Beruflich Dokumente
Kultur Dokumente
Doc No.
: PD/PRR-01/13-14/147
Date
: January 28, 2014
Assign No. : SO/13-14/04095
Date
: November 14, 2013
Prepared by
TABLE OF CONTENTS
CHAPTER
NOS.
PARTICULARS
EXECUTIVE SUMMARY
CHAPTER I
CHAPTER II
PAGE
NOS.
3-6
7 - 10
11 13
14
15
LIE Report for Sugar Factory & Cogen Power at Balaji Sugars, Muddebihal, Karnataka
EXECUTIVE SUMMARY
1.
BACKGROUND
M/s. MITCON Consultancy & Engineering Services Ltd., Pune have been
appointed as Lenders Institutional Engineer (LIE) for the 3500 TCD Sugar
Factory and 18 MW Bagasse based cogeneration power project of M/s Shri
Balaji Sugars & Chemicals Pvt. Ltd. (SBSCPL) located at village YaragalMadari, Tal. Muddebihal, District Bijapur, Karanataka. The plant is around
100 km from Bijapur city.
This report presents the site visit and project status review based on Jan 2nd
2014 visit to site. The report is based on inputs from M/s SBSCPL and
discussions held at their site and head office. Synopsis of this report is
presented below, along with recommended actions.
2.
PROJECT INFORMATION
Table no. 1: Project Information
Project Capacity
Project Owner
Project Location
Project Zero Date
PROJECT UPDATE
SBSCPL has deployed around 10 nos. experienced personnel for overseeing
various activities of the project at site. Most of the occupied land is provided
with barbed wire fencing. Civil work for sugar factory building is complete
and structural column erection is also completed. Civil foundation for sugar
plant equipments are in various advanced stages of completion.
Major column erection for boiler drum have commenced with balance
columns being fabricated at site. M/s SBSCPL is continuously monitoring the
project progress and instructing all suppliers through daily meetings and
monthly monitoring reviews to keep up the pace of work presently observed at
site.
LIE Report for Sugar Factory & Cogen Power at Balaji Sugars, Muddebihal, Karnataka
STG Building: Building structure is ready and Civil work for TG deck
footings will be taken up in coming weeks.
Boiler house: Main boiler columns are being fabricated at site. Four nos.
columns for drum support have been erected in place. Air preheater tubes have
been received at site.
LIE Report for Sugar Factory & Cogen Power at Balaji Sugars, Muddebihal, Karnataka
4.
ENGINEERING PROGRESS
Table below highlights the Engineering Progress of Various Packages.
Table no. 2 : Engineering Progress Status
The design, documentation, engineering inputs & drawings status is briefly listed
below.
All Engineering Layouts have been finalised and are being released at site as
per requirements.
All P&I diagrams have been prepared and are being submitted to Consultants
for vetting and approvals.
The EPC contract documents have been prepared.
Raw water piping scheme will be taken up the Company.
Vendor drawing review of respective packages are in progress.
Vendor drawing review of STG/Boiler/WTP electrical drawings are in
progress
Vendor drawing review of Switch yard and transformers will be submitted by
March 14.
LIE Report for Sugar Factory & Cogen Power at Balaji Sugars, Muddebihal, Karnataka
LIE Report for Sugar Factory & Cogen Power at Balaji Sugars, Muddebihal, Karnataka
CHAPTER I
PROJECT REVIEW AS OF 31ST Dec 2013
1.
INTRODUCTION
The physical front is further divided into infrastructure development and Civil
Construction related to basic infrastructure & foundation work.
2.
INFRASTRUCTURE DEVELOPMENT
Fencing : The site is provided with barbed wire fencing. Presently around 2
km length of barbed wire fens has been erected with balance work for 1.5 km
length.
Manpower : The total strength of the EPC Contractor M/s SS Engineers plus
their sub vendors on site personnel is around 40 nos. Presently three
contractors have been mobilised for mechanical works and fabrication at site.
Additional teams needs to be deployed separately for water wall panels, Eco &
APH tubing, ESP, Insulation, Electrical, C & I works as work progresses.
Work is in progress for fabrication of Boiler support columns and other
structural members.
Storage: Fabrication yard for structural steel work welding as well as for
stacking material receipts has been allocated to the EPC Contractor. The same
LIE Report for Sugar Factory & Cogen Power at Balaji Sugars, Muddebihal, Karnataka
is satisfactory and provides liberal space for site work. Construction power via
DG set has been provided to vendors as per demand on payable basis. KPTCL
power for construction work is likely to be commissioned in coming few
weeks.
BASIC INFRASTRUCTURE
FOUNDATION WORK
Plant building / civil work status
Civil work for sugar plant machinery is completed for cane preparation
and handling equipments. Foundation for mills, Juice clarifier and
auxiliary equipments in boiling house area is in progress.
Civil work foundation for BTG equipments is in progress. Main boiler
footings are ready. Footings for auxiliary equipments are in progress.
Structural work at Power house building is in advanced stages of
completion.
Chimney raft is completed.
Foundation work at molasses tank area is in progress.
3.
BASIC ENGINEERING
Completed milestones:
All Engineering layouts have been completed. P&I diagrams have been
prepared and are being submitted to Engineering Consultants for review and
approval. All contract documents have been completed. The Contract
documents for EPC of entire sugar plant and cogeneration power plant have
been completed. Review of mechanical drawings are in progress.
LIE Report for Sugar Factory & Cogen Power at Balaji Sugars, Muddebihal, Karnataka
4.
5.
6.
Chimney shell concreting work was earlier held up. Amendment for
Chimney height was requested by LE to be taken up with KSPCB at the
earliest. The same is now completed with revised height and as per
KSPCB norms and engineering design to M/s AGL is approved.
Column fabrication work for Boiler columns needs to be expedited.
Additional welders and fabricators to be mobilised by EPC Contractor M/s
SS Engg. and their sub vendor.
Adequate Quality Assurance reports should be prepared and submitted by
all on site vendors to Company and Consultants for their comments /
approvals as necessary. Records of all QA test reports to be maintain at
site. Boiler main columns should be more thoroughly inspected before
fabrication and erection.
Route survey for right of way is undertaken for transmission line towers.
Ordering for all balance plant and equipments to be expedited.
REMARKS
From present work progress and achieved milestones it is noted that civil work
foundations for main plant buildings, sugar mill machinery, cane preparation
equipments, molasses storage tanks, clarifier, main Boiler columns, TG
Building, RCC Chimney, Warehouse and weigh bridge is complete. Civil &
LIE Report for Sugar Factory & Cogen Power at Balaji Sugars, Muddebihal, Karnataka
structural work at Bagasse & Coal Handling Plant (CHP) area needs to be
taken up and expedited. Civil contractors have been instructed to augment
required workforce. Following areas of concern need to be addressed.
LIE Report for Sugar Factory & Cogen Power at Balaji Sugars, Muddebihal, Karnataka
10
CHAPTER II
REVIEW OF FUNDS DEPLOYED AS OF 31st DECEMBER 2013
1.
BACKGROUND
This chapter presents the review of and comments on Cash drawn as of
31st Dec 2013 and project status review based on Monthly progress report
of Engineering consultants. The report is based on inputs from M/s
SBSCPL and discussions held at their site office and head office. Synopsis
of this report is presented below, along with recommended actions.
2.
INTRODUCTION:
The overall project cost as given in table no. 3 approved for the Sugar
Factory and Bagasse Cogen Power Project is Rs. 211.55 Crore with term
loan as Rs. 150.00 Crore excluding bridge loan towards SDF. The term
loan is to be repaid in 28 equal quarterly installments with a moratorium of
2 years after receipt of loan installments.
Table no. 3: Cogen Project Cost as per Project Report, Rs Lakh
Sugar Plant
Cogen
Total
Power
Land & Site Development
Civil Works & Building
Plant & Machinery
Miscellaneous Fixed Assets
Preliminary Expenses
Preoperative Expenses
Contingencies
Working Capital Margin
Total
686
1805
6425
258
13
927
202
574
10890
288
1142
7535
175
9
797
199
120
10265
974
2947
13960
433
22
1746
401
694
21155
LIE Report for Sugar Factory & Cogen Power at Balaji Sugars, Muddebihal, Karnataka
11
Sugar Plant
Cogen
Power
3267
0
7625
10892
1996
892
7375
10263
5263
892
15000
21155
1
2
3
4
% of Term
Loan
35%
30%
20%
15%
The Company has till date incurred an expense of Rs. 5550.86 Lakh for
the implementation of the project. The CA certificate for the same is
attached in annexure. The break up of the expense incurred is as below.
Table no. 6: Project Cost Incurred Update
Sr. no.
Particulars
1
2
3
4
Project Cost
Incurred
Rs Lakh
939.00
1672.49
2534.42
370.71
5550.86
LIE Report for Sugar Factory & Cogen Power at Balaji Sugars, Muddebihal, Karnataka
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Particulars
1
2
Share Capital
Loan from SDF
Total Equity (A)
Term Loans
Consortium of Banks
Unsecured Loans
Total Borrowings (B)
Total (A+B)
3
4
3.
Amount
Rs Lakh
2806.12
Nil
2806.12
4375.00
Nil
4375.00
7181.12
ix)
x)
xi)
xii)
xiii)
LIE Report for Sugar Factory & Cogen Power at Balaji Sugars, Muddebihal, Karnataka
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4.
EQUIPMENT ORDERING :
The major equipment packages like Civil work, Site development, Steel &
cement, Boiler & aux., Chimney, Turbine & aux., Cooling Tower, Pumps,
Raw water pipe line, CHP & Ash systems, water treatment plants, EOT
crane, Transformers, Electrical switchyard equipments, have been ordered
and are in advanced stages of erection and installation.
M/s Balaji Sugars have released advance payments as per contract
agreements to EPC Contractor M/s SS Engineers. Few payments have also
been released to civil work contractors.
All the preliminary and pre-operative expenses incurred are also in line
with project construction activities.
The funds drawn are in line with the project schedule and payment terms
as agreed with various suppliers. The payments made to the respective
agencies are in line with the ongoing project progress and billing schedule
of respective package equipments. No undue advance payments / invoices
have been noticed.
Focus Areas
Project progress on the installation of both sugar mill machinery and BTG
and auxiliary systems needs to be expedited. Bagasse transfer conveyors
and systems from sugar mill to upto cogen plant needs to be planned to
avoid any delays. Manpower deployment of civil contractor and all
package vendors needs to be closely monitored so as to complete balance
work in time.
Power Evacuation Grid and 110 kV EHV System needs to be in place for
sustained evacuation of all exportable surplus power from the cogen plant.
LIE Report for Sugar Factory & Cogen Power at Balaji Sugars, Muddebihal, Karnataka
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LIE Report for Sugar Factory & Cogen Power at Balaji Sugars, Muddebihal, Karnataka
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