generator & Accessories

The steam generator (SG) would be once through type and would
be designed for firing imported coal of GCV 5000 kCal/kg. The SG
would be radiant; two pass / tower type design, single reheat,
balanced draft, dry bottom and semi outdoor type. The capacity
would be 2 % more than the VWO flow requirement of Steam
turbine. Indicative design parameters for the steam generator are
as below.
a. Superheater outlet pressure 255 kg/cm2 (a)

b. Superheater outlet temperature 568°C
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c. Superheater outlet flow 2150 TPH

d. Re-heater outlet pressure 51 Ksc(a)
e. Re-heater outlet temperature 596°C
f. Feed water inlet temperature to 294°C
economizer
The steam generator would have a fuel burning system of corner

fired or front and rear wall mounted type. The furnace would be
appropriately sized to avoid slagging in the water wall section,
pendant/platen super heaters and re-heaters and in the heat
transfer surfaces in convection pass.
The coal burners would be of proven advanced design to reduce

NOX production and the furnace would also be provided with over
fire air ports to further reduce NOX production.
The SG would be provided with circulation system comprising

steam separators to remove water moisture from the
evaporator outlet and to recirculate the water into
economizer inlet, for use during startup. The SG and steam
turbine generator (STG) would be designed for modified sliding
pressure operation, which would increase turbine cycle efficiency
and reduce boiler feed pump power consumption. The load
range for sliding pressure operation would be from about 40%
TG maximum continuous rating (TGMCR) to 90% TGMCR and
constant pressure operation from 90 % to 100 % TGMCR.
The SG would consist of water cooled furnace, radiant and

convection superheaters, reheaters, economizer, regenerative air
heater, steam coil air preheaters. Sequential / selective type
soot blower system would be provided with soot blowers
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located at strategic locations for cleaning the slagged and

fouled heat transfer surfaces during operation.
The SG would be provided with the required number of vertical

spindle medium speed coal mills (MPS mills), preferably with side
mill arrangement which will occupy less space than front/rear mill
arrangement. The milling system would be so designed that two
(2) mills would be spare with unit operating at BMCR capacity
firing design coal and one (1) mill as spare with unit operating at
BMCR capacity firing worst coal. The coal mills would be provided
with dynamic classifiers to control the fineness of the ground coal
thereby to control the unburnt carbon losses. The coal mills would
be provided with gravimetric coal feeders. The coal mills would be
provided with steam blanketing system for the purpose of fire
protection.
The SG would be designed to handle and burn HFO as secondary

fuel upto about 22.5% SG MCR for start up and for flame
stabilization with steam atomization, during low load operation or
during mill changeover. For unit light up and warm-up
purposes, LDO system having 7.5 % SGMCR firing capability
would be used with air atomization.
The draft plant would comprise primary air fans, forced draft fans
and induced draft fans. The primary and forced draft fans would
be of axial blade pitch controlled axial type. The induced draft
fans would be axial blade pitch controlled axial type or speed
controlled (VFD) centrifugal type.
Electrostatic precipitators (ESP) would be provided for the
collection of fly ash. The ESP would be so designed that for worst
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coal firing an outlet dust concentration of 100 mg/Nm3 with one

field out of service as stipulated by State/Central Pollution
Control Boards, would be achieved.
05.02 Steam Turbine Generator & Accessories

The steam turbine generator (STG) would be rated for 660 MW
maximum continuous output at generator terminals, with throttle
steam condition of 242.2bar(a) at 565°C/593°C reheat, 0.1
bar(a) condenser back pressure with 1.5 % make up. The STG
output at valve wide-open (VWO) condition would be 5% above
the maximum continuous rating.
The steam turbine would be a three cylinder, reheat extraction

and condensing turbine. The turbine generator would be complete
with all accessories such as protection system, lube and control
oil system, seal oil system, jacking oil system, seal steam
system, turbine drain system, electro-hydraulic control system,
automatic turbine run up system, on-line automatic turbine test
system and turbine supervisory instrumentation.
The turbine generator would also have all necessary indicating

and control devices to permit the unit to be placed on turning
gear, rolled, accelerated and synchronized automatically from
the control room.
05.03 Feed Cycle Equipment

05.03.01 Condensate Pumps
The condensate from the condensate hotwell would be
pumped by 3x50% capacity condensate pumps (two working
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and one stand by) to the deaerator through the gland steam
condenser, drain cooler and low-pressure heaters.
05.03.02 Boiler Feed Pumps

Feed water would be pumped from deaerator to the steam
generator through high-pressure heaters by means of 2x50%
capacity steam turbine driven boiler feed pumps. A 30% capacity
duty AC motor driven standby boiler feed pump would be provided
to facilitate start-up of the unit.
05.03.03 Low Pressure Heaters

The low pressure (LP) heaters would be of shell and tube with
stainless steel U-tubes (seamless/welded) welded with their
ends rolled in carbon steel tube sheets.
05.03.04 De-Aerator
The deaerating feed water heater would be a direct contact,
variable pressure type heater with spray-tray type or spray
type of deaeration arrangement.
05.03.05 High Pressure Heaters

The high-pressure (HP) heaters would be of shell and tube with
stainless steel U-tubes (seamless/welded) welded with their
ends rolled in carbon steel tube sheets.
05.03.06 Gland Steam Condenser

A surface type gland steam condenser would be used to
condense the gland steam exhausted from turbine glands.
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05.03.07 Condensate Polishing Unit

In order to maintain high purity of the feed water, 3X33%
capacity condensate polishing units (CPU) are envisaged in the
condensate system for each unit.
05.03.08 Fuel Oil System

The annual requirement for the proposed 660 MW unit would be
about 5782 m3 based on consumption of 1ml/kWh (CERC
guidelines) of power generation. The daily average consumption
of HFO would be about 15.84 m3 /day.
05.03.09 Chemical Dosing System

AVT (All volatile treatment) and oxygenated treatment is
considered. Ammonia dosing system would be provided to
ensure chemical conditioning of the condensate/feed water for
controlling the alkalinity. The ammonia solution would be injected
into the condensate at the condensate extraction pump
discharge during start ups.
To reduce iron pick up from the boiler, during normal operation of
the plant, oxygenated treatment is also proposed during normal
operation of the unit. Under this treatment gaseous oxygen
would be injected at CPU outlet and suction of feed water pump
and maintain about 150 - 250ppm. Feed water pH is maintained
in the range of 7.0-8.5.
05.04 Instrumentation And Control System

05.04.01 Plant Control System
The instrumentation and control (I&C) system for the plant is
proposed to be a comprehensive system integrating the
functions of plant monitoring, control and protection to
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facilitate the task of integration, co-ordination and autonomous

operation of the plant sub systems/equipment namely Steam
Generators (SG), Steam Turbine Generator (STG) and their
associated auxiliaries, balance of the plant equipment /
systems, plant electrical system, utility plants like coal handling
plant, Ash handling plant, DM water plant, compressed air
plant, Station common electrical systems including Switchyard.
Separate & independent microprocessor based STG Integral

Control system proposed for steam turbine governing, protection,
sequential logic control (ATRS, ATT, TSE, TSI etc.), HP/LP bypass
control, turbine integral system modulating control( lube oil, gland
steam system etc.), load shedding logic & Generator auto
synchronizing
The control requirements of the main power plant comprising SG,

STG with associated auxiliaries (except for BMS & Boiler
Protection system for SG & STG Integral control systems), and
all other balance of plant system/equipment required for
functioning of main plant like CW / ACW / Miscellaneous water
systems, chemical dozing system (both HP & LP bypass), plant
electrical system, BOP auxiliaries control & regenerative system
controls including control/monitoring for ESP, Condenser Polishing
Unit (CPU) & Mill reject system will be implemented in plant
Distributed Control System (DCS). Control of plant utility systems
like fuel oil un-loading, handling / storage & forwarding, cooling
tower, misc. water systems & Station common electrical system
etc. also will be covered in plant DCS.
Separate & independent PLC based control systems are
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envisaged for major utility plants like Coal Handling / Ash

Handling Plant (both Bottom Ash & Fly Ash Handling system) /
Raw Water & Pre-treatment (as applicable) / DM Water and
effluent treatment Plant (as applicable / Switchyard SCADA,
compressed air plant etc. & other auxiliary systems like DG set,
A/C & Ventilation system, Fire protection & Detection system
etc.
SG Integral control system for BMS & Boiler Protection system,

STG Integral control systems, major utility & auxiliary plant
system PLC based controls are envisaged to be interfaced with
plant DCS through redundant bi-directional OPC link with Ethernet
based TCP-I/P protocol. Other auxiliary systems PLC based
controls are also to be interfaced with plant DCS through suitable
redundant communication links.
05.04.02 Plant Operation Philosophy -
Operation from Central Control Room (CCR)

All equipment/system associated with complete power plant
viz. SG, STG and their associated auxiliaries, auxiliary systems
like chemical dozing systems (HP & LP) etc. & plant electrical
system, fuel oil handling / storage & forwarding, CW / ACW / Misc.
water systems, station electrical system & other main plant
related auxiliary plants will be operated / monitored from CCR.
Electrical system will include all breakers including generator
synchronising breakers for of 415V, 6.6 kV and 11 kV switch
gear. CCR operation includes unit, functional group / drive
level control and operation of equipment/system.
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CCR operation/ monitoring facility will also include facility for

complete monitoring of important utility & auxiliary plants like
Coal /Ash Handling / DM Plant (as applicable) / Raw Water &
Pre-treatment (as applicable) / Effluent Treatment Plant etc.
& other auxiliary plants/ systems as an additional facility, which
will be primarily operated and monitored from respective utility
plant located local control room.
Complete operation & monitoring of utility & auxiliary plants like

Switchyard SCADA etc.are envisaged to be carried out from CCR.
CCR operation/monitoring facility to include limited operation

(start/stop) & complete monitoring of compressed air system & DG
set.
Only monitoring of fuel oil unloading operation will be carried out

from CCR. Relevant operation will be carried out locally near to the
system/equipment
DCS/PLCs will be provided with following additional facilities

and the equipments pertaining to the same will be located in the
respective control room (CCR/LCR):
(a) Maintenance engineer's equipment (MEE) for DCS/PLC/ SG

Integral Control System /STG Integral Control System program
modification.
(b) Historical data storage & retreaval facility in 2 x 100%
configuration.
(c) Shift in charge Engineer's Monitoring Equipment.
(d) Station Incharge’s Monitoring Equipment
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Operation from Local Control Room (LCR)

The utility and auxiliary systems viz., Coal handling plant / Ash
handling plant / DM Water plant & Effluent treatment plant /
Raw Water & Pre- Treatment Plant / A/C & Ventilation System
etc., will be primarily operated & monitored locally from
respective utility plant located local control rooms (LCR)
together with facility for operation and monitoring facility from
CCR as detailed above is envisaged
05.04.03 Other I&C System Facilities / Features

Following special features / facilities are envisaged for I&C
system:
(a) Boiler tube leak detection system: To provide early warning of
boiler tube leak conditions using number of acoustic type
sensors. The system will be independent for each unit and
interfaced with DCS
(b) Furnace Flame monitoring & thermographic analysis system: To
provide thermographic analysis of the flame in the furnace
and also for each burner to provide details of flame
conditions on continuous on-line basis.
(c) Vibration Monitoring and analysis system: The vibration
monitoring and analysis system will provide critical analysis
ofhealth of rotating machines on continuous on-line basis and
provide guidance to the plant maintenance personnel
regarding the nature of fault and the maintenance action
required. The system will provide condition monitoring/analysis
of bearings of all critical machines like STG/ Turbine driven
BFP &Other HT drives / rotating equipment
(d) Management Information System (MIS): MIS will be able to
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provide processed information to management personnel

related to the Plant Operation, Plant Maintenance,
Environmental Information.
(e) Steam & Water Analysers (SWAS): Adequate number of
analytical instruments are envisaged for continuous
monitoring of de-mineralised water, condensate, feed water
and steam.
(f) Environmental monitoring System Analysers comprising Stack
monitoring, Ambient Air Quality & Metereological monitoring
systems.
(g) Plant Security & Surveillance System. A complete integrated
plant security and surveillance system (PSS) is envisaged.
The system will include Perimeter Intruder Detection, CCTV
Monitoring of Plant area/ equipment, Security card access
and Patrol Guard Monitoring System. Suitable monitoring
and alarming facility are also envisaged.
(h) Station LAN: A /gigabit type LAN encompassing and
interconnecting all plant buildings and rooms are envisaged for
usage with CMMS & MIS system. For security surveillance
system a separate terabyte LAN is envisaged.
05.05 Auxiliary Systems

05.05.01 Compressed Air System
For the requirement of instrument air and service air to meet the
plant air requirement adequate number of compressors (working
and standby) with suitable capacity will be installed. The
requirement of the compressed air for the ash handling system
would be met through separate dedicated compressors.
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05.05.02 Air Conditioning System

It is proposed to air-condition the unit control room, electronic
cubicle room, shift charge engineers room, printer room,
maintenance engineers room, UPS room, ESP control
room, static excitation cubicle room, analyser panel room, coal
handling control room, DM plant control room and switchyard
control room. Inside design conditions of 24.5 ± 1.50C dry bulb
temperature and relative humidity not exceeding 60% would
be maintained in all air-conditioned areas.
05.05.03 Ventilation System

For the ventilation of the station building, evaporative cooling
system (Air washer type) is envisaged. This system consists of air
washers, supply air fans, air washer circulating water pumps,
centrifugal fans and air distribution system for distributing the
supply air inside the station building. The exhaust of hot air out
of the station building would be achieved by provision of roof
extractors and wall mounted exhaust fans. For ventilation of other
buildings, supply air fans or louvers, exhaust air fans, roof
extractors or a suitable combination of these complete with
louvers, filters, ducting & grilles would be provided.
05.05.04 Cranes and Hoists
Two nos. Overhead, cabin / pendent operated electric overhead

traveling (EOT) cranes, of 125 / 20 tons capacity would be
provided for the proposed Unit also for handling of various main
plant equipment. Turbine & generator erection would also be
carried out by using the above cranes.
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Mobile crane would be provided to facilitate erection and

maintenance of pump components and drive motors.
An EOT crane of 12 tons capacity crane is proposed to be

provided for maintenance of BFPs for the proposed Unit.
Miscellaneous Lifting Tackles / Hoists
For the equipment, which weighs above 1000 kg, electrically

operated type of hoists and trolleys would be provided. For the
equipment weighing less than 1000 kg, manually operated hoists
and trolleys would be provided.
Workshop Equipment
It is proposed to utilize the work shop equipment available in the

existing power plant and no separate work shop equipment are
proposed to be procured for the expansion plant.
05.06 Electrical Systems
05.06.01 Generator
The generator would be rated to deliver 660 MW at 21 kV, 50 Hz,

0.85-power factor, at 3000 rpm. The generator would deliver
rated MVA within permissible limits of voltage and frequency as
per IEC 60034.
05.06.02 Generator Bus Duct
The terminals of the generator would be connected to the

generator transformer through Isolated Phase Bus Duct (IPBD) of
adequate short circuit withstand capability. Generator Circuit
Breaker (GCB) shall be provided at 21 IPDB.
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05.06.03 Generator Transformer
The GT would be 3 Nos. 21 kV / 220/√3 kV, 275/220/165 MVA

ONAN / ONAF / OFAF cooled 2 winding single-phase banks with
on load tap changer. The generator transformer would step up
generator voltage of 21 kV to the switchyard voltage of 220 kV
05.06.04 Auxiliary Power Supply System

Various auxiliaries would be supplied at the following nominal
voltages depending upon their ratings and functions:
(a) 11000 V, ± 10%, 50 Hz ± 5%, 3 phase, 3 wire, medium
resistance grounded AC supply for motors rated 1500 kW
and above.
(b) 6600 V, ± 10%, 50 Hz ± 5%, 3 phase, 3 wire, medium
resistance grounded AC supply for motors rated 200KW and
above up to 1500KW.
(c) 415 V, ± 10%, 50 Hz ± 5%, 3 phase, 3 wire, solidly
grounded AC supply for motors rated below 200 kW and other
L.T. services.
(d) 240 V, ± 10%, 50 Hz ± 5%, 1 phase AC supply for lighting,
space heating of motors and panels, single phase motors
(below 0.22kW), etc.
(e) 220 V, ungrounded DC supply for protection, control and
indication.
(f) 110 V, 1 phase, grounded AC supply for AC control circuits of
L.T motors.
(g) 240 V, 1 phase AC uninterruptible power supply for panel-
mounted recorders, CRT units, printers, analysers, etc.,
forming a part of the plant instrumentation and control
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system.
The auxiliary system loads would be segregated as unit loads and
common station loads. 2 x 50% rating Unit Transformers (UTs)
would cater to the unit load & 1 x 100% rating station
transformers (STs) would cater to entire station loads under
normal operating conditions. The start-up power for the
auxiliaries would be derived by means of station transformer or
by unit transformer.
The unit can be synchronised with grid by either closing 220kV GT
CB or GCB at 21 kV.
05.06.05 Unit Transformer (UT)

Two (2), two winding unit transformers would be provided.
These would be 32/40MVA, rating, 21/11.5 kV, 3 phase, 50 Hz,
with ±5% OCTC in steps of 2.5% on the HV side.
The unit transformers would supply power to the 11kV unit
switchgear. The unit loads would be distributed equally on each
11kV unit switch gear so that in case of outage of any one bus, it
would still be possible to operate the unit at partial load.
05.06.06 Station Transformers (ST)
Two Station Transformers of rating 40/50 MVA, 21/11.5kV, 3

phase, 50Hz with OLTC +5% to -15% in steps of 1.25% on HV
side would be provided to feed the station auxiliary load
requirement for complete station loads including the Coal and Ash
Handling package loads.
05.06.07 Unit Auxiliary Transformers (UAT)

Two (2), unit auxiliary transformers would be provided to feed
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6.6kV unit auxiliary motor loads. These would be min. 10 MVA,

11/6.9 kV, 3 phase, 50 Hz, with +5 % off-circuit taps in steps of
2.5% on the HV side.
05.06.08 Station Auxiliary Transformers (SAT)

Two (2), Station auxiliary transformers would be provided for
feeding 6.6kV Station auxiliary loads. These would be min. 15 MVA
(catering to ash handling system loads and only internal coal
handling system loads), 11/6.9 kV, 3 phase, 50 Hz, with +5 %
off-circuit taps in steps of 2.5% on the HV side.
05.06.09 Service Transformers

The required number of transformers would be provided
depending on service / location /
segregation of the loads. These transformers would be rated at
2500 / 2000 / 1600 / 1250 kVA, 11kV/433V or 6.6kV/433V They
would supply power to the 415 V auxiliaries of the unit and station
loads.
05.06.10 11000 V & 6600V Switchgear

The switchgear would be rated for symmetrical fault current
of 40 kA for 3 seconds. The 11kV & 6.6kV switchgear would
comprise draw-out type Vacuum circuit breakers housed in
indoor, metal-enclosed cubicles would cater to all 11kV, 6.6kV
motors, 11kV / 6.9 kV & 11kV / 433V transformers. The
switchgear would be equipped with control, protection, interlock
and metering & communication features as required.
05.06.11 415V System

The 415V, 3 phase, 3 wire power for the 415V auxiliaries
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would be obtained from 11kV/433V transformers and

6.6kV/433V transformers.
All power and motor control centres would be compartmentalised
and would be of single /
double front execution as needed. They would be of fully draw-
out design. The circuit breakers would be of air break type. Motor
starting would be direct on line
05.07 DC System
DC loads would be divided into two categories ie, Unit DC loads
and Station DC loads. Each category of loads would be catered by
separate battery and charger system. Two (2) nos. 220V 100%
rated batteries with associated float cum boost chargers would
be provided for each system. Each battery would be capable of
catering to 100% of power and control loads of Unit and Station
systems respectively.
05.08 Emergency Power Supply

To enable the unit to shutdown safely during complete A.C
supply failure in the station, certain important plant auxiliaries
would be provided with a reliable A.C power supply
through a separate source. For this purpose, one (1) 415V quick
starting diesel generator set with automatic mains failure (AMF)
would be provided for each unit additional one (1) no. standby DG
set shall be provided as per CEA regulations. Total no. of DG sets
will be 2 nos.
The diesel generator would feed a separate emergency 415V
Emergency switch gear. This switchgear in turn will feed the
Normal/Emergency PMCCs of the unit. All the essential loads
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such as the A.C emergency bearing lube oil and seal oil pumps,
turning gear motor, battery chargers, emergency lights, and
essential instrument power supply feeders would derive power
from this Normal/Emergency PMCC.
05.09 Un-Interruptible Power Supply System

For panel mounted instruments, CRTs, printers, analysers,
recorder, etc., 240 V single phase A.C uninterruptible power
supply would be made available. This power supply
would be derived from parallel redundant with static bypass un-
interruptible power supply system having two (2) sets of
converters, inverters & 2 X 100 % battery banks. Also a standby
AC supply would be provided as a back up to the inverters,
which would be switched on through static switch in case of
inverter failure. One UPS each shall be provided for unit
loads and station loads with the above configuration.
05.10 Electrical Equipment Protection Systems & Control

The selection of the protective scheme would be based mainly
on reliability, sensitivity, selectivity and technical merits. All main
protections would be of fast acting type in order to isolate the
faulty system from the healthy system in the shortest possible
time, to minimise damage to the equipment and ensure
continuity of power supply, if possible.
05.11 Cabling System

Power cables would be selected based on the following criteria:
a) Continuous circuit current rating
b) De-rating factors for ambient temperature and grouping
c) Short circuit rating of the circuit
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d) Voltage dip
e) Standardisation of cable sizes to reduce inventory.
05.12 Lighting System

Suitable illumination necessary to facilitate normal operation and
maintenance activities and to ensure safety of working personnel
would be provided.
05.13 Safety Earthing And Lightning Protection

A safety earthing system comprising buried steel conductor
earthing grid would be provided for the 220kV switchyard and
other outlying areas. This would be connected to the earth grids
in various buildings. The buried earth grids would be further
connected to earthing electrodes. The selection of earth
conductor sizes would be based on the applicable fault levels &
IEEE-80.
05.14 Communication System

For effective communication in the plant, public address system,
Electronic private automatic branch exchange system (EPABX),
landlines with ISDN / PSTN facility, wakie-talkie, OPGW (Optical
fibre ground wire) communication link along with necessary
terminal equipments will also be provided to ensure fast
communication between Switchyard & Local Dispatch Centre
(LDC).
05.15 Fire Detection / Alarm And Fire Proof Sealing System

Addressable type multi criteria detector based fire detection and
alarm system would be provided to facilitate visual and audible
fire detection at the incipient stage of fire in strategically
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important areas of the power station. This system would

comprise manual call points located at strategic locations in
areas which are normally manned and automatic addressable
type multi-criteria detectors located in plant areas, such as control
room, switchgear room, battery rooms, etc., to detect fire at an
early stage. Linear heat detectors would be provided for the
cable gallery and conveyors. Infrared type amber detector
would be provided for the conveyor gallery. Fireproof sealing
would be provided for all cable penetrations through walls and
floors to prevent spreading of fire from one area / floor to
another.
05.16 Elevators
One freight-cum-passenger elevator of capacity 2000 kg and
speed of 0.55 m/sec will be provided in the steam generator area
to serve major platforms of the steam generator.
05.17 Clock System

A clock system with one Master clock and 16 clocks located at
various strategic locations of the power plant will be provided.
05.18 Evacuation of Power

The power generated from proposed 660 MW captive plant would
be connected to 400 KV switchyard and power will be evacuated
to the steel plant through two Nos. of 210MVA 400/33KV
transformers and through two numbers of 315 MVA -
400KV/220KV inter connecting transformers.
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06 SERVICES, UTILITIES & MANPOWER REQUIREMENT
06.01 General
Besides raw materials i.e. coal, other major requirements of the

plant are water, power and fuel.
06.02 Water System
Sea water will be used for condenser cooling. Cooling water

system will be installed to transfer heat from turbine condenser
and other plant auxiliaries. The cooling water will be cooled either
at Natural draught cooling tower (NDCT) or Induced Draft Cooling
Tower (IDCT) will be decided after Techno-Economic analysis. In
case of adapting NDCT/IDCT for cooling, the sea water intake
would be around 7475 m3/hr, consumption is 1275 m3/hr and
return back to sea would be about 6200 m3/hr. Raw water
consumption shall be 400 m3/hr. The source of raw water would
be clarified water from the existing steel plant.
The raw water will be used in demineralised water plant for SG
makeup, potable water, service and fire protection system etc.
There shall be storage of clarified raw water for 7 days.
The condenser cooling will be achieved by Natural Draught
Cooling Tower (NDCT) or Induced Draught Cooling Tower (IDCT)
in closed sea water cooling system.
The cooling tower will be designed to cool the water from 42°C to
32°C at a design atmospheric wet bulb temperature of 28°C. The
water balance of the proposed plant is shown in Drg. No.
JSW/DW/CPP/PR/007.
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06.03 Clarified Water Chemical Dosing System

Chemical dosing system would comprise of chemicals with anti-
scaling / anti-corrosive and dispersant properties. For each type of
chemical the dosing system would consist of dosing pumps with
PP / SS material of construction with one dosing tank. Acid dosing
system with 1 No. bulk acid storage tank and dosing pumps would
be provided to control the alkalinity in the system.
To prevent / control algae growth in the CW system, chlorine
dosing would be provided. Continuous dosing will be done at the
rate of 1 ppm and shock dosing will be done at a
rate of 3 ppm. Chlorine leak detection and absorption system will
be provided to trap chlorine leakage.
06.04 Water Treatment Plant

The water treatment plant broadly consists of a filtration plant,
DM plant and an Ultra Filtration plant. The Filtration plant consists
of pressure sand filter to remove turbidity and suspended solids.
Alum would be dosed at the inlet to filters to aid filtration process.
06.05 Demineralisation (DM) Plant

It is proposed to provide two (2) x 100% streams DM plant (1
Working + 1 Standby), each stream designed for a net output of
1300 m3/day. The DM water storage tank will be sized to cater to
the one day requirement. The DM water will be used for
condenser cooling system, cooling of SG and TG auxiliaries and
plant service :
The quality of SG make up water required is as follows:
Total Silica as SiO2 Not greater than 0.02 ppm
Conductivity ≤ 0.1 µmho/cm at 25oC
pH 6.8- 7.2
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06.06 Service and Potable Water Systems

The service water system supplies water required for HVAC
system and misc. requirements of station building. Potable water
system will be derived after required filtration and chlorination.
06.07 Chemical Laboratory Equipment

The quality control laboratory, with modern equipment, shall be
provided for the proposed Captive Power Plant. The main
functions of the laboratory will be to analysis the coal, water and
steam samples from the plant.
06.08 Fire Protection System

Fire protection system would be provided covering all the
buildings of the proposed power plant boundary. The water
would be drawn from the raw water storage tank and reserve
capacity of 2000 m3 earmarked for the system. The following fire
protection systems are proposed:
a) Hydrant system
b) Automatic High Velocity Water Spray (HVWS) system for the
protection of transformers and manual HVWS system for
the protection of turbine oil tanks.
c) Automatic Deluge/ Medium Velocity Water Spray (MVWS)
system for the protection of cable vaults and over head
conveyors.
d) Heavy duty portable or trolley mounted fire extinguishers
for the protection of control rooms.
e) Portable fire extinguishers for different areas.
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Adequate number of pumps will be provided and system would be

designed to conform to the rules and regulations of fire safety
standards as per NFPA.
06.09 Power System

The total annual power consumption for the 660 MW Captive
Power Plant is 47 MW considering 7% auxiliary power
consumption.
The power generated from proposed 660 MW captive power plant
would be connected to 400 KV switchyard and power will be
evacuated to the JSW Steel Plant through two Nos. of 210MVA -
400/33KV transformers and through two numbers of 315 MVA -
400KV/220KV inter connecting transformers
The loads will be segregated as unit loads and common service

loads. The unit auxiliary loads will be supplied through unit
auxiliary transformers connected directly to the generator through
isolated phase bus ducts. Start-up for the auxiliaries will be
supplied through station transformer with GT breaker kept open.
Once the unit is started and the generator picks up rated speed &
voltage, GT breaker is closed after synchronising with grid. Tie
feeder will be provided from 6.6 kV station switch gear to 6.6 kV
unit switch gears of the unit so that during non availability of one
unit auxiliary transformer, the station transformer will feed the
loads connected to that unit auxiliary transformer.
An uninterrupted power supply (UPS) system would be provided

to cater to 220V AC, single phase, 50 Hz, 2 wire power supply
requirements of instrumentation and control systems viz. man-
machine interface equipment, analysers, receiver instruments,
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Closed loop controls, sequence controls, protection and interlock

system, annunciation system and sequence of events recording
system
To enable the unit to shutdown safely during complete A.C supply

failure in the station, certain important plant auxiliaries will be
provided with a reliable A.C power supply through a separate
source. For this purpose, one (1) 415V quick starting diesel
generator set with automatic mains failure (AMF) will be provided
for the unit.
The diesel generator will feed an emergency 415V switch gear, to

which all the essential loads such as the A.C emergency bearing
lube oil and seal oil pumps, turning gear motor, battery chargers,
emergency lights, and essential instrument power supply feeders
will be connected. When the station A.C supply is healthy, the
emergency switchgear will be fed from the unit service
switchgear. When the station A.C supply fails, the DG set will
start automatically and will feed the loads connected to the
emergency switchgear. When the normal A.C supply is restored,
these essential loads will be manually changed over to the normal
power supply.
06.10 Instrumentation and Control System

The Automation, Instrumentation and Control System (I&C) shall
be sufficient to monitor and control all significant variables in
accordance with the process requirement, provide all operating
requirements and necessary sequencing, interlocking and safety
functions including alarms for abnormal conditions of the
proposed Captive Power Plant.
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06.11 Process Automation System

The automation system for process control and monitoring will be
based on a modern Distributed Control System latest version
(hereafter referred to as DCS). The DCS system structure is based
on an integrated distribution system with inherent open type
architecture. The system will have mainly two functional levels.
06.12 Communication System

The telephone system will be provided for communication inside
as well as outside the plant. Telephone system shall comprise one
Electronics Private Automation Branch Exchange (EPABX) of
required line capacity and associated cable network along with
Press-to-talk system, CCTV, VHF wireless system as required.
06.13 Repair and Maintenance Facilities

The repair and maintenance facilities will be centralized to take
care of routine repair and periodical maintenance work of the
captive power plant. Major repairing works involving machining,
fabrication and assembly of heavy and critical jobs of specialized
nature are envisaged to be contracted to outside agencies.
06.14 Warehouse
A central warehouse will be utilised to keep spares of equipment,
hardwares and consumables. A Part of the building will be utilised
for easy manual loading and unloading of the materials from
trucks. Forklifts will be used for movement of materials inside the
stores building.
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Project Report
06.15 Ancillary Facilities

Necessary ancillary facilities such as administrative building,
canteen, car park, cycle and scooter stand, first-aid station etc.
shall be provided based on the manpower requirement for the
plant.
06.16 Drainage and Sewerage System

Open type drain has been envisaged for the plant storm water
drainage. The drains will be laid generally by the side of the
roads. Storm water run-off, collected through arterial and trunk
drain, will be discharged suitably for minimum pollution.
Sanitary faecal sewage will be collected from the ablution blocks

through pipeline and the same will be connected to a sewage
treatment plant. The effluent from the sewage treatment plant will
be utilized for the development and maintenance of greenery
06.17 Roads
Adequate plant road system will be provided. The road system will
be integrated with the existing roads.
06.18 Manpower Requirement

The proposed plant will not only require management and
executive manpower but also, skilled, semi-skilled, unskilled and
clerical manpower. However, a number of jobs like major repair
and maintenance, cleaning, transportation and loading / unloading
of bulk materials, etc. will be outsourced.
The total manpower requirement for the proposed 660 MW
Captive Power Plant, covering both works and administration is
estimated at 250 persons given below
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Project Report
The category wise break-up of manpower is indicated in table –

06.02.
Table – 06.02
Category wise break-up of manpower
Sl. No. Category Requirement

1. Managerial 10
2. Executive 20
3. Skilled 80
4. Semi-skilled 70
5. Unskilled 50
6. Clerical 20
Total 250
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Project Report
07 ENVIRONMENTAL MANAGEMENT
The proposed plant would result in air, water and land pollution of
varying nature and degree. This chapter briefly outlines the nature
and sources of pollution and also suggests broad environmental
protection measures to be adopted for limiting pollution within
permissible levels.
07.01 Nature of Pollution
The inputs to the Power Plant will comprise raw materials i.e. coal
along with water, fuel and power. These would therefore lead to
release of emissions to the air, generation of wastewater and solid
wastes. The Process would not be generating any Hazardous
Waste, as there is no Hazardous Chemical involved in the process.
The sources of pollution from the proposed project and the types
of environmental pollution likely to occur are summarized as
below.
Pollutants released Type of pollution

SO2, NOx, dust, heat, noise Air pollution, Noise pollution
and Water pollution
Pollution Prevention and Control Measures
In consideration of the above stated pollution potential of the

power plant, the following mitigation schemes are envisaged in
order to control environmental pollution within the permissible
norms and keep the environment fairly clean.
Ambient Air Quality Stations will be installed for monitoring the

continuous Ambient Air Quality based on meteorological
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JSW Steel Limited
Project Report
conditions, wind direction pattern, etc. for measurement of

following parameters in the ambient air.
• Suspended Particulate Matter

• Respirable Particulate Matter
• SO2
• NOx
• CO2
• CO
Provision for checking Ambient Air Quality outside the plant

boundary will also be made. High volume samplers with
attachments for gaseous sampling and particulate matter sampler
will be envisaged for this purpose
07.02 Air environment protection
The air polluting emittants from the power plant are as follows:
• Dust particulates from fly ash in flue gas
• Sulphur dioxide (SO2) in flue gas
• Nitrogen oxides (NOx) in flue gas
• Coal dust particles due to handling of coal
• Fly ash dust particles from ash silos and ash disposal area
• Ash Handling and Disposal
• Ash Generation
Dust particulates from fly ash in flue gas

The standard for particulate emission applicable to this project is
150 mg/Nm3. The electrostatic precipitators (ESP) proposed to be
installed in this project would be designed to limit the emission
level of the particulate matter to this limit 100 mg/Nm3
7-2
JSW Steel Limited
Project Report
Sulphur dioxide (SO2) in flue gas

One stack (chimney) of height 275 m for effective dispersal of SO2
is proposed to be constructed.
Nitrogen oxides (NOx) in flue gas

To reduce NOx emissions, over-fire air system equipment with air
ports would be installed for the furnace. Further, the steam
generators would be fitted with advanced low NOx burners. The
NOx emissions would be checked for ground level concentrations
(GLC) as per the above indicated Indian Emission Regulations.
Coal dust particles due to handling of coal

Coal dust would be generated generally at the conveyor transfer
points. Hence, coal transfer points would be provided with dust
suppression / dust extraction facilities. Further, in order to arrest
the coal dust generation, all conveyors would be provided with
enclosed galleries. Dust collection system would also be provided
in coal bunkers to evacuate dust from the coal bunkers. Collected
dust would be returned to either the associated belt conveyor or
to the coal bunker. The dust collector outlet emission would be
restricted to 100 mg / Nm³.
Fly ash dust particles from ash silos and ash disposal area
Fly ash storage silo for the unit is proposed to be provided. Fly
ash evacuated from the ESP collecting hoppers would be
transported in closed pipe lines by pneumatic means. At the time
of unloading fly ash in to the silo, some ash laden air would get
vented out. In order to restrict the fly ash dust particles to the
limits of 100 mg/Nm3, a vent filter would be installed on top of
the fly ash silo at the vents.
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JSW Steel Limited
Project Report
The following pollution control measures would be installed for

ash disposal :
a) To reduce the dust nuisance while loading the ash into the
trucks from fly ash silo, the fly ash would be conditioned with
water spray.
b) It is proposed to cover the ash in the open trucks with
tarpaulin to prevent flying of fine ash during transportation.
c) Water sprinkling system would be provided in the ash
disposal area to restrain flying of fine ash due to wind.
d) The ash disposal area would be lined with impervious lining
to prevent seepage of rain water from the disposal area in to
the ground and pollute ground water
Ash Handling and Disposal

• Collection of Bottom ash in dry form.
• Collection of fly ash in dry form to facilitate utilization for
cement plants.
• Disposal of un-utilized ash in conditioned form combined with
bottom ash to the ash pond.
• Dust collection hoppers at all strategic locations will have a
minimum storage capacity of eight (8) hours.
• Pneumatic conveying system (either vacuum system or
pressurized system) will be employed for extraction of fly ash
from the electrostatic precipitator hoppers in dry form.
• During emergency, when ash utilization is not possible, fly
ash will be transported from fly ash silo to ash mound area
located inside the plant boundary by closed trucks with
conditioned ash.
• One common chimney with two flues is envisaged for the
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JSW Steel Limited
Project Report
unit. The chimney height will be 275 m as per environmental

norms.
Ash Generation
Considering ash content of 20% in the coal, approximately 72 t/hr
ash is likely to be generated and in total 0.60 Million tons of ash
per year is likely to be generated from 660 MW coal based
supercritical power plant.
07.03 Noise environment protection
The plant is expected to increase the noise level in the

surrounding due to operation of plant and machinery.
The main sources of noise in a power plant are:
• Steam turbine generator
• Other rotating equipment
• Combustion induced noises
• Flow induced noises
• Steam safety valves
Necessary noise control and abatement measurers will be adopted
to minimize the noise level from the plant during construction and
operation phase to a maximum of 85 db(A) as per the
requirement of OSHA (Occupational Safety and Health
Administration) Standards.
All rotary equipment like fans, blowers, pumps & compressors

would be of low noise design. The grouting of these equipments
will be made free from vibrations. Noise absorbing cladding
around drying ball mill will be provided to reduce the noise level.
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Project Report
The work zone noise exposure of the operating personnel would

be avoided by remote operation from the control rooms by using
required safety equipments.
07.04 Water environment protection
The waste water from Demineralised Plant shall be treated and

led to the guard pond.
Waste water from process blowdown will be recycled and used to

be extent possible. The plant drains which are likely to contain oil
will be first separated of oil in the oil water separator and then
used for preparation of ash slurry or spray in the coal yard to
contain fugitive emissions.
Wash water from Air Pre-heater would be first collected in a

settling basin for the collection of ash particles and then pumped
to the Guard Pond. The treated effluent from the Guard Pond
would be used for gardening, green belt development and
plantation work. Sewage from various buildings in the power plant
would be conveyed through various drains to septic tanks.
07.05 Solid Waste

1. During construction phase, solid waste such as excavated soil,
debris, some metal waste and very small amount of oil &
grease from construction machines will be generated. This
waste may contaminate soil at plant site temporarily and
would be restricted to a small area.
2. Used/Spent oil and grease will be generated during
maintenance of equipment and machine.
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Project Report
3. Solid waste consisting of coal fine particles, fly ash and bottom
ash will be generated in the plant. Coal fine particles will be
reused in the plant, fly ash will be sold to the cement plant
and bottom ash will be used for road filling within the plant
and some part of bottom ash will be sold out.
4. Thus solid waste generated will not be having any negative
impact on the environment.
07.06 Plant safety
Plant safety measures would form an integral part of the

environment protection plan of the proposed plant. Workers’
safety would be of highest degree of concern so as to avoid any
form of personal injury or untoward accident. In-build safety
features of the plant and machinery would be made adequate in
order to avoid hazardous events causing damage to the life and
property.
Efforts would be made to afford the best safety measures and
health services with a view to keep the workplace free of hazards
to the extent possible. Standard programs will be framed and
followed for regular medical check-up, lung function test,
audiometry, vision test, etc. for the workers on a regular basis so
as to prevent and to detect occupational diseases and to promote
their general well being.
07.07 Greenbelt and landscaping
Adequate space would be reserved for gardening and tree

plantations at the site. This would improve the plant aesthetics as
well as prevent the fugitive dust emissions. Unpaved areas, if
any, within the plant boundary would be provided with grass
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JSW Steel Limited
Project Report
cover. This would not only act as ‘lung space’ but would also
improve the plant aesthetics.
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JSW Steel Limited
Project Report
08 PROJECT IMPLEMENTATION
08.01 General
Implementation of a Captive Power Plant is a challenging task and

calls for meticulous planning, scheduling and monitoring to realize
the project goals in budgeted time frame.
JSW has experience of erecting and commissioning Power Plants

at Vijayanagar, Jaigarh & Barmer. This experience will be utilised
in speedy implementation of the project.
08.02 Schedule
The implementation schedule for installation of the proposed 660

MW Captive Power Plant is indicated in the form of bar chart in
the drawing no. JSW/DW/CPP/PR/008. The overall schedule
shows that from the date of start of the project (Zero date), the
plant will be commissioned in 33 months. The schedule as
presented is based upon conventional project implementation
logics for power plant, preliminary vendor information available
and in-house analysis.
08.03 Zero Date
The date of start of project activities has been assumed as “zero

date” for installation of the proposed Captive Power Plant in
Maharashtra.
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JSW Steel Limited
Project Report
09 BLOCK CAPITAL COST
The estimated block capital cost for the 660 MW coal based
supercritical captive power plant is estimated as Rs. 4500
crores.
9-1
660 MW CAPTIVE POWER PLANT - JSW STEEL LTD. - DOLVI WORKS
PROJECT IMPLEMENTATION SCHEDULE
SL. ACTIVITIES DURATION OF DURATION IN MONTHS
NO. ACTIVITY 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36
1 Project Approval 0 Month
2 Basic Design 4 Months
3 Detailed Engineering 10 Months
4 Tendering, Scrutiny and order placement 8 Months
5 Planning & construction of Infrastructure facilities 16 Months
6 Civil works 20 Months
7 Fabrication & Erection of Structures 22 Months
8 Delivery of Equipment 12 Months
9 Erection of Equipment 10 Months
10 Testing & Commissioning of Plant 3 Months
11 Power Generation to commence -
DRG No. - JSW/DW/CPP/PR/008

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FORM-I

Ministry of Environment and Forests

(I) BASIC INFORMATION

Name of the Project/s 660 MW CAPTIVE POWER PLANT (Coal

Existing Capacity / Area etc. NA

Category of Project i.e. ‘A’ or ‘ B’ Category ‘A’

Does it attract the general condition? No

Does it attract the specific condition? No

Location The proposed plant facility is located in existing

The location of the site and study area map is

Village Wadkhal Village

Nearest Town, City, District Alibag 20 Km

Village Panchayat, Zilla Parishad Grampanchayat Wadkhal.

Name of the applicant JSW Steel Ltd

Registered Address JSW Steel Ltd

Address for correspondence JSW Steel Ltd

Tel 02143 – 277501 to 15

Name Shri. V. K. Patidar

Address JSW Steel Ltd

Pin Code 402 107

Fax No. Fax No. : 02143 – 277533 / 42

Details of Alternative Sites examined, Not Applicable

If no, reason Not Applicable

Whether the proposal involves Not Applicable

1. Construction, operation or decommissioning of the Project involving actions,

Sr. Information/Checklist Yes/ Details thereof (with approximate

1.1 Permanent or temporary No The company has already a total of about

1.2 Clearance of existing land, No There will be clearance of existing land,

1.4 Pre-construction Yes Detailed land survey, topographical

1.5 Construction works? Yes Installation of 660 MW power plant (Caol

construction works or housing up during the construction stage, which

1.11 Dredging? No Not applicable

The plant sanitary waste water will be

1.20 New or diverted transmission No Not envisaged

1.23 Abstraction or transfers of No The total water requirement for 660 MW

At present JSW Steel Ltd., Dolvi Works

1.25 Transport of personnel or Yes Construction materials, mechanical and

1.26 Long-term dismantling or No Not envisaged.

1.27 Ongoing activity during No Not envisaged

1.29 Introduction of alien species? No Not envisaged

1.30 Loss of native species or No Not envisaged

1.31 Any other actions? No -

2. Use of Natural resources for construction or operation of Project

Sr. Information/Checklist Yes/ Details thereof (with approximate

2.3 Minerals (MT) Yes Thermal Coal 30,00,000 Tonnes/Year will

2.7 Any other natural resources No Not envisaged

3. Use, storage, transport, handling or production of substances or

Sr. Information/Checklist Yes/ Details thereof (with approximate

3.5 Any other causes No -

4. Production of solid wastes during construction or operation or

Sr. Information/Checklist Yes/ Details thereof (with approximate

4.9 Contaminated soils or other No Not envisaged

4.11 Other solid wastes No Not envisaged

5. Release of pollutants or any hazardous, toxic or noxious

Sr. Information/ Yes/ Details thereof (with approximate

2. Sulphur dioxide (SO2) in flue gas:

One stack (chimney) of height 275 M,