feasibility report for power plant

FINAL PROJECT

RIZWAN SHAKEEL SINDHU

Rag: 29S-641

Feasibility report on purchase of

POWER PLANT FOR INDUSTRIAL UNIT

1 – Page

IN

THE NAME

OF ALLAH,

THE BENEFICENT,

THE MERCIFUL

2 – Page

AKNOWLEDGEMENT

All praises and gratitude due to ALLAH who created man in HIS own image and

enjoyed upon him to ravel on the earth and enter into a profound and analytical study of

Universe for spiritual appreciation of ALLAH’s unity and HIS attribute as well as for

harnessing the material manifestation of the world to the mankind’s profitable utilization.

In the first place therefore we express our utmost thanks to ALLAH.

At the next stage I offer gratitude to our Apostle and prospector Prophet MOHAMMAD

(S.A.W) or his golden saying “GAIN KNOWLEDGE TO BE IN CHAINA” and

“GET KNOWLEDGE FROM CRADLE TO GRAVE”

3 – Page

DEDICATED

TO MY PARENTS

WHO ALWAYS

LOVE ME

And all those who have a soft corner for me in their hearts and always prayer for me for my success.

4 – Page

DECLARATION

I hereby declare that the project work entitled “Feasibility report on purchase of

power plant for industrial unit”

submitted to the Riphah international University Islamabad, is a record of an original

work done by me under the guidance of My Respectable teacher Mr.Syed Tanvir

Hussain Kazmi, and this project work has don.

Performed the basis for the award of any Degree or diploma/ associate

ship/fellowship and similar project if any.

RIZWAN SHAKEEL SINDHU

29S-641

5 – Page

TABLE OF CONTENTS

SR. NO. DESCRIPTION PAGE NO.

1 Executive Summary 7

2 Introduction 8

2.1 Objectives, Scope and Limitations, purpose of study 8

2.2 Introduction to industrial sector 9

2.3 Introduction of textile industry 13

3 Theoretical Aspects 17

3.1 Introduction of ABC Textile mills 17

3.2 Weaving Machine 18

3.3 Production Capacity 20

3.4 Load Estimated 22

3.5 Consumption of WAPDA 23

3.6 Direct & Operating Expanses 24

4 Analysis & Detail discussion 25

4.1 Feasibility 25

4.2 Personal power plant 26

4.3 Rental power plant 43

4.4 Select feasible power plant for industry 54

4.5 Quotations for power plant 55

4.6 Select personal power plant 66

5 Conclusion and recommendation 67

5.1 Conclusion 67

5.2 Recommendation 67

6 Bibliography 68

6 – Page

1. EXECUTIVE SUMMARY

This report template provides the method of making feasibility report for industrial unit

of any investment for the production of business. How we choose the best product for

organization to increase its productivity. Moreover, tell about the industry situation in

Pakistan and what is the problems facing now a days.

7 – Page

2. INTRODUCTION

2.1.a OBJECTIVES

The main objectives of our research are as follows:

1. To check the feasible product for the industry to overcome the problems

2. To see how determine the feasible product

2.1.b SCOPE OF THE STUDY

This research is focusing on the problem facing by the textile unit in Pakistan due to the

energy shortfall, how can we remove it, and what is the feasible way to overcome this

problem.

2.1.c LIMITATIONS

The research is based on fake industry but we use the actual values of the product, actual

capacity of production and actual consumption of the equipments. And actual value of the

quotations of gensets on rent and as well on purchase point of view.

2.1.d PURPOSE OF STUDY

The purpose of this research is to determine:

To understand the problems facing by textile industries (other

industries) in Pakistan due to the short fall of the energy for their

production

How make a feasibility of any product while go for large

investment.

　

8 – Page

2.2 GENERAL INTRODUCTION TO THE

INDUSTRIAL SECTOR

In recent years economists have begun to pay considerable attention to what are

coming to be called "General Purpose Technologies". The central idea is that there have

been a small number of technologies characterized by a potential for widespread use in

many sectors of the economy and, in addition a high degree of technological dynamism.

Further, the diffusion of these general purpose technologies throughout the economy is

said to give rise to "innovational complementarities," that is, "the productivity of R&D in

a downstream sector increases as a consequence of innovation in the GPT. These

complementarities magnify the effects of innovation in the GPT, and help propagate them

throughout the economy.

Needless to say, the concept of a GPT sounds as if it was specifically "custom-

designed" to provide a basis for examining the history of electrification. In fact, I believe

that there is considerable truth to this assertion. The concept has been articulated in an

attempt to demonstrate why some technologies - for example, steam engines, machine

tools, computers and transistors - are more influential, and consequential, than others. But

a central concern has also been to account for the anomalous fact that the computer has

not, or at least has not yet, generated the productivity-increasing consequences that have

long been expected of it. This has led to a reexamination of certain earlier technologies

for some insight into the behavior of GPT, and the history of electricity has served as the

most compelling example.

9 – Page

a. THE SECOND INDUSTRIAL REVOLUTION

Electric power is properly considered as a key element of the so-called "Second

Industrial Revolution" of the last quarter or so of the 19th century and the beginning

of the 20th. This revolution, together with the transformation of the chemical industry

and the internal combustion engine, redefined the whole set of technological

opportunities available to industrializing societies. The electrical and chemical

industries shared the important feature that their development was heavily

dependent upon scientific progress in the 19th century. In the case of chemicals, this

intimate liaison between science and technology dates from the young Perkin's

seminal, serendipitous discovery, in 1856, of mauve, the first of a very long line of

synthetic dyes, but the discovery also marks the birth of modern organic chemistry. It

is fair to say that 20th century industrialization has been, in large measure, a

protracted working out of the trajectories of economic opportunities that were

established by these two major scientific breakthroughs, together with the uniquely-

important internal combustion engine.

Of course, the chemical industry itself was not new, in the sense that human

beings had been conducting useful chemical transformations for, literally, thousands

of years. What is distinctive about the electricity industry, however, is that it was, in

all respects, a new industry, a product of 19th century scientific progress.

Consequently, it should be dated, with apologies to Volta and Galvani, from

Faraday's discovery, in 1831, of electromagnetic induction.

If this paper were an exercise in the history of technology, it would explore in

detail the numerous inventions upon which the later importance of electricity was to

depend: inventions that converted heat or kinetic energy into electricity. This would

include particularly the steam turbine; the inventive activity, especially the work of

Nikola Tesla, that led to the now-ubiquitous electric motor, which converted

electricity into mechanical energy or heat; and the transformer, which made possible

10 – Page

the transmission of electricity over long distances. Far from least, it would include the

electric meter, without which the efficient utilization of electricity would not have been

possible.

But my focus in this paper is both more narrow and more far-reaching. Electricity

is, of course, not a primary source of energy. It is, rather, a form into which primary

energy sources can be converted. Many of the distinctive advantages of electricity

derive specifically from the form that it can take rather than from any narrow

efficiency calculation as measured in terms of BTUs. Indeed, one of electricity's

greatest, but largely unsung virtues, is that it can make use of many energy sources

- fossil fuels (coal, oil, gas), hydro, nuclear, solar. It therefore makes possible the

substitution of one primary energy source for another, a feature that may sometimes

be of considerable strategic as well as economic value, although it is easy to

underestimate the cost of shifting from one primary energy source to another.

In undertaking to examine, in a short paper, the impact of electricity on the

process of industrial development over the past century, there is only one way to

proceed, and that is to be ruthlessly selective. I will simply take the obvious for

granted, then, that everyone is familiar with the immense profusion of products that

can be, literally, "plugged in" or switched on by any affluent householder in Western

Europe, North America or Japan. In doing so, however, it is important not to forget

the human welfare implications of that which we are taking for granted - from the

incandescent electric light bulb to the personal computer. The conventional

measures of improvements in standards of material well-being are generally

acknowledged to be inadequate in taking account of major changes in technology.

But the inadequacies may be especially large in the case of some electricity-using

technologies.

11 – Page

b. FEATURES OF ELECTRIFICATION

Modern industrial societies are commonly described as energy-intensive, which

is, so far as it goes, perfectly accurate. A central feature of industrial development

over the past two centuries is that it has been characterized by a growth in the

amount of energy utilization per worker, or per person. It may also be said, however,

that these societies are, more specifically, electricity-intensive. If one considers the

experience of the US over the past century, one observes a rise in the ratio of total

energy consumption to GNP between 1880 and 1920, but that ratio describes a long,

secular decline after 1920. Closely coinciding with that decline, however, is a steady

rise in the fraction of US total energy consumption that consists of electricity. It may

be said therefore that, in the aggregate, the US economy since the 1920s has

become, simultaneously, less energy-intensive and more electricity-intensive. At first

glance this seems surprising, because there are many times more energy contained

in the primary fuels that are employed in the generation electricity than in the output

of electricity actually produced from that energy - which is to say that there are huge

thermal losses in the generation of electricity.

12 – Page

2.3 TEXTILE SECTOR- OVERVIEW

The share of textile industry in the economy along with its contribution to exports,

employment, foreign exchange earnings, investment and value added makes it the single

largest manufacturing sector for Pakistan. It contributes around 8.5 percent to GDP,

employs 38 percent of the total manufacturing labor force, and contributes between 60-70

percent to total merchandise exports. Indeed, with exports reaching about $8.6 billion in

2004-05, Pakistan is one of the largest textile exporters in the world.

The variety of products ranges from cotton yarn to knitwear. Garment made-ups and bed

wear are the most important export products with an export value of about $1.35 billion

each. Knitwear, readymade garments and cotton yarn also have important shares in total

exports. Overall, the US and the EU are Pakistan’s largest trading partners accounting for

25 percent and 20 percent share of Pakistani exports respectively. Other major importers

include China, UAE and Saudi Arabia. Textile trade is classified into two broad

categories i.e. textile which include yarn, fabric and made-ups, and clothing which

represents readymade garments.

13 – Page

Investment in Textile Sector

Textile industry has made an investment of about $6.0 billion during the last

six years. This investment includes both investments through bank loans as well as

own sources. This investment has been made in the form of BMR expansion and

new capacity. Textile machinery worth US$ 0.6 billion has been imported during

2005-06. the import of textile machinery for the last seven years are documented in

Table and Sector wise Investment is shown in figure

Table Import of Textile Machinery

Year Million US $ % Change

1999-2000 210.9 28.6

2000-01 370.2 75.5

2001-02 406.2 9.9

2002-03 531.9 30.7

14 – Page

2003-04 597.9 12.4

2004-05 700 17

2005-06 (Jul-Mar) 654.2 -6.5

Total 3472

Source: Federal Bureau of Statistics

15 – Page

Reforms in the Textile Sector

The government is providing support for the local production of textile

machinery. A wide-ranging campaign to produce contamination free cotton in the country

with a view to promoting value addition has already been started. As a result, the cotton

prices are now being quoted on a PSCI grade standard basis. To ensure an abundant

supply within the country, cotton is allowed to be imported and exported freely. To

stabilize prices in the domestic market, the Trading Corporation of Pakistan (TCP) has

been intervening as and when required.

In order to prepare the textile industry in the post quota regime the government has set up

a high level Federal Textile Board with Textile Commissioner’s Organization serving as

its Secretariat. The Board has been entrusted the task of looking into the issues of clean

cotton, labor, social and environment laws, modernization of ginneries, rationalization of

tariffs, facilitation in sales tax issues and developing a package to promote garment

sector, especially by improving their competitiveness in international market.

16 – Page

17 – Page

3. THEORETICAL ASPECTS

3.1 INFORMATION OF ABC TEXTILE INDUSTRY

Suppose a textile firm manufacturing a cotton cloth with having 40 machines

(Toyota Air Jet 710) with effective labor and employees. Situated in Lahore on

raiwind Raod have facing the problem shortage of production.

Resources of the firm

Particulars Rs.

Land and Building 30,000,000Furniture and fixture 5,000,000Machines (40 @ 1,000,000) 40,000,000Electric Instruments 2,000,000Contingencies 1,000,000

Total 78,000,000

18 – Page

3.2 WEAVING MACHINERY

Toyota Industries develops and manufacturers air jet looms, which insert the weft

yarn using air. We provide our customers all over the world with state-of-the-art

weaving machinery that excels in speedy and reliable performance

a. JAT710 (Air Jet Loom)

The JAT710 is designed with the same concept as the JAT610: “weaving the highest quality

fabric at the lowest possible cost,” and boasts improved features such as higher speed, lower

vibration and lower energy consumption. Plus it is equipped with the latest electronics technology

such as a new internet-capable color function panel, taking today’s weaving mill into a new

dimension.

Weft insertion: single electric drum, 2-, 4-, 6-color exchange electric drum

Nominal reed space: 140cm, 150cm, 170cm, 190cm, 210cm, 230cm, 250cm, 280cm,

340cm, 360cm, 390cm

Shedding: negative cam, positive cam, crank, dobby, electric shedding, jacquard

Selvage: left/right rotary full-leno selvage device

Toyota Industries Corp. started production of its new JAT710 air-jet loom in January this

year.

In developing the JAT710, Toyota took its best-selling JAT610 air-jet loom a step

further, while keeping in mind that the needs of the weaver have become more diverse

and complex as our world becomes increasingly information oriented. The JAT710 has

been designed under the same concept as the JAT610; i.e., “weaving the highest quality

fabric at the lowest possible cost,” and boasts a number of improved features such as

higher speed, lower vibration and lower energy consumption. Moreover, the latest

electronics technology used on the JAT710 including a new Internet-capable color

function panel takes today’s weaving mill into a new dimension.

19 – Page

Toyota’s new air-jet loom JAT 710

The JAT710 features 20% less air consumption as new technology achieves further

savings in air consumption compared to the JAT610, which is already well received for

its low air consumption.

Operational speeds of up to 1,250 rpm (190 cm reed space) can be attained thanks to

numerous improvements such as a new weft insertion system, a new frame structure and

a higher CPU processing speed. Machine vibration has been reduced by 30% through

further improvements over the JAT610 in the frame structure and beating motion. State-

of-the-art electronics technologies, including a new color function panel and a high-speed

CPU, offer greatly enhanced communication capabilities for advanced weaving mills.

Furthermore, a full range of standard equipment and a variety of options allow the

JAT710 to weave fabrics that were previously mostly woven on rapier looms, including

ultra-wide home furnishings fabrics, stretch fabrics, fabrics of different yarn varieties and

counts, airbags, seersucker and fabrics with tuck-in selvedges.

20 – Page

3.3 PRODUCTION CAPACITY

As there is no any kind of generator facility available so the there is only two shift of

workers doing work and in 16 hours machines works only 10 hours and remaining 6

hours WAPDA Shut down. And performance of machines is that if 10 machines

continuously worked it make 45360 meter cloth in one hour and 40 machines make

1814400 meter cloth in one hour and in 10 hour working it make 1814400 meter cloth in

one day

Calculation

Actual capacity performance

Units Cloth / Meter

One machine on working one hour produced 4536

One machine on working 16 hours produced 72576

40 Machine on working 16 hours produced 2903040

Monthly production (2903040 X 30) 87091200

Yearly production (97091200 X 12) 1045094400

21 – Page

Current performance

Units Cloths / Meter



40 Machine on working 10 hours produced 1 814400

Monthly Production (1814400 X 30) 54432000

Yearly Production (54432000 X 12) 653184000

Shortfall of production

Units Cloths / Meter



40 Machine on working 6 hours produced 1088640

Daily short fall of production 1088640

Monthly shortfall of production (30 days) 32659200

Yearly shortfall of production (12 months) 391910400

22 – Page

3.4 LOAD ESTIMATED FOR TEXTILE UNIT

Name of Equipment Unit KW Consumption No. of Eqp. Total Consumption KW

Toyota Air Jet 700 3.08 40 123.2

Tube lights for Machineries 0.04 2000 80

Tube Lights for Office use 0.04 150 6

Computers 0.5 20 10

Printer 0.5 5 2.5

Scaner 0.3 3 0.9

UPS 4 3 12

Air Conditioners 3 10 30

Fans 0.08 200 16

Fax 0.7 3 2.1

Telephone Exchange 1.5 1 1.5

Refrigerator 1 1 1

Microwave oven 1.5 1 1.5

Water Pump 5.5 2 11

Television 0.7 3 2.1

Photocopy Machine 2 2 4

Total Consumption KW 303.8

Add 20 % Variation 20X303.8/100 60

23 – Page

Suggested power plant 363.8

24 – Page

3.5 Consumption of WAPDA Units

According to units consumption formula one unit consumed when 1 kw electricity

continuously consumed for one hour

1 KW / Hour = 1 unit

304 KW / 10 hours = 3040 units in one day

304 X 30 (Days) = 9120 units in one month

Cost Chart of WAPDA

Units consumed 9120

Units Rate (Rs.) Price (Rs.)

9120 14.00 (9120X7) 127,680

Total 127,680

WAPDA Fixed Charges 10,000

Total Electricity Cost 128,680 Rs.

Total Yearly Cost (128,680 X 12) 1,544,160 Rs.

25 – Page

3.6 DIRECT AND OPERATING EXPANSES

SALARIES OF EMPLOYEES

Name Of Post Monthly Salary No. of Post Total Salary

HR Department -

Admin Manager

30,000 1

30,000

Assistant Admin Manager

18,000 1

18,000

Clerk

8,000 2

16,000

Accounts Dept -

General Manager Finance

40,000 1

40,000

Chief Accountant

30,000 1

30,000

Accountant

20,000 2

40,000

Assistant Accountant

12,000 4

48,000

Cashier

10,000 2

20,000

Clerk

8,000 5

40,000

Sales Department -

Market Manager

35,000 1

35,000

Sales Managers

25,000 3

75,000

Sales Coordinator

12,000 4

48,000

Operator

8,000 1

8,000

Office boys

6,000 2

12,000

Sweepers

4,000 3

12,000

Watchman

7,000 2

14,000

Total

486,000

Annually Salaries 486,000 X 12

5,832,000

26 – Page

Wages for workers

Name of Post Monthly Salary / Labor Hours No. of Post Total Salary

Production Dept

Production Manager 25,000 2 50,000

Supervisor 15,000 6 90,000

Skilled Worker 10,000 / 42 20 200,000

Unskilled worker 6,000 / 25 10 100,000

Minuteness Dept

Skilled Workers 8,000 / 33 3 24,000


Electrical Dept

Engineer 20,000 1 20,000

Skilled worker 12,000 6 72,000


Other Labor

Workers 5,000 5 25,000

Total Wages for Production 785,000

Annual Wages 785,000 X 12 9,420,000

27 – Page

4. ANALYSIS OF AND DATA DISCUSSION

4.1 Feasibility based on following Characteristics

1. Effective cost

2. Proper use of labor

3. Fully use of machines

4. Less wastage of time

5. Maximum output

6. Maximize the profit

7. Fill filed gap of the shortfall of electricity

8. Supplier advantage

9. Competitive advantages

10. Fulfill the market demand

28 – Page

G00012/RM/2011 Feb 12, 2011

M/S ABC Textile Mills

Lahore

Kind Attn: Manager Procurement

QUOTATION FOR FG WILSON 500KVA DIESEL GENERATING SET

Dear Sir,

With Reference to the above mentioned subject and the subsequent telecon regarding

the supply of Diesel Generator, we have pleasure in submitting our most competitive

proposal for your kind consideration. F.G Wilson (Engineering) Ltd is a pioneer in the

design and manufacture of diesel generator sets. For over 40 years, FG Wilson has been a

major global player, world leader in the provision of power generation solutions ensuring

power is provided whenever, and wherever it is needed.

29 – Page

Established since 1949, S.M. Jaffer & Co. Headquartered in Karachi has offices in

geographically strategic locations (Lahore, Faisalabad, Islamabad & Peshawar) and

hence, we are by no means out of contact when required. We are sure our offer is as per

your expectations and looking forward to serve you at our best. Thanking and assuring

you of our best services at all times, we remain.

Yours faithfully,

S. M. Jaffer & Co.,

RAHIM BUKSH ABDUL WAJID

KURESHI

Deputy Manager Sales Regional Manager

Sales

Cell: 0300-8488544 Cell: 0300-8475932

30 – Page

TECHNICAL SPECIFICATION

F. G. Wilson Perkins Range diesel engine driven Generator set arranged for manual

electric start / stop operation, with following dominant features. D.G. Set Model P500

(F.G.WILSON)

Prime Rating 500 KVA – 400 KW

Standby Rating 550 KVA – 440 KW

Voltage 380-415 V

Phase 3

Wires 4

Power Factor 0.8

Sound Hz 50

Engine Make PERKINS

Alternator Make F.G.WILSON

Governor Electronic

31 – Page

ENGINE:

Turbo Charged, 12/V cylinders in line pressure lubricated, 4 stroke, diesel

engine having a continuous output at 500 R.P.M. under NTP conditions with

a 10% overload

capability for one hour in any consecutive 12 hour period.

ENGINE COMPLETE WITH:

Close control electronic governor to BS, Fuel injection equipment with fuel

lift pump. Fuel oil and lubricating oil filters. Replaceable element

type 24-volt electric engine starting motor. Engine driven battery

charge alternator.

COOLING SYSTEM

Engine driven tropical radiator with centrifugal water pump.

Cooling water circulating pump engine driven.

Cooling water temperature control thermostat.

Fan and pulley safety guards.

32 – Page

ALTERNATOR:

The alternator is brushless, self-exciting, self-regulating, fan ventilated, ingress

protection rating IP23 with class H insulation, pitch windings and interconnected damper

windings. Voltage regulation is maintained within the limit of ± 0.5% from no load to full

load, including cold to hot variations at any power factor between 0.8 lagging and unity.

Radio suppression is inline with British standard.

CONSTRUCTION / BASEFRAME;

The engine and alternator are coupled through a heavy-duty flexible drive. The

engine alternator and radiator are mounted on a robust fabricated steel base frame with

integral lifting points. Anti-vibration mountings are incorporated within the assembly.

STARTING BATTERIES:

A 24-volt lead acid battery assembly of ample capacity is supplied complete with

all necessary connectors and cables. Fitted to the base frame on battery tray complete

with retaining clamp. Batteries are supplied dry charged.

GUARDS:

Protection is provided for all rotating parts - i.e. fan cooling and alternator air

intake and outlet grills.

33 – Page

POWER WIZARD 1.0 SERIES CONTROL PANEL Common look and from 10 to 2000kVA for ease of

Operation and service

9-32V DC providing a single module to cover whole product range

Simple menu layout for ease of navigation and

Monitoring

Two display languages, (English and a customer

Language*) to aid service and commissioning

Last 20 event log to aid fault finding

Robust electronics package for industry leading reliability

Configurable using front key pad/laptop

Shortcut keys for immediate access to engine or AC metering

Integrated metering and controls reducing components and wiring aiding reliability and

ease of service

Common engine wiring system allows simple upgrading between levels of panel

Can be serviced using standard EST tool

STANDARD FEATURES

PANEL CONSTRUCTION AND FINISH

Components installed in a heavy duty sheet steel enclosure

Phosphate chemical pre-coating of steel provides

34 – Page

Corrosion resistant surface

Polyester composite powder topcoat forms high gloss and extremely durable finish

Lockable-hinged panel door provides for easy

Component access

MOUNTING

Mounted to generating set base frame on robust steel stand

Vibration isolated from generating set

INSTRUMENTATION

LCD display with adjustable contrast and backlight with auto power off

AC Meter

o Volts 3-phase (L-L & L-N)

o Amps (per phase & average)

o Frequency

DC Meter

o Battery Volts

o Engine Hours Run

o Engine Jacket Water Temperature (in 0C or 0F)

o Lube Oil Pressure (in Psi, KPa or bar)

o Engine Speed (RPM)

35 – Page

PROTECTION

Fail to Start

Low Oil Pressure

High Engine Temperature

Low / High Battery Voltage

Battery Charger Failure (if fitted)

Under speed, Over speed

Loss of Engine Speed Detection

2 Spare fault channels

20 Event fault log (name of event, engine hours at first occurrence of event, engine

Hours at latest occurrence of event, number of occurrences of event)

CONTROLS 2 LED status indicators (1 red shutdown, 1 amber warning)

Run key & LED indicator

Auto key & LED indicator

Stop key & LED indicator

Lamp Test key

Alarm Acknowledge key

Menu navigation key

Engine and AC metering shortcut keys

All control module keys have tactile feedback

Lock down emergency stop push button

CAN 1 data link – J1939 for communicating with electronic engine control modules

36 – Page

BATTERY CHARGER

Static battery charger will be provided for both trickle and boost charging of the batteries

when the engine is not in operation.

OUTGOING CIRCUIT BREAKER CUBICLE

A free standing steel formed cubicle containing the 3 pole Air circuit breaker of suitable

rating, Magnetic and thermal trips are provided for plant protection against plant overload

and short circuit conditions.

EXHAUST SYSTEM

The exhaust system incorporates the following loose equipment:

Flexible pipe section

Residential silencer

WORKS TESTS:

The equipment is tested against a resistive load, plus a full functional check on the

control equipment. A copy of our works Test Certificate will be supplied

FINISH

The equipment is finished with a self-etching primer applied to the complete generator

set with final finish in high gloss enamel paint.

HANDBOOKS, ETC

One set of the following are supplied in our standard format:

Engine operation and maintenance manual

Circuit diagram and general arrangements

Control system manual

37 – Page

NOTE:

1. Any item other then B.O.Q shall be charged extra

2. Any kind of permission is not included in above prices.

3. Crane if required will be charged extra.(For Roof Top Delivery)

4. All prices other than Genset are exclusive of G.S.T

5. Sound Level of Locally Fabricated Canopy is 85dB (A) @ 1 meter.

6. Cables to be charged at actual.

7. R.C.C Foundation Pad is of our standard scope and size.

PLEASE CHECK THE COMPLETE PRICES WITH DETAILS

IN BELOW MENTIONED B.O.Q

TERMS AND CONDITIONS:

Delivery : Immediate from stock, subject to the prior sale.

Payment : 100% advance with confirmed order.

Force Majeure : Our offer is subject to Force Majeure Condition.

38 – Page

FG WILSON

ENGINE : PERKINS UK

ORIGIN : UK

Validity : Our Offer is valid for 15 Days Only.

Guarantee : 12 months or 2000 hours whichever comes first against any

Manufacturing defective Parts.

Currency Rate : Our quoted prices are firm and final for the validity period

mentioned above. However our prices are based on present day

import levies and exchange rate. Incase of any change in above

the price will be adjusted accordingly.

Note:

We are exempt from deduction of Income Tax as per S.R.O. 97(I)/2002 dd 12-

02-2002 as the income tax has been paid at the import stage.

D.G.Set price is based on zero rated Sales Tax as per custom S.R.O.

39 – Page

PRICE B.O.Q FOR FG WILSON 500 KVA GENSET

S.No Description Qty Unit Rate (Rs.) Amount (Rs.)

01. Diesel Generating Set (500KVA

Prime Rating)

As per Specifications

01 No. 5,500,000.00 5,500,000.00

,

02.

Locally Fabricated Sound Proof

Canopy

Sound Level 85dB(A)

01 No.

500,000.00 500,000.00

03. AMF/ATS Panel 03 Pole

(for 01 WAPDA meter only)

01 No. 70,000.00 70,000.00

04. Transportation / Loading &

Unloading at Ground Floor

(Up to Site)

01 Job 15,000.00 15,000.00

05. Supply, Laying & Termination of

Power Cable 300sq.mm, 4 Core

with all allied materials.

Mtr 1616/- To be charged at

actual


Earth Cable 240sq.mm, 1 Core.

Mtr 450/- To be charged at

actual.

08 Supply, Laying & Termination of

Control Cable 2.5sq.mm, 3 Core. Mtr. 450/- To be charged at

actual.

08. Making of Earth pit for the neutral

& body of Genset (without boring)

As per our Standard

03 No.s 5,000.00 5,000.00

40 – Page

09. Commissioning of DG Set without

Fuel & Material

01 Job 5,000.00 5,000.00

10. Making of R. C.C Foundation Pad

as per standard scope and size.

01 Job 25,000.00 25,000.00

11. Labor & Installation Charges 01 Job 5,000.00 5,000.00

TOTAL FOR ABOVE (without Cables) Rs. 6,055,000.00

41 – Page

42 – Page

Genset operating cost

Fuel Cost

Fuel Consumption (0.2 X 500) 100 liter

But we use 70 % capacity of the genset and at that time consumed fuel 70 liter per

hour

Rs.

70 X 70 at one hour 4,900

For Six hour 6 X 4900 29,400

Monthly cost for 30 days 782,000

Yearly Cost 782000 X 12 9,384,000

Total –A 9,384,000

Maintenance Cost

Genset Service required after 200 hours

Following items are required for service

Fuel Filter 931 5,000


Oil Filter 929 5,000

Lube oil 68 liter @ 400 27,200

Total Cost 42,200

Monthly running the genset 6 X 30 180

Yearly Running the genset 180 X 12 2160

Service required yearly 2160/200 10 Times

Total Service Cost 42,200 X 10 422,000

Total – B 422,000

43 – Page

Depreciation

Total Genset Value including Installation 6,055,000.00

Annually Deprecation @ 10 % 605,500.00

After ten years residual value of genset is 1,000,000.00

As per market value

Total Annual Cost for Genset

Rs.

Fuel Cost 9,384,000

Maintenance Cost 422,000

Depreciation 605,500

Total 1 0,411,500

44 – Page

New Generation Technology From

Suite # 216 Mashrique Centre Block 14, Gulshan-e-Iqbal, Karachi.

Web Site: www.raeng.com E-mail: [email protected]

Tel # 0213 – 485 2125 , 0213 -485 2126 - Fax # 021-34142300

Ref: 212-2011 Dated: 1-2-2011

M/S: ABC Textile Mills

Lahore

Kind Attn: Manager Procurement

Subject: QUOTATION FOR 500KVA DIESEL GENERATING SET

Dear Sir,

With Reference to the above-mentioned subject and the subsequent telecon regarding

the supply of Diesel Generator, we have pleasure in submitting our most competitive

proposal for your kind consideration.

Yours faithfully,

R.A. Engineering & Services

Mr. Azeem

Deputy Manager Sale

45 – Page

http://www.raeng.com/

mailto:[email protected]

TECHNICAL SPECIFICATION

F. G. Wilson Perkins Range diesel engine driven Generator set arranged for manual

electric start / stop operation, with following dominant features. D.G. Set Model P-500

(F.G.WILSON)

Prime Rating 500 KVA – 400 KW

Standby Rating 550 KVA – 440 KW

Voltage 380-415 V

Phase 3

Wires 4

Power Factor 0.8

Sound Hz 50

Engine Make PERKINS

Alternator Make F.G.WILSON

Governor Electronic

ENGINE:

Turbo Charged, 12/V cylinders in line pressure lubricated, 4 stroke, diesel

engine having a continuous output at 500 R.P.M. under NTP conditions with

a 10% overload

capability for one hour in any consecutive 12 hour period.

46 – Page

ENGINE COMPLETE WITH:

Close control electronic governor to BS, Fuel injection equipment with fuel

lift pump. Fuel oil and lubricating oil filters. Replaceable element type

24-volt electric engine starting motor. Engine driven battery charge

alternator.

COOLING SYSTEM

Engine driven tropical radiator with centrifugal water pump.

Cooling water circulating pump engine driven.

Cooling water temperature control thermostat.

Fan and pulley safety guards.

ALTERNATOR:

The alternator is brushless, self-exciting, self-regulating, fan ventilated, ingress

protection rating IP23 with class H insulation, pitch windings and interconnected damper

windings. Voltage regulation is maintained within the limit of ± 0.5% from no load to full

load, including cold to hot variations at any power factor between 0.8 lagging and unity.

Radio suppression is inline with British standard.

CONSTRUCTION / BASEFRAME;

The engine and alternator are coupled through a heavy-duty flexible drive. The

engine alternator and radiator are mounted on a robust fabricated steel base frame with

integral lifting points. Anti-vibration mountings are incorporated within the assembly.

47 – Page

STARTING BATTERIES:

A 24-volt lead acid battery assembly of ample capacity is supplied complete with

all necessary connectors and cables. Fitted to the base frame on battery tray complete

with retaining clamp. Batteries are supplied dry charged.

GUARDS:

Protection is provided for all rotating parts - i.e. fan cooling and alternator air

intake and outlet grills.

PRICE B.O.Q FOR 500 KVA GENSET FOR RENT FOR ONE YEAR

S.No Description Qty Unit Rate (Rs.) Amount (Rs.)

01. Diesel Generating Set (500KVA

Prime Rating)

As per Specifications

365

Days

One

Day 10,000.00 3,650,000.00

04. Transportation / Loading &

Unloading at Ground Floor

(Up to Site)

01 Job 15,000.00 15,000.00


Power Cable 300sq.mm, 4 Core

with all allied materials.

Mtr The length

required

Charged damage


Earth Cable 240sq.mm, 1 Core.

Mtr

The length

required

Charged damage

48 – Page

08 Supply, Laying & Termination of

Control Cable 2.5sq.mm, 3 Core. Mtr.

The length

required

Charged damage

08. Making of Earth pit for the neutral

& body of Genset (without boring)

As per our Standard

03 No.s 5,000.00 5,000.00

09. Commissioning of DG Set witht

Fuel & Material

01 Job 5,000.00 5,000.00

10. Making of R. C.C Foundation Pad

as per standard scope and size.

01 Job 25,000.00 25,000.00

11. Labor & Installation Charges 01 Job 5,000.00 5,000.00

TOTAL FOR ABOVE (with Cables) Rs. 3,705,000.00

Less Special discount (5,000.00)

Total Annul Rent including all material Rs. 3,700,000.00

49 – Page

50 – Page

51 – Page

52 – Page

53 – Page

Genset operating cost (Rental Genset)

Fuel Cost

Fuel Consumption (0.2 X 500) 100 liter

But we use 70 % capacity of the genset and at that time consumed fuel 70 liter per

hour

Rs.

70 X 70 at one hour 4,900

For Six hour 6 X 4900 29,400

Monthly cost for 30 days 782,000

Yearly Cost 782000 X 12 9,384,000

Total –A 9,384,000

Maintenance Cost

Genset Service required after 200 hours

Following items are required for service Rs.



Oil Filter 929 5,000

Lube oil 68 liter @ 400 27,200

Total Cost 42,200

Monthly running the genset 6 X 30 180

Yearly Running the genset 180 X 12 2160

Service required yearly 2160/200 10 Times

Total Service Cost 42,200 X 10 422,000

Total – B 422,000

54 – Page

Rental Cost

Total Genset Rent including Installation 3,700,000.00

Total Annual Cost for Genset

Rs.

Fuel Cost 9,384,000

Maintenance Cost 422,000

Annual rent 3,700,000

Total 13,506,000

55 – Page

Cost Rental plant Personal Plant

Fuel Cost Annually 9,384,000 9,384,000

Maintenance Cost 422,000 422,000

Depreciation Nill 605,500

Rental cost 3,700,000 Nill

Total Annually Cost 13,506,000 10,411,500

4.4 SELECTION THE FEASIBLE POWER PLANT FOR

INDUSTRIAL UNIT

COMPARISON THE POWER PLANT ON RENT AND PURCHASED

Rental power plant annually cost Rs. 13,506,000

Personal power plant Annually cost Rs. 10,411,500

56 – Page

Comments:

As we see in the graph compression of rental and persona power plant there are fuel cost and maintenance cost is equal. and the difference between depreciation and rental cost is too much if we go for rental power plant we have to bear to much rental cost and if we go for personal power plant we only bear the depreciation cost which is to much less as compare to rental power plant.

So personal power plant is more feasible as compare to rental plant

57 – Page

4.5. Quotation for plant

Services & Supply inc www.dieselserviceandsupply.com Contact Us800-853-2073

M/s: ABC Textile MillsLahore

Kind Attn: Procurement Incharge

Sub: QUOTATION FOR 500 KVA GENSET

Dear Sir,

With Reference to the above mentioned subject and the subsequent telecon

regarding the supply of Diesel Generator, we have pleasure in submitting our most

competitive proposal for your kind consideration.

(Option – 1)

Introduction about product

New 515 kW Standby Rated (460 kW Prime Rated) Diesel Kohler Generator Set.

Powered by a Volvo TAD1641GE engine which conforms to EPA Tier 2 non-road

emissions regulations. 10/12-lead reconnectable (190 - 600 V, three phase) @ 60 Hz with

a brushless, permanent-magnet alternator. This generator set offers a UL 2200 listing and

a one-year limited warranty that covers all systems and components. Comes enclosed in a

weatherproof housing.

58 – Page

http://www.dieselserviceandsupply.com/

Generator Specification

Kohler Co. provides one-source responsibility for the generating system and

accessories.

The generator set and its components are prototype-tested, factory-built, and

production-tested.

The 60 Hz generator set offers a UL 2200 listing.

The generator set accepts rated load in one step.

The 60 Hz generator set complies with ISO 8528-5, Class G3, requirements for

transient performance.

The 60 Hz generator set engine is certified by the Environmental Protection

Agency (EPA) to conform to Tier 2 nonroad emissions regulations.

A one-year limited warranty covers all systems and components. Two-, five-, and

ten-year extended warranties are also available.

Alternator features:

The pilot-excited, permanent-magnet (PM) alternator provides superior short-

circuit capability.

The brushless, rotating-field alternator has broad range reconnectability.

NEMA MG1 ,IEEE, and ANSI standards compliance for temperature rise and

motor starting.

Sustained short-circuit current of up to 300% of the rated current for up to 10

seconds.

Sustained short-circuit current enabling down stream circuit breakers to trip

without collapsing the alternator field.

Self-ventilated and dripproof construction.

59 – Page

Superior voltage waveform from a two-thirds pitch stator and skewed rotor.

Digital solid-state, volts-per-hertz voltage regulator with ±0.25% no-load to full-

load regulation.

Brushless alternator with brushless pilot exciter for excellent load response.

60 – Page

Other features:

Controllers are available for all applications.

The low coolant level shutdown prevents overheating (standard on radiator

models only).

Integral vibration isolation eliminates the need for under-unit vibration spring

isolators.

An electronic, isochronous governor delivers precise frequency regulation.

Engine Make : Volvo

Generator End Make : Volvo

Model : 500REOZVB

KW : 515

Fuel Type : Diesel

Serial# : SDMO38

Description : New 515 kW Standby Rated (460 kW

Prime Rated) Diesel Kohler Generator Set. Powered by a Volvo TAD1641GE engine,

which conforms to EPA Tier 2 non-road emissions regulations. 10/12-lead reconnects

able (190 - 600 V, three phase) @ 60 Hz with a brushless, permanent-magnet alternator.

This generator set offers a UL 2200 listing and a one-year limited warranty that covers all

systems and components. Comes enclosed in a weatherproof housing.

61 – Page

Prime Ratings: 460 kW (575 kVa)Standby Ratings: 515 kW (644 kVa)

Hertz: 60 Hz

Alternator Type: Brushless, Permanent-Magnet

EPA Tier Level: 2

Engine Manufacturer: Volvo

Engine Model: TAD1641GE

Cylinder Arrangement: 6 Inline

Max Power at Rated RPM: 565 kWm (757 BHP)Prime Fuel Consumption at

100% load: 121.9 Lph (32.2 gph)75% load: 89.7 Lph (23.7 gph)50% load: 60.6 Lph (16 gph)25% load: 33.7 Lph (8.9 gph)

Standby Fuel Consumption at

100% load: 139.3 Lph (36.8 gph)75% load: 101.4 Lph (26.8 gph)50% load: 68.1 Lph (18 gph)25% load: 38.6 Lph (10.2 gph)

Price : $89,886.00

Price in PKR : $89,886 X 86 = 7,730,196

Installation on client end

62 – Page

63 – Page

64 – Page

65 – Page

66 – Page

67 – Page

(Option –2)

Engine Make : Caterpillar

Generator End Make : CATERPILLAR

Model : 500 kW

Model Year : 1995

Hz : 60

KW : 500

Hours : 231

Phase : Three Phase

Fuel Type : Diesel

Serial# : 81Z18403

Unit# : 84127

Description:

Caterpillar 500 kW, Standby Rating, 751 Amp @ 277/480 Volt, Three Phase, 60 Hz,

CATERPILLAR Generator End, Generator End Model: SR4B, Generator End Serial#:

8HG00533, Weatherproof Enclosure, Engine Make Caterpillar, Engine Model: 3412,

Engine Serial #: 81Z18403, 625 kVa, # of Leads: 12, Reconnectable, CPL/Arrangement

#: 107-2878, 742@553kW Hp, @ 1800 RPM, Auto Start/Stop, Safety Shut Down, Air

Cleaner, 800 Amp Circuit Breaker, Muffler, Block Heater, Digital Panel, Digital Engine

Panel, Battery Charger, Radiator, 800 Gallon Double-Wall Base Fuel Tank, Skid

Mounted, Generator Dimensions: 152" L x 71" W x 124" H, Overall Dimensions: 163" L

x 79" W x 184" H, Overall Weight: 19000 lbs.

Price: $64,500.00

68 – Page

Price in PKR $64,500 X 86 = 5,547,000

69 – Page

4.6. Selection Of Feasible Genset

Company Name Brand Name Genset Prices (Rs.) Installation Cost

S.M.Jaffer & Co. F.G.Willsion 5,500,000.00 555,000.00

Nationwide Diesel Kohler 7,730,196 Client Scope

Nationwide Diesel Caterpillar 5,547,000 Client Scope

Comments:

The above graph shows the prices of two companies Generators (500kva) with

three different bands the price of S. M.Jaffer & Co. Brand (F.G.Willsion) is Price

Rs.6,055,000/- with installation. The Nationwide Diesel Company Brand (Kohler) is

price Rs. 8,285,196/- with installation and 2nd Brand (Caterpillar) is Price Rs.6,102,000/-

with installation. So I suggest that S.M.Jaffer & Co. Brand F.G.Willsion (UK) is best

then other two brands as the generator price is showed.

70 – Page

5. CONCLUSION AND RECOMMENDATION

5.1 Conclusion

Textile industry which I have chosen is badly facing the short fall of energy since

a couple of years and bears a lot of shortage of production and cost of employees which

directly effected on the companies per unit cost which reduces the profit margin. So the

final conclusion of my work or research is that if a industry invest the money to

purchased a personal power plant which reduces the short fall of energy and increase the

production capacity of the industry as well as it is useful for future as an assets of the

company and beneficial for coming years.

5.2. Recommendation

I recommended on the basis of above quotations of different brands of different

companies with their quoted price margin is feasible among these is S.M.Jaffer & Co.

with less price of their specific F.G.Willsion (UK) Brand. Which is good for industry to

purchased and installed it.

71 – Page

6. BIBLIOGRAPHY

Personal interviews

Name of persons Designation Organization Contact

Mr. Adnan Habib Service Manager S.M.Jaffer & co. 0301-8469415

Mr. Nizar Alwani Accounts Manager S.M.Jaffer & co. 0302-8488543

Mr. Asif Installation incharge S.M.Jaffer & co. 0333-4718282

Mr. Azeem Depty sale manager R.A Rental power

Mr. Rahil Saqib Production incharge Master textile Mills 0345-4148156

Though Internet

http:/www.google.com

http://www.smjafferco.com

http://ringpower-systems.com/equipment.html

http://www.dieselserviceandsupply.com/New-Generators/Kohler-515-SDMO38.aspx

http://www.opfblog.com/?s=energy+crises+in+pakistan&searchsubmit=

72 – Page

feasibility report for power plant

Documents