Professional Documents
Culture Documents
Development Board
Volume 1 of 2
B0
General Specification
0.1 Subject of Specification
0.2 General Auxiliary Systems
0.2.1
0.2.2
Location of site
0.2.2.2
0.2.2.3
Meteorological condition
0.2.2.3.1
General
0.2.2.3.2
Rainfall
0.2.2.3.3
0.2.2.3.4
Earthquake
0.2.2.3.5
Wind
0.2.2.3.6
0.2.2.3.7
Geological conditions
0.2.3
Layout
0.2.4
Configuration
0.2.5
Design requirements
0.2.5.2
0.2.5.3
0.2.5.4
Civil
0.2.6
Mode of operation
0.2.7
0.2.8
0.2.7.1
Environmental conditions
0.2.7.2
Fuel
0.2.8.1
Characteristic of coal
0.2.8.2
Ash
0.2.9
General
0.3.2
0.3.3
General
0.3.3.2
Mechanical
0.3.3.3
0.3.3.4
Civil
0.3.4
0.3.5
Documentation
0.3.5.1
0.3.5.2
0.3.5.3
0.3.6
0.3.7
0.3.8
0.3.9
0.3.7.1
General
0.3.7.2
0.3.7.3
Training at site
Spare parts
0.3.8.2
0.3.8.3
Consumables
Maintenance works
0.3.10 Options
0.3.10.1
0.3.10.2
0.4 Interfaces
0.4.1
Limits of supply
0.4.2
0.4.3
Metering
0.4.4
Communication systems
General requirements
0.6.2
0.6.3
0.6.4
0.6.5
0.6.6
Vibration
0.6.7
Standardization of makes
0.6.8
Accessibility
0.6.9
Signs
Pumps
0.6.16.2
0.6. 16.2.2
0.6.16.2.3
0.6.16.2.4
0.6.16.2.5
Cleaning at workshop
0.6.16.2.6
Cleaning at site
0.6.16.2.7
0.6. 16.2.8
0.6.16.3
0.6.16.4
Responsibility
0.6.16.4.2
Required documents
0.6. I 6.4.3
Welding procedure
qualification
0.6.16.4.4
Personnel qualification
0.6. 16.4.5
Welding process
0.6.16.4.6
0.6. 16.4.7
Documentation
0.6.16.5
0.6.16.6
Insulation
0.6.16.7
Standards
0.6.17.2
Standard voltages
0.6.17.3
Climatic conditions
0.6.17.4
Inductive interferences
0.6.17.5
0.6.17.6
0.6.17.7
Protective measures
0.6.17.8
Auxiliary equipment
0.6.17.9
0.6.17.10
0.6.17.11
0.6.17 .14.2
0.6.17 .14.3
Actuator drives
0.6.17.14.4
DC motors
0.6.17.14.5
Painting
0.6.17 .14.6
0.6.17.14.7
Frequency converters
0.6.17 .14.8
Tests
0.6.17 .14.9
Motor list
Measuring units
0.6.18.2
0.6.18.3
0.6.18.4
0.6.18.5
Tests
0.6.18.6
Field equipment
0.6.18.6.1
Measuring
systems/transmitters
0.6.18.6.2
Flow measurements
0.6.18.6.3
Temperature measurements
0.6.18.6.4
Pressure measurements
0.6. 18.6.5
Analyses measurements
0.6. 18.6.6
Level measurements
0.6. 18.6.7
Electrical measurements
0.6. 18.6.8
Position measurements
0.6. 18.6.9
Contact devices
0.6.18.6.10
Vibration measurements.
0.6.18.6.11
Control valves
0.6.18.6. 12
Actuators
0.6.18.6.13.
Local instrumentation
0.6.18.7
0.6.18:8
Control cubicles
0.6.18.9
0.6.18.10
0.7.2
General
0.7.1.1
0.7.1.2
Works inspections
Material tests
0.7.2.2
Tests at site
0.7.2.3
0.7.2.2.1
General remarks
0.7.2.2.2
Hydraulic tests
0.7.2.2.3
0.7.2.2.4
Manufacturing tests
0.7.2.3.1
Welding
0.7.2.3.2
Pressure testing
0.7.2.3.3
Testing of corrosion
protection
0.7.2.4
Mechanical equipment
0.7.2.5
Electrical equipment
0.7.2.6
Section B2: Steam Turbine Plant with Condensate and Steam System
Annexes
General Specification
10
Subject of Specification
This section forms an integral part of the Tender Documents issued by the
Bangladesh Power Development Board, Dhaka.
0.2
0.2.1
11
The equipment of the Plant shall be designed in accordance with the requirements contained in the Tender Documents and as illustrated on the
Tender Drawings attached.
Highest reliability and availability, convenience of operation and
maintenance, neat and orderly arrangement, are of utmost importance.
The functional requirements of the various systems and the pleasing
physical appearance of the completed Plant shall also be taken into
account.
Due care shall be undertaken concerning the environmental impact out of
the Plant and sufficient protective measures shall be incorporated in the
design of the Plant for envirolUl1ent protection especially on air pollution,
water pollution and noise. The environment protection measures shall be
done in accordance with the Environment Protection Guidelines of UNDP,
ADB, World Bank and Environmental Protection and Emission Control
Standards of Bangladesh.
In all instances, the listing of items of the Plant shall be understood as
general, and shall include upon completion, even if not specifically mentioned, other necessary components and appurtenances required for
proper, continuous and reliable commercial operation of the complete
installation, including any and all auxiliary and ancillary systems.
0.2.2
The only large industrial area nearby is this coal mine including its
residential complexes.
The nearest town is Phulbari, a Thana (Upazila) headquarter as primary
administrative center of the country. Phulbari is located about 6 km south
of the site.
The major railway junction and surrounding township Parbatipur is about
16 km to site. The railway is connected to site.
12
The Maddhapara Hard Rock Mining Project, a separate large scale industrial project is located 12 km east of the site.
To reach site from Dhaka by car needs approximately 6 - 7 hours at
normal climatic conditions.
The closest airport to site is Saidpur. It takes about 1 hour by car from site
to the airport. The airport is in operation now.
Metalled road is connecting Dinajpur, Phulbari, Parbatipur, Saidpur and
site.
The area is situated at approximately 30 m over sea level. The groundwater
flow goes from north to south. For cooling, industrial and housing purposes of
the existing 2x125 MW plant, the ground water is being pumped from deep
wells gathering area at north of site. Discharge water from coal mine after
required treatment will be used as cooling water and the existing deep tube
well water will be used for potable water & demi water production of the
proposed 250 MW. The waste water/sewage water after suitable treatment
shall be dumped in a soakaway at the south site of site.
The bottom ash from the boiler and the fly ash from boiler &electrical
precipitator shall be dumped in a pond on site. These ashes shall be
transported wet and during the dry time of the year the ash shall be wetened
by water. The water leaving the pond shall be treated in such a way that it will
be suitable for irrigation or for pumping away to the nearby river Tillay.
A dry ash conveyor transportation and dumping system shall be considered
as an option.
13
0.2.2.3.2 Rainfall
Rainfall from May through September contributes over 85% of the annual
total. However, rainfall intensives tend to be high and concentrated in a
comparatively small number of heavy storms, even when monthly rainfall
figures are relatively low. The monthly precipitation data are as follows (in
mm):
Average in
Dinajpur
Average in
Rangpur
Peak
at one day
Maximum
per month
January
11
February
13
15
March
16
27
April
70
110
May
241
307
85
307
June
297
499
140
700
July
592
660
142
640
August
442
430
132
442
September
307
412
431
890
October
144
120
104
242
November
December
16
17
2,008
2,812
Annual
Note: Above mentioned data are very old, probably in the period of 1981- 1988
14
Min.
Temp. in
'88 (0C)
Mean.
Temp.81
- 88 (0C)
Rangpur
Mean
Hum.'81
- 88 (%)
Max.
Temp. in
'88 (0C)
Min.
Temp. in
'88 (0C)
Mean.
Mean
Temp.81 Hum.'81
- 88 (0C) - 88 (%)
January
24.9
11.6
18.4
70
25.3
11.7
16.8
79
Feb.
27.5
14.2
70.9
61
29.0
145
19.0
71
March
33.5
13.5
25.4
54
33.7
12.6
23.6
63
April
40.0
10.5
28.0
57
37.5
16.8
26.5
69
May
36.3
19.0
28.2
70
35.6
20.8
.27.3
79
June
37.5
23.8
29.0
76
36.3
23.9
28.7
84
July
34.0
23.0
28.5
82
34.1
22.5
28.4
87
August
36.7
22.1
29.3
82
32.4
26.2
28.8
85
Sept.
32.0
25.6
28.4
84
31.8
25.4
27.8
87
October
31.5
22.2
27.5
76
31.4
22.6
26.2
84
Nov.
28.8
16.4
23.7
70
28.3
17.5
22.1
79
Dec.
26.5
13.1
19.6
72
26.0
14.1
18.3
81
Annual
32.4
17.9
25.6
71
31.8
19. 1
24.5
79
0.2.2.3.4 Wind
The wind in Barapukuria changes its direction according to seasons. The
wind tends to blow from the west, or in dry season from northeast and
from the east or the southeast in rainy season. The predominant wind
direction is generally east-west. The wind speed is relatively moderate
and it is said that there is also a high proportion of calm days through the
year.
15
Monthly average prevailing wind speed (knots and direction/1knot = 0.514 m/s)
Rangpur (1979-1988)
YEAR
JAN
FED
MAR
APL
MAY
JUN
JUL
AUG
SEP
OCT
NOV
SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD
1979
6 NNW
SE
SE
SE
1980
NE
SE
SE
SE
NE
NE
1981
NE
NE
n.a.
n.a.
NE
1982
SE
SE
NE
NE
NE
19&3
NE
SE
SE
SE
NE
NE
1984
NE
SE
NE
1985
NE
NE
SE
SE
SE
SE
NE
1986
5 NNE
SE
NE
1987
NE
NE
NE
SE
SE
SE
NE
1988
NE
SE
SE
NE
NE
n.a. n.a.
n.a. n.a.
16
= 0.514 m/s)
YEAR
JAN
FEU
MAR
APR'
MA\'
IUN
JUL
AUG
SEP
ocr
NO\'
SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD
1981
NW
NW
NE
NE
NE
NE
NE
1982
NW
SE
NE
1983
NW
SE
NE
1984
SE
NE
1985
NE
1986
SE
1987
NE
1988
NE
NE
17
0.2.2.3.5 Earthquake
General
Bangladesh is historically less affected by earthquakes. During the last some one
hundred years widespread damages were caused by only the Great Earthquake
of 1897 which had its epicentral tract in the Shillong plateau. Two other major
earthquakes, the Bengal Earthquake of 1885 and Srimangal Earthquake of 1918
caused severe damages only in limited areas surrounding their epicenters. The
present geological information does not indicate existence of seismically active
faults within the country. However, north and east of Bangladesh, there are areas
of high seismic activity in India and Myanmar and earthquakes originating in
these areas affect adjacent regions of Bangladesh.
v = Z.I.K.C.S. W
Basic horizontal seismic coefficient (0.06 for Zone II)
Where Z
Importance factor
(1.5 for important facilities, 1.0 for others).
18
Geological conditions
The stratigraphical sequence has been divided on purely litho logical grounds
into the following groups:
Madhupur Clay (Recent - Pleistocene)
Dupi (Tila Formations)
-Upper (Pliocene)
- Lower (Pliocenelate Miocene)
- Upper Coals Sequence
- Seam VI Sandstone
Sequence
- Seam VI
- Lower Sandstone
Sequence
- Tillites
Dasement (Pre-Cambrian)
The outline of Madhupur Clay and Dupi Tila Formation are as follow:
Bulk Density : 1.91 - 2.19 t/m3
a)
Madhupur clay
The Madhupur Clay formation was found across the entire site beneath a thin soil
horizon. It varies in thickness between 3 and 15 m, but is generally 10-12 m in
thickness. Lithologically, the fonnation comprises series of firm and stiff silty clays
interlaminated and interbedded with silts and siIty sands. The silt and sand
horizons increase in frequency to the base of the formation. The geotechnical
and hydrogeological characteristics of Madhupur clay are summarized as follows:
19
119
30~85
Permeability:
Ph:
b)
Shear
Resistance Angle
14~ 33
17~ 11.6
9.79 x 10 - 5 - 5 X 10 - 7 m/s
6.8 - 7.4
130
Shear Resistance
Angle
24.5
10 - 45
2 - 4
Triaxial test
Undrained multistage
Consolidated drained
62
Unconsolidated undrained
16
27.5
These tests were carried out on undisturbed samples of cohesive materials such as silt or
clayey silt of the Upper Dupi Tila formation.
20
Permeability
No permeability test has been carried out for this formation. However, the
permeability of this formation is considered larger than that of Madhupur Clay,
judging from its soil composition.
pH: 7.2
Topographic conditions
The project area in Dinajpur district, between Phulbari and Parbatipur is situated
in the deltaic plain of the Jamuna and Padma Rivers. It is flat and its altitude is
about 30 m above mean sea level, which is relatively higher than the other areas
of Bangladesh.
0.2.3
Layouts
The detailed arrangement shall be proposed by the Contractor under
consideration of easy maintenance, access, short links for piling and cabling,
interfaces to the power grid.
The plant area shall be developed upto existing plant level (if required). The ash
pond shall be lowered below the natural ground for about 3 m and shall be
provided with bud walls up to + 5 m above the natural ground. The park area
shall remain at about natural ground level with the exception of the outfall canal.
0.2.4
Configuration
One coal fired boiler with turbine generators represent the core components of
the Plant.
The cooling requirement of the Plant shall be accomplished by a wet cooling
tower system. For ash transport, the cooling tower blow down water shall be
used. But for commissioning fresh water is required.
0.2.5
0.2.5.1
Design requirements
The Plant shall be designed for base load operation. Also extended shorttime
operation and longer periods of part load down to synchronized minimum load
must be possible without restrictions.
The design lifetime of the Plant shall exceed 200,000 operating hours.
The thermodynamic process of the Plant is to be optimized by the Tenderer/
Contractor according to the proposed equipment.
The Plant shall be built-up of one independently operable power unit.
An economic optimal balance between investment, maintenance expenses and
Plant availability (planned and unplanned outages) shall be proposed .
21
Redundancy concept
Due to the block-wise structure of the Plant, the Tenderer/Contractor may
propose only 1 x 100% implementation of very costly major equipment like:
cooling water pumps, compressors, etc., but by no means for the boiler feed
water system.
These moderate investment solutions can be accepted if the Tenderer/
Contractor proves with corresponding spare parts and maintenance proposals
that overall an optimum economic solution will result; otherwise 3 x 50%, or 2x
100% solutions are preferable.
The Tenderer/Contractor shall
a) design and configure all components of the Plant
b) propose spare parts stock (spare part building and content)
c) propose maintenance works in such a way that:
0.2.5.2
unplanned outage time of power unit shall not exceed 1.7% of the time in a
calendar year
250 MW Net
80%
38.0% (minimum)
3 75,000 m2
0.2.5.2
0.2.5.3
Civil
The area of the Power Station for protection against flooding is considered to be
22
filled up to the existing plant level (if required) to protect the Power Plant against
the flood.
The coal storage area shall be paved. drained and partly covered. The drain shall
be discharged to the ash pond. The ash pond shall be excavated. fertile soil to be
stored aside and the pond shall be lined with clay. The ash pond overflow shall
be treated to meet the relevant standards and shall lead via outfall canal to the
Tillay river. Try ash storage shall be considered as an option.
The treated sewage water may be discharged to the Tillay river.
The ash pond and the park shall be separated from each other and the Plant by
fences and gates.
0.2.6
Mode of operation
All the equipment and the facilities shall be suitable for safe and economical
continuous and also for short-time operation under the extreme ambient air.
water and coal conditions specified.
The design of the Plant shall be based on the following operation and dispatching
requirements:
a)
The power unit shall be capable of following the daily and seasonal demand
profile of the electrical network.
b)
The power generation shall be fully dispatch able within the technical limits
of the Plant to be specified by the Tenderer, but at least between 40% and
100% of the net power output of the Plant without supporting fire.
c)
Full compliance with the conditions of the admissible air pollution is required
within 40 - 100% of power unit's power range.
0.2.7
0.2.7.1
Environmental conditions
The present environmental conditions in Barapukuria are as follows:
a) Atmospheric quality
There are no industrial activities to pollute air within a radius of 10 km from the
planned Power Station site (except existing 2 x 125 MW coal fired units). Though
there are effects of automobile, etc. emission and smoke generated by burning
after harvesting and from houses, the air pollutant concentration is expected to
be at a very low level.
b) Water quality
As prospective raw water sources, Coal mine discharge water (for normal use)
and wells (during emergency case to meet at least 50% of total requirement) are
considered. Water quality is given in Annex.
23
c) Soil quality
The study team collected the soil (in the year 1998) from the site for analysis
and the results are as follows:
Analysis result of metal content in soil
MgO
CaO
0.7
0.2
Item
Barapukuria
soil
Na20
K20
0.2
2.2
B203
mg/kg
427
201
pH
EC
S/cm
Mg1+
Ca2+
K+
Na+
B3+
0.2
1.0
<0.1
mg/kg
Barapukuria soil
6.5
12.7
0.1
0.2
0.2.7.2
24
0.2.8
0.2.8.1
Fuel
Characteristic of coal
These data should be compared with new data which will be analyzed by the coal
mine and examined by the personnel of the Power Plant. After having further
investigation on the Barapukuria coal, the coal analysis data for the planning of the
boilers at the Owner/Owner's Representativeing stages should be finalized.
At the time being the proximate analysis (average characteristics of whole seam) is
as follows:
Net Calorific Value
Gross Calorific Value
Total moisture
Inner moisture
Fixed carbon
Ash Content
Volatile content
Sulfur
23.500 MJ/ kg
25.540 MJ/ kg
26.000 MJ/ kg
8.20%
1.71%
46.92%
50.24%
51.11%
17.81%
19.07%
19.40%
27.07%
28.98%
29.48%
0.16%
Carbon
83.0%
Hydrogen
Oxygen
Nitrogen
Sulfur
5.1%
9.4%
1.7%
0.77%
99.97%
25
0.2.8.2
Ash
At the time being the following ash analysis (oxides in ash dry basis) (mean % of
whole seam) is available:
Si02
54.4%
AI2O)
35.6%
Fe203
2.9%
Ti02
3.2%
Mn304
0.11%
eaO
0.56%
K20
0.66%
Na20
0.06%
MgO
0.18%
P20S
0.46%
SO3
0.13%
0.2.9
Initial Deformation
> l,400C
Hemispherical
> l,400C
Flow
> 1,400C
26
0.3
0.3.2
General
The scope of this Tender Specification covers all supplies and services required
for meeting the purpose of the complete Plant, even if these are not expressively
mentioned in the following.
The works include the following main components, where the detailed scope of
supply shall be seen in the corresponding sections as listed below:
Section B1
Section B2
:
:
Section B3
Section B4
Section B5
Section B6
Section B7
Section B8
Section B9
Section B10
Section B11
Section B 12
:
:
:
:
:
:
:
:
:
:
0.3.2
27
All fees required due to a split-up into multiple applications shall be covered by
the Contractor.
0.3.3
0.3.3.1
General
material and personnel costs (e.g. for testing authority staff, BPDB and if
necessary also Owner/Owner's Representative's staff) for tests and inspections which are mandated by legislation
all as-built documents (on data carriers; data formats as requested by the
Owner/Owner' s Representative)
0.3.3.2
Mechanical
all connection and adaptation works for tie-in into general supply and/or
evacuation systems
all necessary vents, drains and rinsing connections as well as tundishes with
necessary.
all temporary installations required for tie-in measures including postweld
28
all base frames, mounting plates, grouted in parts, rag bolts, covers, etc.
all required steel parts embedded in concrete
all couplings and coupling guards for electric motors and other drives
all lifting equipment and hoists (for repair work where loads exceed 50 kg)
(cranes, hoists, monorails, etc.), electrically operated if lifting or lowering
heights exceed 8 m
required safety equipment, pressure relief valves, etc.
all thermal and noise insulation including cladding as well as any other noise
attenuation measures
stairways, ladders, platforms, galleries and walkways to all plant components, including escape routes as necessary
all necessary steel structures, stairs, ladders on platforms weather protec-
tion
complete primer and top coatings conforming to color code, clarified with
the Owner/Owner's Representative/Owner/Owner's Representative
noise abatements measures
all corrosion protection and electric trace heating for outdoor installations
(e.g. gas ducts, etc.)
complete labeling of all plant components according to the Owner/Owner's
Representatives system and in plain language (English and Bangla) and
Power Plant Classification System Coding (PPCS)
provision of all connections and temporary pipe work for steam purging of the
live steam line
flushing of all other lines including disposal of the effluents; protection with
29
all standard accessories and auxiliary equipment which normally form part of
the scope of supplies
all tests, inspections and works acceptances as well as all certificates and
reports of these
exchange of filter elements following reliability test run up to Provisional
Taking Over of the relevant Unit
valve trims for purging and subsequent exchange
0.3.3.3
0.3.3.4
Civil
Soil investigations
30
0.3.4
any
site fill
plumbing
facade works/glazing works; non asbestos
metalwork
flooring work
fire protection with plumbing; fire protector
corrosion protection
potable water, service water and waste water, sewage water, storm water
(permanent and during construction), etc.
transport of all dumping material to dump locations (at least once a week
total)
interpretation of soil bearing test
transport insurance
31
0.3.5
0.3.5.1
customs clearance
transportation to site
unloading at site
Documentation
Documentation with Tender
General
components
schematics of the principal plant systems
personnel.
space requirement for construction site and equipment
Representative's
32
lists of spare parts for warranty period, lists of spare parts for LTSA
period
Mechanical
flow diagram of all systems
performance diagrams of main pumps, compressors, fans, etc
start-up curves for cold (all material on ambient temperature) and warm start
up to MCR of one Unit
Steam turbine and boiler
correction curves for variations in
Generator
Detailed descriptions/references of the main components such as:
stator and rotor design
excitation equipment
cooling system
power chart (generator capability curve MW, MVAr, p.f.)
no load and short circuit characteristic
Boiler
Description for the equipment offered giving information about:
NOx, CO, S02, etc. emission characteristic for coal operation versus load at
full load
33
Drawings
dimensioned front and side sectional elevations and sectional plan of the
boiler, turbo group, showing drum, casing, insulation, access and
observation doors and all tube banks and all accessories (conveyors,
breakers, etc., all boiler pressure parts, turbine/generator details, mill,
ash extractor, ash transportation, etc.
design of the membrane walls and supporting by buckstag
Graphs, correction curves for boiler
tentative start-up diagrams for cold start, warm start and hot start
Electrical system
provided
construction power supply arrangement
general arrangement of 230 kV switchyard equipment
control system architecture showing all components provided for this Power
34
availability
redundancy concept
Civil
architectural outline drawings for all buildings and building structures showing
the arrangement of the complete plans, inclusive of all levels and sections
site plan of the complete plant showing all buildings, building elements, roads,
landscaping etc .
schematic design of building
Maintenance
For boiler with accessories, steam turbine, generator and the total scope of supply
maintenance and overhaul charts should be submitted. Both major and minor plant
outages for inspection and/ or routine maintenance should be shown on the chart,
together with the nature of the work to be undertaken and the expected duration of
the outage. This information should also include all the auxiliary plant to be supplied
under the Contract.
0.3.5.2
35
construction works, stating dates for completion of any preparatory work from
others which may be necessary.
detailed erection, installation and commissioning schedule
thermodynamic diagrams
start-up and shutdown diagrams with descriptions
welding procedures (for workshop and site), to be approved before execution
of the welding
36
for all lifting operations (repair, maintenance, etc.) a lifting plan has to be
electric motors
starting curves (torque of motor and driven machine, time, speed) for all
motors of 50 k W and more
cable lists
standard circuit diagrams for all different kinds of electrical consumers
circuit diagrams for all individual electrical equipment
EMC concept with coordinated over voltage protection (NEMP level is not
37
required)
overall protection and metering diagrams for the whole protection equipment
generator charts and exciter characteristics
list of subcontractors
list of the overall- I&C equipment
list of spar parts
manufactured
list of instruments including code, measuring range, alarm and limit values,
reference drawings
38
list of control valves including operating and design data, materials, makes,
logic diagrams
description for all functional group controls
list of recorders
graphic displays for monitors of options.
general site plan of the entire site showing all buildings and installations,
traffic routes and landscaping etc.
architectural arrangement drawings, design layouts and itemized drawings
39
floating floors/systems
underground services and ducts with equipment appertaining to the services
layout of roads
principal details and sections for traffic areas, especially for ramps and
retaining walls
structural drawings pertaining to outlet and inlet water channels and tie-in to
existing channels
foundations and other underground concrete works for the transformer area
civil drawings of roads and if applicable for up rated bridge over cooling water
outlet channel.
Designation
Preliminary
Final
In weeks
In weeks
19
23
and offices
19
23
29
33
39
78
40
65
65
20
after availability
of maintenance
instructions of
the corresponding
suppliers
87
26
2
Stock-keeping lists (including spare
part lists containing requisition before provisional before provisional
numbers, consumables, etc.
taking over
taking over
29
43
17
23
39
41
As-built drawings
4
before provisional
taking over
at provisional
taking over
0.3.5.3
Unless agreed otherwise, six (6) hard copies and three (3) sets of electronic copies
of all documents are to be submitted in English language for approval.
There shall be no installation and/or any commissioning activity without the relevant
documentation approved by the Owner/Owner's Representative.
The final documentation shall be submitted in English language.
Diagrammatic symbols for electrical drawings
Diagrammatic symbols complying with IEC 27, 34, 37 and 117 are to be used for
selling out the circuit and terminal layout.
0.3.6
0.3.7
0.3.7.1
0.3.7.2
42
the cost of return air tickets (economy class) from Bangladesh to the country
where the plant/fire fighting training centre is located
All efforts shall be exercised by the Contractor to operate the Plant by the
Owner's operation personnel under the Contractor's supervision and
guidance.
The instructors shall be capable of speaking and writing fluent English. These
instructors must have previous experience of providing training to a third country
having mother tongue other than English,
Before Provisional Taking Over, the Contractor has to demonstrate the success of
the trainees by demonstrating their ability to operate the Unit. The Owner/Owner's
representative has the right to refuse the trainers in case of non-adequacy with the
job requirements.
43
0.3.8
0.3.8.1
Spare parts
Spares as well as wear-and-tear parts shall cover those parts recommended by
the Contractor to enable the Plant to be operated for 05 years LTSA period after
completion of the guarantee time (final take-over). These parts shall be offered
on separate sheets.
Each spare part shall be labeled with its PPCS number.
All items shown in these schedules shall form part of the contract price and the
Owner/Owner's Representative may order all or any of the parts at his discretion
and adjust the contract price accordingly.
All spare parts required for testing of the Plant according to "Inspection and
Testing" and for all action before Provisional Taking Over Certificate form part of
the principal scope of supply and are not to be included in the spare parts list.
They shall be included in the scope of the relevant machinery without pricing, it
means for the time of commissioning, the trial operation and provisional takeover.
All spare parts required for warranty period (24 months) shall be supplied by the
Contractor.
Major items of spare parts must be priced individually but minor items can be
grouped together. The spare part shall be offered on separate price sheets.
The Contractor shall segregate in the schedule those "consumable" spares
necessary for the efficient day to day maintenance of any items of Plant, those
"spare parts" to be replaced after certain running time and those "strategic"
spares which, in his opinion the Owner/Owner's Representative should hold to
minimize the outage of the Plant due to breakdown.
Each item shall be labeled in BangIa and English as well as with PPCS coding
system and be separately packed against damage and sealed to prevent
deterioration from corrosion in a dry weatherproof building.
The spare parts shall be placed in bins, racks, drawers, shelves, cabinets, etc. to
be provided by the Contractor.
The Contractor shall not use any of the spare parts without written permission
from the Owner/Owner's Representative. The Contractor shall deliver the spare
parts for a 24-h-MCR-operation period of five (05) years LTSA. The stores shall
be suitable for these conditions.
0.3.8.2
44
Consumables
Lubricants and greases
All lubricants proposed for the Plant operation shall be suitable for all operating
45
The Contractor shall also provide all chemicals, and other consumables required
for the efficient operation and maintenance of the plant at full load 24 hours per
day for 05 years LTSA period after final take over.
0.3.9
Maintenance works
Deleted
0.3.10
Options
Deleted
46
0.4
0.4.1
Interfaces
Limits of supply
The interfaces for the Plant shall be as follows; all mentioned equipment,
connections, connection materials, counter flanges, shut-off valves, safety valves
are included in the scope of supply:
fuel
230 kV switchyard
instrumentation
control
and
communication
systems
raw water,
industrial,
water
potable
cooling
47
interfaces to existing
facilities on site roads and
railways to the Plant site
0.4.3 Metering
Sufficient metering devices shall be provided to enable an energetic balancing of the
power units and additionally to enable balancing of all process flows.
Metering of electrical signals is indicated in Annex C-B8-2, and frequency, voltage,
active power, reactive power, and energy shall be metered for each power unit at
the switchyard.
The accuracy and signal interface requirements for metering devices shall be
according to the Metering Code (which will be submitted by the Owner/Owner's
Representative during contract execution).
48
0.5
Declaration by Bidder
B0/F-1
B0/FA-1
Design Data
B0/FD-1
Guarantees
B0/FG-1 to 14
B0/FZ-l
49
Bidder/Contractor
Bidder: ____________________________
__________________________
Stamp and Signature of Bidder:
B0/F-1
50
Bidder/Contractor
'.
B0/FA-1
51
Bidder/Contractor
Unit
Data
Steam generator
Steam turbine
Construction
Maintenance
Civil Contractor
Compressor Station
Emergency diesel
B0/FD-1
52
Guarantee Schedule
BPDB, Barapukuria Power Plant 250 MW
Section B0: General. Specification
Net Power Output, Po
Unit
kW
Days
Hours
Hours
(H100% )
Hours
Hours
Hours
Hours
(H75%)
(H50%)
B0/FG-1
53
Minimum Requirements
Unit
Data
year
General Guarantees
The Works conform to the Specification and shall be
free from defects in design, Owner/Owner's
Representativeing, materials, construction and
workmanship.
The. Plant furnished hereunder, and all materials,
equipment, tools and supplies incorporated therein
or becoming a part of the supply shall be new,
unused and shall be fully suitable for the intended
use, and shall meet all of the performance
requirements set forth in the Contract.
The Plant shall be fully suitable for use of the
specified fuel.
The Plant and all portions thereof shall be suitably
coordinated as to functions and interrelations,
properly responsive to controls and sufficiently stable
in operation to avoid objectionable fluctuations in
operating temperatures, pressures, rates of flow and
the like during all stages of operation.
Warrantee period
B0/FG-2
54
Minimum Requirements
Unit
Data
Guarantee Data
Data to be guaranteed for the whole load range and
complete range of ambient conditions
Absence of excessive vibration during operation of the
turbine generator. Maximum effective vibration velocity
measured at bearing housings:
Maximum vibration of components:
(vibration criteria as per guide line ISO 10816) .
dB{A)
85
dB{A)
75
dB{A)
55
dB{A)
60
"good", according
to VDI rule 2056
W/m2
200
mg/l
0.02
to be in accordance with
IEC regulations
535
535
%of MCR
60 -100
% of MCR
70 -100
% of MCR
30
m /h
m3/h
B0/FG-3
55
Guarantee Conditions
Fuel coal net calorific value (LHV)
Fuel coal Gross calorific value (HHV)
Ambient air temperature (dry bulb)
Relative humidity
Power factor
Maximum temperature rise in generator windings
according to IEC 34.1, Class B
Correction curves for deviations in operating
conditions, drwg. Nos
Electrostatic precipitator efficiency on the
basis of the specified coal
Condition A: Maximum Continuous Rating
Live steam flow
Live steam pressure at boiler outlet
Live steam temperature at boiler outlet
Reheat steam temperature at boiler outlet
Cooling water flow
Cooling water temperature at cooling tower outlet
Gross output (at generator termional)
Gross specific heat consumption (qgrA)
Swallowing capacity at steam turbine
(100% live steam pressure)
Condition B: 75% Load Operation
Live steam flow
Live steam pressure at boiler outlet
Live steam temperature at boiler outlet
Reheat steam temperature at boiler outlet
Gross output (at generator termional)
Gross specific heat consumption (qgrA)
Minimum Requirements
Unit
kJ/kg
kJ/kg
C
%
-
Data
23,500
25,560
26
70
0.85
99.5
kg/s
bar
C
C
kg/s
C
MW
kJ/kWh
kg/s
kg/s
bar
C
C
MW
kJ/kWh
B0/FG-4
56
Minimum Requirements
Unit
(qgrA)
kg/s
bar
C
C
MW
kJ/kWh
MW
MW
Data
Drwg.No.
B0/FG-5
57
Minimum Requirements
Unit
Data
mbar/min
8,000
mg/m3
mg/m3
mg/m3
%
B0/FG-7
58
Minimum Requirements
Unit
Data
12,000
general
20,000
8,000
refractory
8,000
general
16,000
8,000
%of
MCR/min
%of
MCR/min
Load changes
%MCR
35
1:5
B0/FG-8
59
Minimum Requirements
Unit
Data
10
10
Auxiliary consumption
10
30
mm/s
2.5
mg/l
0.02
Rejection
Further to the stipulations stated in other parts of
the Tender Documents the Owner/Owner's
Representative reserves the right to reject in the
following:
Should the deterioration of the guarantee values be
greater than the following values then the
Owner/Owner's Representative shall have the right
to reject the respective scope of this Section
B0/FG-9
60
Bidder/Contractor
Unit
Data
10
bar
145
constant load
bar
load variation
bar
Overshoots
a) Live-steam temperature:
constant load
load variation
b) Live-steam pressure:
B0/FG-10
61
Bidder/Contractor
Unit
Data
constant load
load variation
d) Boiler drum level:
10
mm
mm
25
50
mbar
mbar
%O2
0.4
%O2
1.0
bar/oC
1.5/5
3/ 10
85
constant load
load variation
e) Boiler furnace pressure:
constant load
load variation
f) Combustion oxygen content:
constant load
load variation
g) load variation Steam pressure and steam temperature reducing
station HP bypass control
constant load
bar/ C
load variation
Under all operating conditions, the noise level of control valves
dB(A)
shall not exceed measured at one meter distance.
To make sure that the permissible noise level is under no
circumstances exceeded, the requirements in respect of the
pipeline and insulation design to be fulfilled by the piping an
insulation contractor shall be specified by the Contractor with the
tender.
Other control and monitoring systems
The Contractor shall guarantee that the equipment provided is
within the tolerances stated in the specification. The Contractor
shall also guarantee that the equipment carries out in a safe and
efficient manner the task for which it is provided.
The quoted values data shall be guaranteed.
Testing procedures
All components supplied shall be tested in accordance with the
requirements and the individual guarantees and the general
performance of the installation shall be demonstrated at the tests
during erection and the acceptance and performance tests.
B0/FG-11
62
Bidder/Contractor
Unit
Data
63
Bidder/Contractor
Unit
Data
If the main performance data are not fulfilled during the acceptance tests, the Contractor shall be obliged as a first measure
to improve the supplied control equipment by suitable control
Owner/Owner's Representativeing measures making full use
of all theoretical and equipment Owner/Owner's
Representativeing possibilities e.g. by
load dependent parameter variation
disturbance variable feed forward
further optimization efforts
modification of characteristics curve of control valves and
actuators etc.
For this purposes the Contractor is given the chance to
modify the equipment in a reasonable time specified by the
Client according to the system operation needs.
If, after final optimization, the quality of the closed loop control
does not meet the requirements the Contractor shall be
obliged to take the actual transient functions at the plant and to
compute the theoretical possible quality of the control loops
based on the actual data.
The Contractor of the equipment involved, the Client and/or
his representative reserve the right to participate in these
tests.
If the actual achieved control deviation does not exceed those
based on the theoretically calculated possible control quality,
the requirements shall be considered as fulfilled.
Should the plant fail to meet the above guarantees after due
account has been taken of the above specified tolerances, the
plant will be made available to the Contractor so as to allow
the Contractor to make good the plant by modifying or
replacing defective or wrongly designed parts.
If, even after remedial measures have been carried out, the
required guaranteed values are not achieved, then the
client shall be entitled to reject the complete plant or parts
thereof.
B0/FG-13
64
Bidder/ Contractor
Unit
Data
m3/h
m3
h
h
kg/cycle
kg/cycle
kg/cycle
kg/cycle
S/cm
<0.01
mg/I
mg/I
mg/I
mg/I
<0.02
<0.003
<0.02
<0.01
B0/FG-14
65
Bidder/ Contractor
Days after
effective
Date
Date
B0/FZ-1
66
Table of Contents
0.
xxx
0.1
0.2
0.3
0.4
0.5
XXX
XXX
XXX
XXX
XXX
0.6
0.6.1
0.6.2
General requirements
Standards and codes
0.6.3
0.6.4
0.6.5
0.6.6
0.6.7
0.6.8
0.6.9
0.6.10
0.6.11
0.6.12
0.6.13
0.6.14
0.6.15
0.6.16
0.6.16.1
0.6.16.2
0.6.16.2.1
0.6. 16.2.2
0.6.16.2.3
0.6.16.2.4
0.6.16.2.5
0.6.16.2.6
0.6.16.2.7
0.6. 16.2.8
0.6.16.3
0.6.16.4
0.6.16.4.1
0.6.16.4.2
0.6. I 6.4.3
0.6.16.4.4
0.6. 16.4.5
0.6.16.4.6
0.6. 16.4.7
0.6.16.5
0.6.16.6
67
0.6.16.7
0.6.17
0.6.17.1
0.6.17.2
0.6.17.3
0.6.17.4
0.6.17.5
0.6.17.6
0.6.17.7
0.6.17.8
0.6.17.9
0.6.17.10
0.6.17.11
0.6.17 .12
0.6.17 .13
0.6.17. I 4
0.6.17.14.1
0.6.17 .14.2
0.6.17 .14.3
0.6.17.14.4
0.6.17.14.5
0.6.17 .14.6
0.6.17.14.7
0.6.17 .14.8
0.6.17 .14.9
0.6.17 .15
0.6.18
0.6.18.1
0.6.18.2
0.6.18.3
0.6.18.4
0.6.18.5
0.6.18.6
0.6.18.6.1
0.6.18.6.2
0.6.18.6.3
0.6.18.6.4
0.6. 18.6.5
0.6. 18.6.6
0.6. 18.6.7
0.6. 18.6.8
0.6. 18.6.9
0.6.18.6.10
0.6.18.6.11
0.6.18.6. 12
Measuring systems/transmitters
Flow measurements
Temperature measurements
Pressure measurements
Analyses measurements
Level measurements
Electrical measurements
Position measurements
Contact devices
Vibration measurements.
Control valves
Actuators
68
0.6.18.6.13.
0.6.18.7
0.6.18.8
0.6.18.9
0.6.18.10
Local instrumentation
Racks, junction boxes
Transmitter racks and piping
Programmable logic controller
Control cubicles
69
0.6
Any changes on the design of any part, of the Plant, which may become necessary
after signing of the Contract have to be submitted by the Contractor in writing to the
Owner/Owner's representative for approval, being sufficiently substantiated and
justified.
The Plant shall be brand new and clean, and designed, manufactured and arranged
so that it will have a functional design and a pleasant appearance. All parts of the
Plant shall be arranged in such a manner as to facilitate surveillance by the operator
and to ease maintenance, operation and control.
The parts of the Plant shall be designed and arranged so that they can be easily
inspected, cleaned, erected and dismantled without necessitating large scale
dismantling of other parts of the plant. They shall be designed, I1lClnufactured and
put into operation in accordance with the latest recognized rules of workmanship,
modern engineering practice and with good standards of prudence applicable to the
international electricity generation industry which would have been expected to
accomplish the desired result at the lowest reasonable cost consistent with reliability,
safety and expedition.
The regulations, standards and guidelines listed in the Specification as well as all
applicable laws and governmental decrees, regulations, orders, etc. shall be
observed in the design, calculation, manufacture, erection, installation, testing,
commissioning and start-up of all parts of the Plant.
The following shall be considered in the design and engineering of the Plant
facilities:
All parts of the Plant shall be suitable in every respect for continuous operation at
maximum output as well as part loads and expected transient operating
conditions peculiar to the site and shall be able to safely withstand the stresses
arising from the operating conditions without any reduction in its planned life
which shall be at least equal to 200,000 operating hours.
The Contractor shall familiarize himself with the conditions on site and in the
country, especially with respect to transportation of heavy loads and flood.
70
All live, moving and rotating parts shall be provided with appropriate effective
protection in order to avoid danger to the operating staff. All metal parts shall be
electrically grounded.
All equipment shall be designed to ensure start-up from any condition, i.e. from
cold, warm or hot condition without necessitating special or preparatory
measures.
Before starting his works, the Contractor shall deliver those standards in English
language, which will be used on site to the Owner/Owner's representative and
the Engineer.
71
0.6.3 Plant and equipment identification (e.g. Power Plant Coding System KKS)
The Contractor shall apply a plant identification system showing the name and number
of each item of plant and its respective arrangement drawing number and add any
additional items necessary to fully identify the plant. The identification and numbering of
equipment, systems, items, etc. of supply, as well as of all documents and drawings
shall
be
in
accordance
with
the
IDENTlFICA
TION
system
(KraftwerksJiennzeichnungssystem = Power Plant Coding System PPCS) or equal. The
IDENTIFICATION system is available from
VGB-Kraftwerkstechnik GmbH,
VerIag technisch-wissenschaftlicher Schriften Klinkestrasse 27
- 31,45136 Essen, Germany.
The Contractor shall work with this or any equivalent system that the works me going on
smoothly.
There is to be only one description for anyone item of plant and this must be used
consistently for plant, electrical and instrumentation designations throughout.
The Contractor shall supply all labels, nameplates, instruction and warning plates
necessary for the identification and safe operation of the plant, and all inscriptions shall
be in the English/Bangla languages.
All labels, nameplates, instruction and warning plates shall be securely fixed to items of
plant and equipment with stainless steel rivets, plated self tapping screws or other
approved means. The use of adhesives will not be permitted.
Nameplates for plant and equipment identification and record purposes shall be
manufactured from stainless steel or aluminum with a mat or satin finish, and
engraved with black lettering of a size which is legible from the working position.
Warning plates shall be manufactured from stainless steel or aluminum engraved
red white lettering on a white background and sited in the position where they afford
maximum safety of personnel.
All equipment within panels and desks shall be individually identified by satin or mat
finish stainless steel or aluminum labels, or laminated plastic labels where
approved.
Each circuit breaker panel, electrical control panel, relay panel, etc. shall have a
circuit designation label on the front as well as on the rear panels engraved with
black lettering in accordance with the circuit designation system. Circuit
designations must be precise and convey complete information. There should be no
doubt whatsoever for the operation as to which area of the plant a particular feeder
is supplying with power. Labels such as interconnector 1, feeder 2 are not
acceptable. Corridor type panels shall in addition have circuit designation labels
within the panels.
Pipe work systems shall be identified with a color identification systems in conformity
with the colors according to the chosen standards, with colors af the nameplates
and, if necessary by color bands and with identification numbering and plain
language. The direction of flow shall be shown.
72
Each valve shall be fitted with a stainless steel or aluminum name plate indicating
the valve service and reference number in accordance with the IDENTIFICATION
system.
Where possible valve nameplates shall be circular and fitted under the hand wheel
captive nut. They have to be of such a diameter that there is no danger for persons
operating the valve or that they do not prevent lock-off of this valve; on check valves
and small valves the Contractor may provide rectangular nameplates fitted to
brackets on the valve or attached to a wall or steelwork in a convenient position
adjacent to the valve.
73
oil
grease
paint residues
splatters
mill scale
welding splashes and
Welding slag.
74
75
that such conditions of poor weather within 2 hours after application can arise.
Temperature of the coated parts has always to be above 5C and 3 K above dew
point.
All specified dry film thicknesses (DFT) are minimum thicknesses.
Welding seams mounted at site have to be taped with an adhesive tape of about 30-50
mm after surface preparation (blasting or manual derusting) and prior to application in
the manufacturing plant and to be coated with stripping coat.
Chequered plates, nap plates, etc. have not to be covered with adhesive tape, but have
to be coated with stripping coat in a dry film thickness of at least 150 m.
Edging lines on steel structure have to be taped prior to application and after blasting
in sufficient width or have to be protected with varnish before application. Thickness
of prime coat may be 50 m max.
During repairing works at site on shop-primed structures, it is important that different
coats will have different colour shades. Number of layers has to be the same as the
original coating system to be used.
Application of temporary primer on structures which have to be insulated has to be in
accordance with a sufficient corrosion protection for the period of storage
respectively erection time.
Galvanizing
Galvanizing work shall conform in all respects to the chosen standards and shall be
performed by the hot dip process unless otherwise specified.
It is essential that details of steel members and assemblies which arc to be hot-dip
galvanized should be designed to suit the requirements of the process. They should
be in accordance with the chosen standards.
Vent holes and drain holes shall be provided to avoid high internal pressures and air
locks during immersion and to ensure that molten zinc is not retained in pockets
during withdrawal.
Careful cleaning of welds is necessary before welded assemblies are dipped.
All defects of the steel surface including cracks, surface laminations, laps and folds
shall be removed in accordance with BS 4360. All drilling, cutting, welding, forming
and final fabrication of unit members and assemblies shall be completed, where
feasible, before the structures are galvanized.
The minimum average coating weight shall be as specified in the chosen standards.
Structural steel items shall be first grit-blasted (Sa 2 1/2) or pickled in a bath, and the
minimum average coating weight on steel sections 5 mm thick and over shall be
900 g/m2, on steel sections 2 - 5 mm thick 600 g/m2 .
Galvanized contact surfaces to be joined by high-tensile friction-grip bolts shall be
roughened before assembly so that the required slip factor is achieved. Care shall
76
be taken to ensure that the roughening is confined to the area of the mating faces.
Protected slings must be used for off-loading and erection. Galvanized work which is to
be stored at the works or on site shall be stacked so as to provide adequate ventilation
of all surfaces to avoid wet storage staining (white rust).
Small areas of the galvanized coating damaged in any way shall be restored by:
cleaning the area of any weld slag and thorough wire brushing to give a clean surface
the application of two coats of zinc-rich paint, or the application of a low melting point
zinc alloy repair rod or powder to the damaged area, which is heated to 300C.
Connections between galvanized surfaces and copper, copper alloy or aluminum
surfaces shall be protected by suitable tape wrapping
77
Coating Systems
SystemNo
Surface location
Structural steel works, piping,
SA 2.5
No.of
coats
Generic type
Primer
Zinc-Epoxy
80
80
Finish
80
80
160
up to 120
Primer
Zinc-Epoxy
80
80
1-2
1
160
50
160
50
290
Primer
Zinc-Epoxy
50
50
Primer
Zinc-Epoxy
80
80
Intermediate
110
110
Finish
2-Comp.Polyurethane
50
50
SA 2.5
vessels, tanks
OUTDOOR
Intermediate
Finish
up to 120
SA 2.5
up to 120
Coating
systems
INDOOR
Surface
preparation
vessels, tanks
Temp. C
.
up to 120
SA2.5
OUTDOOR
240
up to 120
SA 2.5
Primer
Finish
Zinc-Epoxy
Epoxy High Solid
80
80
50
100
180
78
Coating Systems
SystemNo
Surface location
Piping, reactors
Temp. C
Surface
preparation
> 120
SA 2.5
< 120
SA 2.5
Coating
systems
Primer
No.of
coats
Generic type
Zinc Ethysilicate
75
75
Primer
Zinc Ethysilicate
75
75
Finish
Silicone Acrylic
50
Primer
Zinc Ethysilicate
75
100
175
75
Finish
Silicone Aluminium
25
When Finish
Coat is
required, such
as sea climate
with chloride
exposure
125
OUTDOOR
Insulated
Stacks
OUTDOOR
<200
Steel surfaces
200 - 450
SA 2.5
Un insulated
Galvanized surfaces
Medium
Prime and
Glassflake reinforced
temp.oC
SA 2.5
Finish
1
500
High Solid Epoxy.
up to 60
Coat in One
Additional 1 x Finish Coat 2-Comp. Polyurethane, 50 m, when exposed to UV and colour retention is required or when exposed to weathering.
10
up to 120
Mechanical
cleaning from
contaminants
and zinc salts
by means of
washing or
steam or
sweep- jetting
blasting with
fme sand
50
125
125
500
79
0.6.6 Vibration
Unless otherwise stated or agreed by the Owner/Owner's representative or ; the
Owner/Owner's representative each rotating machine has to comply with the
requirements for vibration magnitude (criterion I) designation as "zone A" stipulated
by ISO Specification 10816 or equivalent for the respective group of machinery. If
the vibration magnitude is greater than stipulated as "zone B", the Owner/Owner's
representative has the right to reject the concerned equipment. .
0.6.8 Accessibility
The Contractor shall supply and erect sufficiently large safe platforms, galleries,
stairways and access ways necessary for providing safe and easy access to all the
plant items for operation and maintenance. The Contractor shall ensure that the
whole of the access ways is of W1iform design and pattern throughout the works.
Ladders are only to be provided as an extra means of escape. No dead ends are
allowed, especially where the escape way may be blocked by fire/steam, etc.
The design of all stairways, access ways etc. shall conform to the requirements of
Section 0.6.11.
0.6.9 Signs
General
Safety colors, safety symbols and safety signs must comply in construction,
geometrical form, color and meaning with the chosen standards.
Signs for plant identification during the erection period are subject to the
Owner/Owner's Representative approval.
The signs should be of a material which is weather-resistant and of sufficient
durability for the conditions prevailing on site.
80
Temporarily dangerous areas (e.g. construction sites, assembly areas) may also be
marked by movable signs. The safety signs must be mounted or installed in such a
manner that there is no possibility of misunderstanding.
Information signs
Information signs should supply the necessary information to acquaint personnel
with the physical arrangement and structure of site, buildings and equipment, e.g.
floor numbers, load-carrying capacities including marking of floor areas, working
loads of cranes, lifting gear and lifts, room identification, etc. The routing of
underground pipes and cables is to be indicated by substantial marker blocks
showing the relevant identification numbers.
In the choice of information signs in situations not covered by the chosen standards
the possibility of using pictograms should be considered. Pictograms are particularly
suitable for the identification of rooms, areas and buildings in the non-technical areas
of the plant, sanitary and amenities buildings, etc.
Emergency signs
In the event of accidents, all necessary information should be available immediately
to those affected. Thus, a sufficient number of signs of appropriate size should be
installed, e.g. escape routes (including marking of floor areas), emergency exits, fire
alarms, fire extinguishers, instructions for special fire-extinguishing agents, warnings
against fire-extinguishing agents (C02), first aid equipment, first aid points, accident
reporting points, telephones, etc.
Mandatory signs
Signs indicating obligatory actions must be provided installed wherever certain action
is necessary, e.g. do not obstruct the entrance; keep right, etc.
Signs should also indicate when the wearing of protective clothing and equipment is
necessary and obligatory, e.g., protective goggles, protective clothing, helmets, head
guards, breathing equipment, ear muffs, etc.
Warning signs
Warning signs should refer to the existence or possible existence of danger, e.g.,
flammable substances, explosive substances, corrosive or noxious substances,
suspended loads, general danger, width height restriction, steps, risk of trapping,
slipping, falling, etc.
In addition to warning signs, appropriate black-yellow ~trip markings should also be
used where necessary.
81
Quantity
Length
Mass
Time
Temperature
Temperature Difference
Electric Current
Luminous Intensity
Area
Volume
Force
Pressure (absolute)
Pressure below 1 bar
Stress
Velocity
Rotational speed
Flow
Density
Name of Unit
Millimeter
Kilogram
Second
Degree Celsius
Kelvin
Ampere
Candela
Square meter
Cubic meter
Liter
Newton
Bar
Kilopascal
Millibar
Newton per square millimeter
Meter per second
Revolutions per minute
Cubic meter per day
Cubic meter per hour
Kilogram per hour
Liter per second
metric ton per hour
For gaseous substance: standard
cubic meter per hour (referred to
OC and 1013 mbar)
Kilogram per cubic meter
Kilogram per standard cubic
meter
Newton meter
Kilogram square meter
Joule
Joule per Kelvin
Symbol
mm
kg
s
C
J
J/K
J/m3
J/g
W
W/m2
W/mK
Ns/m2
K
A
cd
m2
m3
I
N
bar
kPa
mbar
N/mm2
mls
rpm
m3/d
m3/h
kg/h
L/s
t/h
Nm3/h
kg/m3
Kg/Nm3
Nm
kgm2
82
Quantity
Kinematics' viscosity
Surface tension
Concentration
Electrical conductivity
Frequency
Electric charge
Electric potential
Electric field strength
Electric capacitance
Electric resistance
Conductance
Magnetic flux
Magnetic flux density
Magnetic field strength
Luminous flux
Illuminance
Thermal resistivity
Energy
Name of Unit
Meter squared per second
Newton per meter
Parts per million
Micro Siemens per meter at 25C
Hertz
Coulomb
Volt
Volt per meter
Farad
Ohm
Siemens
Weber
Tesla
Ampere per meter
Lumen
Lux
Kelvin meter per Watt
Kilowatt hour
Symbol
m2/s
N/m
ppm
S/m
Hz
C
V
Vim
F
n
S
Wb
T
A/m
lm
Ix
Km/W
kWh
For the thermodynamic properties of steam and water the latest edition of the
"VDI- Wasserdampftafeln" (= Water Steam Tabular) shall be used which is based
on the formulations published by the International Formulation Committee (IFC)
under the title "The 1967 IFC Formulation, for Industrial Use".
0.6.11
,i
steel
All aspects of platforms, stairways, ladders and other access ways shall comply
with the requirements of applicable 'standards.
83
nature, handling and storage of all fuel oils, gases and chemicals etc., and provide
plant, equipment, buildings and other services accordingly, including all facilities to
ensure the safety of the operating and maintenance personnel.
The Contractor shall provide drawings to define all the hazardous zones taking
account of all sources of hazards under normal and abnormal operating conditions,
(regardless of whether or not these areas are specifically listed in the
specification).The zoning philosophy shall be subject to the approval of the
Owner/Owner's representative.
In particular, equipment directly concerned with plant which may give rise to a
hazardous situation shall be designed to requirements with electrical connection
safety barriers or intrinsically safe equipment. Where required by the Engineer,
certification shall be provided to confirm the suitability of the equipment and
devices.
The Contractor shall be responsible for ensuring that all electrical equipment
installed in any hazardous zone is designed and tested to suit the relevant zone
classification and shall be to the approval of the Employer. Cables shall not be laid
in trenches etc with fuel pipe work.
Fire protection provisions
Unless otherwise specified or agreed with the Owner/Owner's Representative, the
following design principles should be observed as minimum fire prevention
requirements:
Pipeline insulation and the in-fills of cable and pipeline wall penetrations are to
be of non-combustible material.
All pipelines or vessels with internal temperatures of more than 180C shall be
so arranged as to avoid any contact with flammable liquids if fuel or lube oil
lines should leak. Sufficient physical separation shall be ensured.
Particular care should be taken to eliminate any risk of hot pipeline insulating
material becoming impregnated with flammable liquids in the case of fuel or
lube oil line leakage. The insulation is to be covered in its entirety, with an oil
resistant sheet, over which the cladding is to be fitted.
Cable and pipeline ducts must be so arranged and sealed as to avoid all risk of
flooding with fuel oil, lube oil or any other flammable liquid. In addition to
sealing the cable and pipeline ducts, the cable basements must be completely
scaled against leakage from above as well, in order to preclude the ingress of
lube oil or other flammable liquids.
Covered floor ducts must be easily accessible for inspection and cleaning.
All parts of plant and equipment are to be arranged so that no corners or pits
that would be difficult to inspect and clean and in which flammable matter could
collect are formed.
Fuel preheating temperatures should be limited to a margin of at least 10K
below the fuel flash point.
Lubricating oil lines in the turbine-generator lube oil system arc not to be
connected with compression-type joints but rather with welded or screwed-type
points.
84
0.6.13
Maintenance isolation
All major equipment shall be arranged to facilitate safe isolation frol11 all
hazards for maintenance purposes. In addition all valves must be capable of
being locked either in the open or closed position by means of a chain and
padlock.
Non return valves are not acceptable as a means of isolation.
0.6.14
Materials
All materials shall be brand new and of the best quality for use in the conditions
and the variations in temperature and pressure that will be encountered in
service without undue distortion or deterioration or the setting up of undue
strains in any part that might affect the efficiency and reliability of the plant.
All materials shall correspond either to the approved standards and the
respective code number or to exact analysis data, and full information
concerning properties and applied heat, chemical and mechanical treatment
shall be submitted for Owner/Owner's Representant's spot check.
Special attention must be paid to eliminating the possibility of corrosion
resulting from galvanic effects. Design, selection of materials and all methods
of erection shall be such as to keep these effects to a minimum. Materials
complying with codes and standards listed below shall be used for the design
and construction work.
Unless the materials meet these codes and standards, they shall be subject to
the Owner/Owner's representative's spot check.
Materials and standards
(A)
(B)
(C)
(D)
(F)
a.
b.
c.
a.
Structural steel
Structural steel tubes
Crane rail
High strength friction grip bolts
(H.S.F.G. bolt)
b.
Torque shearing bolt
c.
Ordinary bolt
Electrodes for arc welding
Ordinary Portland cement
Reinforcing bars
85
0.6.15
86
When all plant has been erected and lagged or at such other time as may be
agreed with the Owner/Owner's representative for sub-assemblies, the
installation shall undergo a procedure for site cleaning proposed by the
Contractor and subject to the approval of the Employer.
0.6.16
Mechanical equipment
0.6.16.1 Pumps
General
All pumps shall be designed for continuous operation unless otherwise specified.
Pumps shall be installed in positions convenient for operation and servicing.
Where multiple pump installations are required, each pump and its associated
equipment shall be arranged in such a manner as to permit easy access for
operation, maintenance and pump removal without interrupting plant operation.
Pumps installed for parallel operation or as stand-by sets are to be of identical
design, i.e. interchangeable.
Lifting lugs and eyes and other special tackle shall be provided as necessary to
permit easy handling of the pump and its components.
General design and construction
All pumps shall be designed to withstand a test pressure of 1.5 times the
maximum possible pump shutoff pressure under maximum suction pressure
conditions. If a pump can operate at sub-atmospheric suction conditions, the
entire pump shall be designed for full vacuum.
All pump shafts shall be of ample size to transmit the maximum possible output
from the prime mover. The pump shaft and coupling are to be so dimensioned
that the maximum permissible torque of the shaft is higher than the maximum
transmissible torque of the coupling. Directly coupled pumps shall be used
preferably.
Renewable wear rings shall be fitted to the casing and impeller where
economically justified.
All pumps and accessories in contact with the pumped fluid shall be constructed
of materials specifically designed for the conditions and nature of the pumped
fluid, and be resistant to erosion and corrosion.
Product water flushing lines are to be supplied for each pump handling seawater
to avoid corrosion if the pump is out of operation for extended periods.
The pump glands or mechanical seals shall be so arranged that repackaging or
fitting of replacement seals can be carried out with the minimum of disruption to
plant operation. In case of operating under vacuum conditions liquid sealing is to
be provided.
The pump casing shall preferably be split for ease of maintenance and be
87
designed such that the impeller and shaft are capable of being withdrawn from
the casing without disturbing any of the main paperwork. and valves carrying the
pumped fluid. In general, all horizontal pumps with draw-outrotors are to be fitted
with a coupling to facilitate disassembly without removing the motor. Pull-out
design of the shaft shall be applied to vertical wet pit and dry pit pumps as well.
Each .horizontal pump shall be mounted with its drive on a common base plate of
rigid construction. Vertical pumps are to be provided with foundation frames. In
case of submersible pumps suitable frames shall be provided in the pump sump.
It shall however be possible love these pumps without entering the sump.
Pumps must be carefully set to ensure that the net positive suction head
available under all operating conditions will be adequate for the type of pump
employed. The NPSH values are to be referred to the least favorable operating
conditions -lowest atmospheric pressure, lowest level of water <W the suction side
of the pump, and highest temperature of the pumped fluid. An adequate safety
margin of normally greater than 1 m to the max. NPSI-1 required shall be
provided.
Pumps shall operate smoothly throughout the speed range up to their operating
speeds. The first coupled critical speed must be at least 20% higher than the
maximum operating speed. The determination of the shaft diameter and the
distance between two consecutive bearings must include a sufficiently large
safety margin to satisfy this condition.
Where necessary, the pumps are to be fitted with devices to ensure a minimum
throughput.
Bearings
For large pumps the bearings shall be of automatic oil lubricated sleeve type,
unless otherwise specified. Bearings on vertical shaft pumps shall be so spaced
to prevent shaft whipping or vibration under any mode of operation.
Bearings housings on horizontal shaft pumps shall be designed to enable the
bearings to be replaced without removing the pump or motor from its mounting.
Bearing housings on horizontal shaft pumps shall be effectively protected against
the ingress of water, pumped fluid and dust by suitable nonferrous deflectors.
All bearing oil wells shall be fitted with visual oil level indicators. Non pressure-oil
lubricated bearings shall be equipped with constant level oilers.
Pumps characteristics
When several pumps arc installed for the same service, they shall be suitable for
unrestricted parallel operation.
The pump flow/head characteristics shall be such that within the operation range
the head will continuously increase with decreasing flow, maximum head (shut
off head) being at least 10% higher than the duty point head.
88
Fittings
All pumps shall be installed with isolating valves, a non-return valve and suction
and discharge pressure gauges unless otherwise stated. Accessible couplings
shall be supplied with removable type guards.
Coupling halves shall be machine matched to ensure accurate alignment.
Couplings as well as gears must have a rated capacity of at least 120% of the
maximal potential power transmission requirement.
All positive displacement pumps shall be fitted with a discharge relief valve
capable of passing the maximum pump delivery flow.
Venting valves shall be fitted to all pumps at suitable points on the pump casing
unless the pump is self-venting, due to the arrangement of the suction and
discharge nozzles. Drainage facilities shall be provided on the pump casing or
adjacent pipe work to facilitate the dismantling of pumps.
All pumps other than submersible pumps shall have temporary strainers fitted in
the suction pipe work during all initial running and commissioning phases.
Permanent strainers shall be provided where specified.
89
90
0.6.16.2.4
91
the pipe shall be fixed in a constant position if not otherwise instructed by the
Engineer. The Contractor is responsible for meeting all the requirements for
pipe connections established by the manufacturers of the turbine, the pumps
and other relevant equipment.
92
0.6.16.2.
0.6.16.3
The maximum flow velocities for the individual media must not bc ex exceeded
at maximum throughput (unless expressly specified in the documents):
Type of pipe work
max. velocity
Steam lines:
High-pressure live steam lines (PN > 64)
Intermediate-pressure steam lines (PN
25140)
60 m/s
40 m/s
93
35 m/s
25 mls
80 m/s
20 mls
0.5-2.5 m/s**
3-5 m/s
1.5 m/s
3.0 m/s
1.0 m/s
2.0 m/s
20.0 m/s
25 m/s
The design and routing of the feed water suction lines must be optimized considering the allowable
velocity or depressurization caused by load changes.
The following standard pipe sizes shall preferably be used for main process
lines:
Nominal
Diameter in mm: 25, 50, 80, 100, 150, 200, 250, 300, 350, 400, etc.
inch: 1, 2, 3,
4,
6,
Pipes with a diameter size smaller than 25 mm (one inch) may be used only
for control air, control oil, chemical dosing, scaling water, instrument
connections, sampling pipes and other instrument and analysis lines.
For the design of safety valves installed downstream of reducing stations,
high pressure bypass valves or equivalent control valves, the maximum
throughput of the fully open reducing or bypass valve including injection
water quantity is to be taken as the basis for calculation. All cross sections
and lines for safety devices that protect against excess pressure (safety
valves, rupture discs and similar items) must be designed to ensure the
necessary blow-off rate and fault free functioning
All safety valves shall have a test certificate issued by an approved authority.
The design pressure is equal to the response pressure of the devices
protecting the piping. In the case of pump discharge lines a pressure corresponding to 1.1 times of the shut-off head of the pump at the ambient
temperature is to be taken as the minimum design pressure. The main cooling
94
water and seawater supply systems must be designed according to . the water
hammer calculation.
The design temperature is the highest possible fluid temperature occurring
in the length of line concerned. Possible tolerances of the temperature control
system and any temperature allowances provided by the requirements of the
standards shall be considered.
For live steam lines the design pressure of the boiler shall be taken as the
design pressure of these lines up to the inlet of the turbine main stop valves.
In addition to the required wall thickness in accorda'1ce with calculations, a
corrosion allowance of 3 mm shall be added for unprotected carbon steel, 1.5
mm for alloy steel, and 0.5 mm by stainless steel.
For the piping systems with a nominal pressure specified as PN > 40 as in DIN
2401, or equivalent, the drainage and ventilation facilities shall be fitted with
double valves.
All vents, drains or dump points with more than 10 bar/10000C operating
pressure/temperature shall lead to the flash tanks and into funnels at visible
points with covers.
Guidelines for the design and construction of pipe work and accessories
Design and construction of all parts of the pipelines and accessories should
correspond to the present state of the art and shall be based on the latest
standards.
The pipe work and its accessories shall be designed and arranged so that all
parts subject to operation and maintenance can be operated, inspected,.
maintained and replaced without difficulty and with a minimum of effort. All
important parts must be accessible.
Provisions to allow for isolation and for access must be foreseen on all parts
subject to acceptance resets by the local authorities.
The nominal bore of gate valves shall be the same as the nominal diameter
of the pipeline in which they are installed.
None of the forces and moments transmitted by the pipes to connected
machines, apparatus and other components must exceed the maximum
permissible values, given by the manufacturers of these items. Attachments
to turbine foundations shall be carried out only as agreed with the turbine
manufacturer.
All steam traps shall be provided with a bypass and lines which open to a
funnel.
As far as expansion joints and other parts of pipe work are concerned it shall
be borne in mind that differential settlement can occur. The reaction forces
and moments of the piping system to be withstood by fixed points~ walls,
foundations and other dvil structures shall be reduced to the utmost
minimum by suitable means (e.g. expansion joints shall be provided where
required).
95
Since the steam pipes may be filled with water for a short time (e.g. when
flushing or pressure testing), supports shall be dimensioned accordingly. The
load information to be given by the Contractor to the civil designers shall
take account of this requirement.
96
97
All pipe hangers and support stands shall be attached to the piping and
structural supports such that they will be vertical when the piping is at operating
condition. So far as practicable, hangers and supports shall be of the same
type and component assembly.
All hangers shall be carefully adjusted. After plant start-up checks shall confirm
that all hangers and supports are in the correct position.
The Contractor shall prepare a complete documentation of a1\ pipe hangers
and supporting elements. These documents shall contain the following
information:
loads, forces and moments, and their directions at all supports, hangers at
normal operating conditions, etc.
measurements of the loading points referred to the axes 'of the buildings
item No. of the supports, hangers etc. according to the piping group
All hangers shall be carefully adjusted. After plant start-up checks shall
confirm that all hangers and supports are in the correct position.
The Contractor shall prepare a complete documentation of a1\ pipe hangers
and supporting elements. These documents shall contain the following
information:
loads, forces and moments, and their directions at all supports, hangers at
normal operating conditions, etc.
measurements of the loading points referred to the axes 'of the buildings
item No. of the supports, hangers etc. according to the piping group
Trace heating
Trace heating shall be provided for fuel oil pipes and other pipes as required.
Electric type trace heating is preferred.
Protection of buried pipe work systems (as far as not installable in ducts)
All buried pipe work of steel or cast iron or other materials prone to corrosion
shall be protected from corrosion by catholic protection and a system of tape
wrapping to be applied in the workshop.
The design of the catholic protection system(s) shall be executed by a specialist
and authorized company under consideration of the following:
98
the calculated current required is too low may suitable sacrificial anodes be
used for protection,
0.6.16.4
0.6.16.4.1 Responsibility
Each Contractor must have the necessary facilities available to ensure that the
materials are properly processed and all tests can be carried out.
It must have his own supervisory staff and trained workers for the manufacture.
Each Contractor shall be responsible for the quality of the welding carried out
by his organization and shall conduct tests not only of the welding procedure to
determine its suitability of ensuring welds which will meet the required
specifications and tests, but also of the welders and welding operators to
determine their ability of applying the procedure properly. No production work
shall be undertaken until both the welding procedure and the welders or
welding operators have been qualified.
The Owner/Owner's Representatives acceptance of welding execution docs
not releases the Contractor of his responsibility.
instruction for issue and return of welding auxiliary materials their drying and
warming, storage and identification
99
record of performed welding and repairs by welding, their test results and the
welder or welding operator who made them
100
I f not otherwise agreed upon, the tests and certificates shall be valid as per
adopted pressure code.
The regular renewal of the qualification of welding personnel shall be done
according to the same standard and specification used for their initial
qualification. If at any time, in the opinion of the Owner/Owner's Representative, the work of any welder appears questionable, such welder will be
required to pass additional qualification tests to determine his ability to perform
the type of work on which he is engaged. All such additional qualification tests
and the physical tests on the welded specimens shall be made at the expense
or the Contractor and in the presence of the Owner/Owner's Representative.
The sample welds shall be carried out on specimens of similar shape,
thickness and chemical analysis as for the material to be welded, and in a
position which shall represent as far as possible the worst conditions under
which actual welding would take place.
The procedure of preparation of the test pieces, and the standards to be used
for the examination shall be in accordance with the relevant standards or as
may be agreed upon between the Contractor and the Owner/Owner's
Representative.
Each qualified welder and welding operator shall be assigned an identifying
number or symbol by the Contractor which shall be used to identify the work of
that welder or welding operator.
The performance qualification tests for welders and welding operators
conducted by one contractor on ASME base shall not qualify a welder or
welding operator to do work for any other manufacturer or contractor.
0.6.16.4.5
Welding process
101
102
0.6.16.4.5.5 Non-conformities
The Contractor shall issue an instruction sheet for handling of nonconformities.
Each non-conformity has to be noted by him. He shall present a proposal of
acceptance or removal of the defect to the Owner/Owner's Representative.
Every major repair procedure needs the approval of the Owner/Owner's
Representative.
If heat treatment has already been performed, the repair documents for
approval shall include the heat treatment plan after completion of the repair.
0.6.16.4.6.2 Pre-heating
If pre-heating is required according to welding schedule, the temperature
shall be maintained during the welding operation. In case of interruption of
welding and preheating, a stress relief heat treatment shall be done prior to
the interruption.
In any case, the welding schedule or welding procedure specification for the
material being welded shall specify the minimum preheating temperature.
Preheating for welding or thermal cutting may be applied by any method
which does not harm the base material or any weld metal already applied or
which does not introduce foreign material into the welding area which is
harmful to the base material or weld
103
0.6.16.4.7
Documentation
The above-mentioned records and instruction sheets and documents requested by this Contract or relating standards shall be stored by the Contractor during the erection time and shall be part of the general power plant
documentation.
0.6.16.5
globe valves
gate valves
butterfly valves
up to and including DN 50
ON 80 and above
DN 400 and above for LP steam and exhaust
steam (DN 80 and above for waterlines
(cooling water, process water etc.), operating
temp. max.180C
up to and including DN 50
DN 80 and above
DN 25 and above (fuel oil, natural gas,
compressed air)
104
HP and large size gate valves to be opened under differential pressure shall
be equipped with pressure equalizing valves (globe valves).
All valves (especially including ball valves) shall be fitted with indicators to
determine the valve position. In the case of valves fitted with extended
spindles, indicators shall be fitted both to the extended spindle and to the:
valve spindle.
All globe valves shall be equipped with throttling cones with parabolic
characteristic.
In general, LP safety valves, butterfly valves, ball valves and orifices as well
as all control valves shall be flanged. All valves for steam, feed water and
condensate, HP safety valves (inlet side) shall have welded ends, corresponding to the connected pipes.
Design of valves and materials used must comply with the relevant standards. They must be chosen in accordance with the requirements to be met
and to corresponding pipe work .
For limiting hand wheel forces, for control and operation purposes it may be
necessary to install gears and drives.
The max hand wheel force of 25 deka Newton must not be exceeded.
All block valves DN 500 arc to be provided with electrical actuators with
manual override. The actuators arc to be operated by local control points
which can be locked.
Preferably electrical actuators shall be installed. Actuators shall be suitable
for fitment to valves and floor-stands with hand wheels for manual operation
and provision to switch over from electrical to manual operation and vice
versa (see chapter actuators).
For pneumatic or hydraulic actuators similar requirements must be fulfilled.
Fail-safe functions shall be incorporated.
105
The Contractor shall furnish and install steam traps at each low point. Each
steam trap installation shall include a permanent strainer,. upstream and
downstream globe valves and a globe valve as free drain. Steam traps shall
be supplied with weld ends.
Drain traps shall be provided with inlet and discharge valves, vents and handcontrolled bypasses and, when discharging into a closed header, shall also
be provided with discharge non-return valves.
Steam traps shall preferably be of the thermodynamic or bimetallic type with
multistage nozzles selected to suit the service conditions.
No traps which incorporate internal screens or check valves shall be used
unless specifically required.
Each trap shall be sized to provide ample capacity at the minimum working
differential pressure, and to open the orifice at maximum working differential pressure.
Condensate drainers such as used on LP saturated steam or compressed air
lines shall be of the ball-float type.
All gate valves shall be of the fullway gate type and when in full open
position. the bore of the valve shall not be obstructed by any part of the gate.
The internal diameter of all valves at the end adjacent to the pipe work shall
be the same as the internal diameter of the connecting pipe.
All valves shall have bolted gland stuffing boxes. Screwed glands and
bonnets will not be accepted.
Spindle glands shall be of the bridge type. In all cases where applicable,
spindles shall have back-scaling seats to allow renewing of the spindle
glands with the valve open under pressure conditions.
HP gate valves shall be equipped with self scaling lid covers. The selfscaling lid covers shall be equipped with a safety device at the body with
shut-off valve and interlocking system. This system must be approved by
the authorities.
All valves of the HP piping systems shall be suitable for pickling.
The valves for live steam, HP feed water and HP injection water shall be
made of forged steel. Forged steel or cast steel shall be used for the remaining systems. Valves made of gray cast iron are not acceptable.
Acceptance certificates for piping components and valves shall be delivered
to the Owner/Owner's representative for approval.
a) Relief valves shall be installed in the vertical upright position.
b) The outlet piping of relief valves discharging to a closed system, such
as a blowdown or Dare header shall be arranged so that the discharge
line flows down to the header without pockets.
106
0.6.16.6 Insulation
Thermal insulation
The thermal insulation shall be designed and installed in accordance with the
chosen standards, considering the following minimum requirements:
All pipes and equipment to be insulated must be indicated on the flow sheet and
technical data sheets with the following code letters:
HI
= heat insulation
CI
= cold insulation
CWI
= chilled-water insulation
PPI
107
Blanket (W/m K)
0.034
0.040
0.048
0.058
0.070
0.083
0.100
50
100
150
200
250
300
Sheet thickness
0.7 mm
Sheet thickness
0.9 mm
Sheet thickness
1.2mm
Tank tops shall be provided with insulation strong enough to support a man's weight.
The sheets shall be secured and connected at the longitudinal scams with at least five
stainless steel self-tapping screws per meter run.
Plain sheets for fiat surfaces shall not exceed 1 meter square and shall be stiffened by
crimping.
At the longitudinal and circumferential joints, the sheets shall overlap by at least 50
mm so as to drain off the liquid and to trap the liquid in the insulation.
Places at which the metal sheets are penetrated for pipe hangers, thermometer
sockets, etc. shall be sealed with funnel-shaped recesses or sheet metal rims.
The seams and penetrations of any sheet metal insulating jacket installed
108
outdoors as well as in the boiler and turbine house in areas with risk of water
spray etc., shall be sealed against penetration of water by means of a suitable
silicon based sealant.
The inside of the aluminum jacket shall be protected against contact corrosion
from the wire mesh of the insulating mats by suitable means (e.g. Kraft paper or
equivalent).
In the case of pipe insulation thicknesses greater than 60 mm, where insulation
blankets are used spacers shall be provided at maximum intervals of 950 nun to
ensure a uniform insulating thickness on all sides and a perfectly circular shape"
of the sheet metal jacket. The sheet metal jacket shall be supported by support
webs (for pipe diameters below 100 nun) and enclosed support rings (for pipe
diameters 100 mm and above). If the enclosed support rings are not provided with
ceramic spacers, the spacers made of steel shall be insulated with one heat
insulation strip in the case of operating temperatures of up to 200C, and with two
heat insulation strips where the operating temperature exceeds 200C.
To provide protection against contact corrosion, the external circumference of the
support ring shall be fitted with heat insulation tape 1 mm thick with two woven
edges.
Insulation of furnace and main parts of the boiler
Insulation of up to 80 mm layer thickness shall be applied in one layer, above
that in two layers with offset joints and seams.
The mats shall be secured in position by suitable means and stitched to one
another by galvanized binding wires of diameter 1.0 mm minimum.
Insulation of flanges, valves and fittings
All flanges, valves and fittings shall be provided with two-piece or multi-part caps
made of aluminum sheet of the specified thickness. Each piece or part shall be
double jacketed and the various ports shall be held together by quick release
clamps or lever hooks to facilitate assembly and disassembly.
All caps of the welded-in fittings shall be made longer by approximately twice
the insulation thickness so that the welding seams will be exposed after removal
of the cap.
All manholes shall be provided with heavy duty hinged insulated covers
wherever possible. Such covers shall be secured with easily accessible
clamps.
Insulation or tanks and process equipment:
Tanks and process equipment shall be insulated in the same way as pipes, except
that the insulating material shall not be attached by wire but by using strong
galvanized steel bands.
Spacers shall be welded to process equipment only if this is essential for
satisfactory retention of the insulation. Welding of spacers to process
equipment is subject to approval by its manufacturer in writing.
109
Piping sizes
mm
280c to 50 C
if required for
condensation
Insulation
flange
joints
required
required
Materials and thickness of insulation for piping and equipment outside the
building exposed to weather:
The material and thickness of insulation for the various temperature groups of
piping exposed to the weather outside of buildings shall be as specified in this
article, except that the thickness will increase 13 mm in excess of thicknesses
indicated therein.
110
Chilled-water insulation
Material: Polyurethane foam or equal 40 to 50 kg/m3. Spacing rings shall be fitted
around the pipes at an interval of 800 to 900 mm. Aluminum-sheet covers shall be
screwed (stainless steel) to the spacer rings. The overlapping has to be in
accordance with specified requirements of this Section. The hollow space between
the pipes and metal-cover sheets shall be spray-filled with polyurethane foam or
equivalent. .
Cut-outs in the dover sheets for pipe supports shall be sealed with a permanent
plastic putty.
Valve and flange connections have to be insulated.
111
112
Unless otherwise specified; all heat exchanger tubes and casings must be
designed to withstand 1.2 times the zero flow pressure of the relevant pump at
cold conditions, or 1.2 times of the maximum positive operating pressure, as
applicable. The minimum design pressure is 6 bar, and the design shall be proof
against full vacuum. The test pressure must be 1.5 times the design pressure.
The heat exchangers shall be designed for the maximum temperature incurred
plus 20 K.
Heat exchangers must be capable of continuous unrestricted operation with up to
10% of plugged tubes, and a corresponding factor of conservatism of at least this
amount must be used in the design of the heat transfer areas.
Considerable importance will be attached to the ease of cleaning the heat
exchangers.
Where any heat exchanger part in contact with liquid can be isolated, and there is
a possibility of being heated from the other side, safety valves are to be provided
for pressure relief.
Pipes from drains, vents and safety valves are to be grouped together, and routed
to easily observable points equipped with covered funnels or to the flash tanks.
The overall design and conception of the heat exchangers and accessories is to be such that
they are suitable for the degree of automation envisaged for the individual system.
0.6.17
0.6.17.1 Standards
In addition to the standards as mentioned elsewhere in this document, the design
and manufacture of all electrical equipment shall comply with the latest editions of
the IEC recommendations, e. g. the following:
IEC 34
IEC 56
IEC 72
IEC 76
IEC 79
IEC 86
IEC 123
IEC 129
IEC 137
IEC 141
IEC 144
IEC 157
113
IEC 162
IEC 214
lEC 269
IEC 287
lEC 292
IEC 298
230/400 V 10% for power supplies to small electric power consumers and
motors up to 150 kW, for lighting and domestic power outlets.
230 V safe AC system for uninterrupted essential supplies to consumers,
where no break in supplies can be tolerated.
The general arrangement of the particular voltage level for each part of the plant
within the scope of the Contract' arid the connections of the power supply systems
can be seen from the general single line diagram.
114
brown
red
green
blue
silver
yellow
violet
pink
earth
black
115
splashing water and sand, additional sealing, special seawater or acid resistive coating
etc., depending upon the particular site conditions.
General diffusing lights in switchgear rooms and lights for figments in. luminous
ceilings for offices and control room must be designed at least to class IP32. The
lamps for external lighting and halide lights for internal lighting must have protection
class IP54.
Electrical operational equipment liable to occasional submersion or operation
continuously under water (such as submersible motor-pumps), is to be designed to
meet class IP58 protection in accordance with IEC 34-5.
Electrical operational equipment which must be installed in areas exposed to danger
from explosions must have the required explosion-proof design appropriate to the
flash-point group classification of the explosive mixture as laid down in IEC 79 and
VDE 0 170/0 171. Attention must be paid to VDE 0165 with respect to the use of
electrical operational equipment in workshops and storage premises exposed to the
risk of explosions.
In all rooms and areas where the local and operational conditions and
surroundings can lead to the accumulation of gases, vapors, mists or dusts which,
in combination with air, form explosive mixtures, the operational equipment and
installations to be used iri these circumstances must be of ~ explosion-proof
design. All operational equipment must be designed to comply with the class of
protection dictated by the ignitable mixture (e.g. compression-proof casing,
external ventilation, inherent safety, etc.).
Electrical operational equipment should be located outside rather than inside
buildings or other structures exposed to the risk of explosion. Whenever
operational equipment has to be installed within areas liable to the risk of
explosion, protection against explosion must, in general, be applied wherever
explosive mixtures can arise. In this connection, the ignition of explosive mixtures
must be reliably prevented by adopting the correct choice of design and
construction of the operational equipment and the incorporation of supplementary
safeguards where applicable.
Electrical, chemical, thermal and mechanical influences must on no account
impair, in any way, the protection afforded against explosion. In particular the high
ambient temperatures and the influence of nearby heat sources at the installation
point must be taken fully into account.
0.6.17.7 Protective measures
In view of the potential dangers of electrical power, the following measures are
required for the protection of life, equipment and materials. Basically, all 'live' parts,
i.e. all parts of electrical, operational equipment at an electrical potential above or
below earth potential when in operation, and with a rated voltage over 42 V, must
be insulated or covered so that they cannot be touched accidentally
In addition, measures must be taken by the Contractor to prevent the occurrence
or persistence of excessively high contact potentials on conductive parts of
electrical operational equipment (frames etc.) brought about by faults in insulation.
For installations up to 1000 V, voltages over 65 V are considered to be excessive
contact voltages. Within enclosed electrical installations, with voltages over 1000
116
V, the contact potential shall be according to the values. given in VDE 0141
section 4. (Verein Deutscher Elektroingenieure)
The following rules and regulations are to be observed in carrying out protective
measure and in earthling procedure:
IEC 79 and 364 including VDE 0100 and 0190 for installations up to 1000 V
VDE 0101 and 0141 for installations above 1000 V.
In areas exposed to the hazard of explosion, the protective measures outlined in
VDE 0165 are to be adhered to in the erection and installation or electrical plant
and equipment.
Protective measures for installations up to 1000 V
Protection against direct contact
All 'live' parts of electrical operational equipment that can be reached by hand must
be protected against direct contact either by means of insulation or through
constructional design, position or arrangement, or by means of special devices. If,
in the case of enclosed switchgear or control cabinets, access is required in the
course of normal operation (e.g. for replacing fuses). protection against direct
contact must still be ensured when the switchgear or control cabinet has been
opened up.
Protective insulation
Protective insulation is to be provided by means of additional insulation over and
above the insulation provided for operational purposes. This measure must prevent
the occurrence of a dangerous contact potential.
Use of low voltages as a safety measure
This safeguard applies to all equipment, which is required to operate in metal
enclosures, boilers, tanks etc. The operational voltage of tools and lighting
equipment must not exceed 42 V AC.
Isolating transformers shall be provided by the Contractor for the purpose of
producing the protective low voltage. A separate 42 V system will not be provided.
Connection to neutral
The LV network shall be of the TN type, i.e. the LV neutrals of the 6.6/0.42 kV
auxiliary transformers are earthed directly.
Neutralization (protective multiple earthling) is intended to prevent the persistence
of an excessively high contact potential on conductive parts of the installation
which do not form part of the actual operating circuit. For these purpose an earthed
middle conductor (N) (which becomes the neutral conductor N/PEN) is required.
An installation is considered to be neutralized when all parts of the installation
requiring protection arc connected to the neutral conductor or to a protective
conductor (non-fused earthed wire) which is itself connected to the neutral
conductor;
117
The neutral conductor must be earthed in the vicinity of the particular local
distribution transformer, where it serves as the system earth.
The connection of the conductive non-live parts (e.g. consumer enclosures, frames
of electrical apparatus) shall be carried out.
in the case of conductor cross-sections up to 10 mm2 Cu via a protective
conductor to the neutral conductor
in the case of conductor cross-sections from 10 mm2 Cu upward direct to the
neutral conductor ...
Symmetrically connected power consumers are to be connected to the neutral
conductor (N/PEN), using a four-wire power cable. All unsymmetrical connected
power consumers (wall sockets, plug boxes, heating circuits etc.), where the cable
cross-section is less than 10 mm2, arc to be connected to a special protective
(earthing) conductor which is t<1 run alongside the neutral conductor. Because of
the clear demarcation between the neutral conductor, carrying operational current,
and the protective (earthing) conductor, which (under non-fault condition) carries
no current, NO connection between either N and PEN, or N and earth is
permissible beyond the point of separation of the neutral conductor (N/PEJ(J) into
PEN and N. Unsymmetrical connected consumers must be connected to four-wire
power cable for cable cross-sections equal to, or greater than 10 mm2.
The neutral conductor is to be insulated in the same manner as the phase
conductors. The use of constructional parts of the switchgear as a neutral
conductor is not permitted.
Protective measures against installations over 1000 V
Protection against contact
At least the following measures arc to be taken for all parts that are 'live' when in
operation:
in general areas:
in electrical rooms:
118
119
Heaters shall be connected to a suitable terminal box with main switch and
indicating lamp. They shall be placed in an accessible position. All equipment.
whether fitted with a heater or not. shall be provided with suitable drainage and be
free from pockets in which moisture can collect.
0.6.17.9
for
e.g.
Steel-clad cubicles and enclosures with fixed, integral switchgear and apparatus
must be provided.
The switchgear cubicles must be partitioned off and incorporate a bus bar system,
the necessary instruments, control switches, switch panels of the individual switch
and apparatus chambers. The main bus bars are to be installed on the rear face,
topside of the switchgear cubicle in a lockable shuttered compartment.
Connections to switching devices, MCB's fuses etc. are to be made from these bus
bars. The lower part of the cubicle will house the terminal 'strips and connecting
blocks, the clamps for the cable terminals and if required parallel connection
copper straps for the connection of more than 2 cables in parallel. An adequate
number of ball studs must be provided within the switchgear cubicle suitable for
earthing the main and distribution bus bars as well as the switchgear itself by
means of portable earthing and short circuiting equipment (to be provided once per
switchgear panel row).
The space in the interior of the cubicles must be divided into a section with 'live'
parts, 'live' switching elements etc. and a section with control and measuring
equipment. The sections arc to be separated by reinforced sheet- steel.
.
Care must be taken that in the event of arcing hot gases will not escape to the front
of the cubicles (the operational side).
Ammeters are to be provided on the cubicle front panel for the cubicle feeders and
the supply outlets for motors higher than 55 kW or motors of lower rating, but
particularly important for the process. A single voltmeter with 4-position voltmeter
changeover switch must be provided for measurements of bus bar voltage
between each phase and neutral. Measuring instruments should, in general, be
square in shape.
All cubicles, cabinets, panels, etc. shall be designed for an ambient temperature of
40C (outside the enclosure) in non-air conditioned areas. Special precautions
shall be taken in the design of electronic devices for protection and control systems
housed in the cubicle in order to allow for these conditions.
Heating elements are to be provided generally in each local cubicle or cabinet and
shall be humidity controlled.
It must be possible to disconnect power supplies to the cabinets by means of
manually operated power circuit-breakers (MCB's).
For easy monitoring and a rapid grasp of the operational state, colored mimic
diagrams with the required switch position indicators, apparatus symbols and pilot
lamps must be provided in every case on main process cubicles and switchgear
cubicles. Lamp test facilities for all signed lamps connected shall be provided. All
cubicles shall be provided with the required earthing screws.
120
0.6.17.10
121
In hazardous areas, the necessary explosion proof control cabinets and level
control equipment must be provided in accordance with IEC 79 and VDE
0165/170/171.
Local control points
The local control points are to be equipped as the minimum requirement with:
ON button
OFF button
Running lamp
FAULT LAMP
TRIP HEALTHY indication
Lamp test.
When two motors are installed, serving as operation and stand-by lIlIil, then in
addition to a double set of the above items, the following equipment has to he
installed as the minimum requiem:
MOTOR 1 - MOTOR 2 (running motor/stand-by motor)prc-selection
switch,
automatic transfer to the stand-by motor in case of failure of the running
motor.
Level controls
In the case of pump motors controlled by levels, in addition to thc level control
in each case the MANUAL - AUTOMATIC selector switch and the necessary
local points are to be fitted. Control of individual pump motors must be effected
as follows as the minimum requirement:
MANUAL - AUTOMATIC selector switch
level control with maximum and minimum contacts
low level contact on motor OFF
bottom maximum contact on motor - ON
top maximum contact as warning to the central control room
low-low level contact as pump dry-running protection and alarm signal
to the central control room
local control point with ON and .OFF button, .running and fault lamp.
When two pump motors are installed for the same purpose the control is to
be effected as follows, as a minimum requirement:
MANUAL - AUTOMATIC selector switch
PUMP 1 - PUMP 2 (running pump / stand-by pump) pre-selection switch.
level control with three high level contacts:
first (I): high level contact for pre-selected ON
second (2): high level contact for alann signal to the central control room
low level contacts for pumps OFF
low-low level contacts as pump dry-running protection and alarm signal to the
central control room .
local control and lamps as listed above for local control cabinets, for each
motor.
122
123
All explosion proof equipment shall be of approved 'design and must have
undergone type tests according to the appropriate standards. The selection of
such equipment with reference to design features and allocation to hazardous
groups shall be subject to approval by the Owner/Owner's Representative.
0.6.17.13
124
for locking in the neutral position. A similar lock shall be provided for each
selector switch for Locking the switch in any of its positions.
Approved means shall be provided for locking the cubicle doors, live terminal
shutters, etc.
The locks or padlocks shall be coordinated for the different applications and
shall be supplied with three keys. A key cabinet at the end of each board shall
be provided for storing the keys of that board. All eyes shall have six master
keys to open any lock or padlock/supplied.
Each key shall have one identification label fixed above the key hanging
hook inside the cabinet.
The cabinet door keys shall be similar and shall be six in number.
0.6.17.14
Electric motors
General
All motors shall be of approved manufacture and shall comply with the
requirements of this Contract. They shall be complete with terminal boxes,
cable glands and, where specified, with heaters and monitoring instruments.
Motors of the same type must be fully interchangeable and shall comply as far
as applicable with IEC motor standard dimensions. All AC motors shall be of
the squirrel cage type provided with either deep slots or double squirrel cages.
All motors shall preferably be from the same manufacturer. The general
construction shall be stiff and rigid, no light metal alloy casings will be accepted
for motors above the size of 10 kW. All precautions shall be taken to avoid any
type of corrosion.
All motors shall be fitted with approved types of lifting hooks or eye bolts as
suitable.
Rating
The service voltages of the motors shall be as follows:
6600 V, AC 3-phase, 50 cps, for motors above 150 kW
400V, AC 3-phase, 50 cps, for motors up to and including 150 kW
220/110 V DC for all motors intended to work on the DC system.
The rating of each motor shall be adequate to meet the requirements of its
associated plant. The service factor, being the ratio of the installed motor
output to the required power at the shaft of the driven machine at its
expected maximum power demand, shall be applied as follows:
Power demand
Up to 1 kW
More than 1 kW up to 10 kW
More than 10 kW up to 50 kW
More than 50 kW
Service factor
1.3
1.2
1.15
1.1
125
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
Climatic protection provisions for mounting in the open in n humid and hot
climate. Insulation class F. During operation at rated power of the driven
machine, the motor insulation must only be stressed in accordance with the
requirements of class B insulation.
Motor parts made of iron internally and externally sandblasted and surfaceprotected.
Paint finish resistant to chemicals and seawater.
Bolts dichromate.
All joint faces and gaps sealed.
Anti-condensation heating to be switched into operation when the motor feed
circuit is in the off position. Heater supply power 'on' indicting -lamps is to
be provided.
Special treatment of windings with resin impregnation plus immersion in
varnish.
Varnish-insulated laminations.
Pressboard material protected by varnishing.
Selection of special grade of sealing which are resistant to seawater.
Totally enclosed fan cooled type. For motor ratings the cooling air available
at the specific location has to be considered.
Condensation outlets to be provided at the lowest point in the housing.
Design and construction of the 1110tors shall comply with IEC 34-1, 34-5 or VDE
0530 and DIN 40050.
Electric features
The following electric features shall apply:
a)
b)
c)
d)
e)
f)
g)
126
h)
Protective features
The following protective\'e features shall apply:
i)
High voltage motors must be fitted with measuring points for the
determination of slot and bearing temperatures.
Six Pt 100 resistance thermometers (2 per phase, one each utilized for overtemperature warning, the other for over temperature trip) are to be provided
for slot temperature measurement, and a double thermocouple or resistance
thermometer per bearing must be provided for bearing temperature
measurement.
Each Pt 100 shall be connected, potential free, to a terminal strip. The
connections to the thermometer as well as the associated over-voltage
cutouts shall be brought into separate terminal boxes.
j)
k)
l)
m)
Other features
Terminal boxes
The main terminal boxes on the high voltage side shall be provided with a pressure
relief joint for the purpose of reducing the danger of an accident as a result of
short-circuits, and shall be fitted with a terminal block suitable for any desired type
of connection .
A permanently attached connection diagram shall be mounted inside the terminal
box cover. If motors are suitable for only one direction of rotation this shall be
clearly indicated.
Terminal boxes shall be totally enclosed and designed, to prevent the ingress of
moisture and dust (minimum IP 55). All joints shall be flanged with gaskets of
neoprene or similar material. The terminal box shall be scaled from the internal air
circuit of the motor.
Cable connecting boxes must be longitudinally divided to facilitate filling of cable
sleeves and end caps.
127
In case lightning arresters for vacuum type switchgear controlled motors are to be
foreseen, they shall be incorporated in the terminal box or in a separate box.
Inside the terminal box an earthing clamp for connection of the cable shield must
be foreseen.
The opened terminal boxes must have provision for local earthing to be carried out.
Bearings
Motors smaller than 2000 kW shall preferably be provided with a constant level
gravity-fed type oil lubrication system with reservoir and oil breather.
Motors with roller bearings must be provided with a lubricator and lubricant supply
regulator fitted with solid brass cages that can be refilled while the machine is
running.
The bearings of the motors. must be free from stray bearing currents.
Where sleeve bearings are being used they shall be of the self forced lubricating
type. If forced lubrication is required it shall be arranged common to both -the
motor and the driven machine and provisions shall be made to ensure lubrication
during start-up and shut-down operations without the necessity to start an auxiliary
lube oil pump. Self-lubricated bearings shall be equipped with an easily accessible
lubrication pot with overflow pipe and oil collecting vessel.
All bearings shall be easily controllable during operation or standstill without
dismantling the bearings. The bearings shall further be protected and sealed
against dust penetration and oil leakage.
Connections, star-point terminal boxes, etc.
All motors must have the star-point connection brought out separately to terminals.
For all motors with a rating of 2000 kW or above a differential relay for winding
protection shall be provided and installed in the associated switchgear. In that case
the star-point connection shall be brought out separately to terminals.
The differential current transformers are to be designed to class 5P1 0 with a rating
matched to the protection system. The CTs shall be accommodated in the starpoint terminal box.
Coupling
The motor shaft halves of the couplings, finish-bored, balanced. and complete with
keyways are to be drawn on to the motor shaft and balanced out together with the
rotor. A coupling guard will be provided.
Running quality
The running quality must be within the classification of "good" according to the
VDE recommendations (VDl 2056 group D), i.e. the vibration velocity must be less
than or equal to 1.8 mm/s (rms.).
128
Cooling
Air cooling for the motors is the preferred method; where water-cooling is applied,
conditioned, treated water is to be used.
Motor air exchanger-circuits should be suitable for the prevailing atmospheric
conditions, i.e. ambient temperature,' content of humidity and salt in the air, etc.
are to be considered.
Where motors are installed outdoors, a weatherproof design shall be chosen. At
least one drilled hole shall be provided at the lowest point of the casing for draining
condensed moisture. All MV motors and LV motors of IEC size 132 and above
shall be equipped with automatically controlled heating elements for protection
against internal condensation of moisture during standstill periods.
Heaters of small motors shall be controlled by thermostats those of big motors by a
normally closed contact of the motor starter.
Motors shall have a closed internal cooling air circuit recooled by an external
cooling air circuit drawn, from the opposite side of the driving end. MV motors
installed in the turbine hall shrill be recooled by water taken. from the service water
s)'stem. The air/water coolers shall he arranged in such a way as to give free
access for cleaning purposes without dismantling them or the associated C.W.
pipes.
Motors installed outdoors and directly subjected to sun radiation shall be rated
such as not to overstep the maximum metal temperature of 85C. Where
necessary such motors shall be provided with fabricated steel sun coverings.
Approved means shall be provided to protect motors installed vertically against
ingress of dirt, etc.
Reverse speed
If reverse running can occur in the case of equipment driven by a motor (e.g.
cooling water pump), the motor must be designed for maximum possible
reverse speed.
A reverse rotation alarm and starting-circuit interlock are to be provided to
ensure that the equipment can not be started while running in reverse.
The same features as for high voltage motors shall apply. Anti-condensing
heating shall be provided for motors of 55 kW and above.
Electric features
Shafts
Where not otherwise specified, motors must be filled with a free shaft end
0.6.17.14.3 Actuator drives
All actuators for valves, dampers etc are to be fitted with socket and plug of wellestablished make to IEC 309, VDE 0620, CEE 17 or equivalent for the power cable
connection. For the control cable connection separate socket and plug shall be
provided.
Self-cooling at respective ambient temp. Conditions is mandatory. Fan cooling is
not accepted
130
0.6.17.14.4 DC motors
As far as possible the use of DC motors is to be avoided and must be agreed by
the Engineer. The max. starting current must not exceed two times of the rated
motor current (referred to the motor rating at 40C ambient temperature).
DC motors shall be capable of operating continuously under rated output
conditions at any voltage between 90% and 110% of the nominal voltage. Unless
otherwise approved the speed drop between no-load and full-load shall not exceed
10% of no-load speed. All DC motors shall operate with a fixed brush setting for all
toads.
Brush gear for DC motors shall be designed to ensure constant brush pressure.
Carbon brushes shall be provided which stand at least six months of operation
without replacement. Each brush shall be independently adjustable but shall not
require adjustment" throughout its life.
The brush holder shall not touch the commutator as the brushes wear and current
carrying through the pressure fingers will not be accepted.
A sufficient number of brushes, not less than two per pole, shall be fitted to ensure
that vibrations do not effect the commutation.
The minimum safe wearing depth of commutators shall not be less than 6 mm and
the minimum safe diameter shall be marked on them.
0.6.17.14.5 Painting
All motors, whether for outdoor or indoor installation, shall receive a coating of
paint which is resistant to sea water and corrosion.
All internal and external steel parts of the motors must be sand-blasted and
impregnated. Following this, a paint finish resistant to chemicals and seawater
must be applied. The' bolts used must be chromated at least.
0.6.17.14.6 Protection against explosion hazards
Low-voltage motors, which arc to be installed in areas exposed to the risk of
explosion, must comply with the rules laid down in VDE 0165/0170/0171 for
explosion-proof design in relation to the flash-point group classification for the
particular explosive mixture.
131
Technical requirements
The design of the converter (maximum continuous rating) is to be based on the
maximum shaft output required by the equipment assembly.
The converter should operate in two-quadrant mode.
Indirect converters with a constant indirect voltage are to be preferred to types
with a constant indirect current. Power should be supplied to the converter
cubicles from below. If possible, the DC link reactors should be integrated in
the converter cubicles.
Maintenance work and cable connections must always be possible from the
front of the converter cubicles.
The terminals on the input and output sides are to be rated. such that parallel
cables can be connected.
The converter allows the speed of three-phase asynchronous motors to be
adjusted steplessly. It must be fully equipped for remote control and monitoring
in the control room.
An on-load disconnector and a power contactor are to be provided at the power
input of the converter.
For motors with a rating lip to 400 kW the frequency converter shall be
designed in at least a six-pulse circuit on both the line and motor sides.
For motors with a rating above 400 kW the converter should be designed in a
12 pulse circuit supplied via converter transformer.
In the case of a current converter, the line rectifier is to take the form of a
line-commutated, fully controllable three-phase bridge. A self commutated,
fully controllable three-phase bridge is to be provided for the inverter on the
load side.
In the case of a voltage converter, the line rectifier is to take the form of a
fully controllable three-phase bridge. A self com mutated three-phase bridge
with turn-off thyristor branches is to be provided for the inverter on the load
side.
The line rectifiers are to be designed for a braking current which is at least
85% of the motor rated current.
The converter is to be disconnected if the voltage drops to less than 80% of
the rated voltage or if one or more phases of the line voltages are missed.
When the line voltage is restored, the converter is to be connected again
automatically, providing the break in the power supply did not last longer
than five seconds. The plant check back signals (floating change-over
contacts) must continue to be received during this period, while alarms are
to be suppressed. It must be possible for the converter to be connected at
.any coasting-down drive speed and with in-phase voltages. The specified
frequency set point is to be resumed automatically.
If the voltage reduction or the power failure lasts for a long time, the drive must
132
133
.winding after shut-off periods. The protection against voltage surges and short
circuits, the noise levels and the freedom from partial discharges up to twice
the rated voltage will be verified by means of type tests.
The windings are to be protected by means of a temperature monitoring
system, comprising the following minimum components:
3 PTC resistors (1 for each phase)
1 tripping unit with isolated change-over contacts for remote signaling
(alarms).
The equipment types are to be agreed with the client in the event of an order
being placed.
All the lines belonging to the protection and monitoring systems are to be
applied to a transfer terminal strip as individual signal lines.
Instrumentation and control
The instrumentation is subdivided into a local section in the converter cubicle
and into a "remote" section in the control room. All the measures necessary to
enable the drive to be remote-controlled and remote-monitored must be
implemented, i.e. all the 24 V DC interposing relays which are required to
convert the on/off commands from the instrumentation and control system,
signal transducers, etc.
A suitable automatic compensation facility is to be provided, to ensure that
the transfer between LOCAL mode and REMOTE mode is bump less in
both directions. The emergency shutdown function of the equipment must
act on the converter directly, regardless of whether 'local' or 'remote' mode
is set.
Local instrumentation and control.
The following are to be provided as a minimum in the converter cubicle:
Controls
a) local/remote converter control (key-operated switch)
b) "on" and "off' converter controls
c) set point adjuster (speed)
d) incoming master switch, "on-off'
e) all the controls necessary for internal converter settings and adjustments,
as specified by the manufacturer
Indications, signals, monitoring
a) line voltage indicator
b) output frequency
c) output current
d) operating status signals, in accordance with the specifications of the
instrumentation and control supplier, though at least "Ready", "Drive
running and Zero and set speed reached
e) motor temperature monitor - alarm Motor temperature monitor - shutdown
f) signals concerning internal operating states of the converter, in accor-
134
a)
b)
c)
d)
e)
f)
All event signals and check back signals must be made available on the
terminal strip as floating change-over contacts
System perturbation
The perturbation caused by the voltage harmonics in the feeding three-phase
system, which are a result of the converter drives, must not exceed (he \
specified limit values, i.e. 5% for the 5th harmonic voltage, 4% for the 7th and
2% for each of the 11th and 13th. IEC 801.1 - 801.4 are also to be observed
in this connection. The system perturbations are to be curbed by means of
suitable measures if necessary. The contractor is responsible for
demonstrating conformance with the above-mentioned limit values.
135
0.6.17.14.9 Tests
Each motor shall be factory tested and shall undergo a test at site. The
following tests shall be performed under full responsibility of the Contractor:
Workshop tests
(*)
Tests at site
measurement of insulation resistance
measurement of motor vibrations.
At motors rated 100 kW or higher in addition:
measurement of starting period.
0.6.17.15 Labels
General
The proposed material of the labels, the size, the exact label inscriptions as well as
proposals for the arrangement of the labels shall be submitted to the Engineer for
approval. Where applicable, Bengali designations shall appear above or to the
136
right of the English designation. The Bengali translations and writings shall ,be
readable Bengali and samples shall be submitted beforehand for approval.
Equipment labels and instruction plates
Labels written in English shall be provided for all instruments, relays, control
switches, push buttons, indication lights, breakers, etc. In case of instruments,
instrument switches and control switches, where the function is indicated on the
dial plate or the switch escutcheon plate, no label is required. The label shall be
fixed close to the instrument in such a way that easy identification is possible.
Fixing on the dial glass of instruments will not be accepted. The wording shall
conform to the wording used in engineering documents and shall be submitted for
approval to the Owner/Engineer.
All construction units shall be identified by their plant identification number.
Cubicles and similar units shall also bear this identification number on the rear side
if rear access is maintained.
All equipment inside cubicles, panels, boxes etc., shall be properly labeled with
their item number. This number shall be the same as indicated in the pertaining
documents (wiring diagrams, equipment list, etc.).
Instruction plates showing in l3angali and English the sequence diagrams or
cautions for maintenance shall be fitted on the inside of the front door of the
electrical switchgear.
Each separate construction unit (cubicle, panel desk, box, etc.) shall be provided
with top mounted labels made of anodized aluminum with black inscriptions giving
the overall designation in Bengali and in English.
Warning labels
Warning labels shall be made of synthetic resin with letters engraved in Bengali
and English.
For indoor circuit breakers, starters, etc., transparent plastic material with suitably
contrasting colors and engraved lettering shall be provided.
L V switchgear shall have yellow labels with 5 cm black letters reading "MAINS
400 VOLTS" .
MV switchgear and transformers shall have red labels with 7.5 cm white fetters
reading "DANGER 400 V or 6600 VOLTS".
All switch room door labels (lettering as before) shall be as follows:
DC battery supplies
137
0.6.18
0.6.18.1
Measuring units
All instruments shall be calibrated and inscribed in the metric system. No
other measuring units than the following ones shall be used for the
measured variables.
for pressures of steam, water, oil, compressed air and high pressure gas
for combustion air, flue gas and low
pressure gas
for temperatures
bar
mbar
mm or m
-1
for levels
S cm
for conductivity
rpm
for positions
3
Nm /h
t/h
% Vol.
m or mm/sec
mm
cps
for frequency
138
0.6.18.2
A,kA
for currents
V,kV
for voltage
MW, kW
MVAr, kVAr
Wh, kWh
V Arh, kVArh
144 x 72 mm or
72 x 72 mm
96 x 48 mm or
96 x 96 mm
48 x48 mm
72 x 72 mm or 144 x 72 mm or
144 x 144 mm or
96 x 48 mm (when incorporated in
mimic diagrams)
- Recorders:
The control switches, adjusters, etc., on the panels and desks shall harmonize with the above mentioned indicator sizes.
0.6.18.3
plant before they reach a critical operating condition or shall start certain
units (e.g. stand-by) in order to avoid a critical operating condition. In
addition, such dangerous conditions must be immediately indicated to the
operating personnel by means of an alarm.
Passive interlocks are intended to prevent operational errors or wrong
commands from being carried out in the event of selective faults in the
automatic control.
Active and passive interlocks must not be capable of being switched off
operationally from the central control room. All protections have to work fully
automatically and independent of the operator and always have to be
effective for all procedures (manual, partial automatic, fully automatic).
After a stop or close action by protection, the restart of the equipment shall
be possible only after the fault is rectified and the protection signal is reset.
Simple cancellation of protection signal by start command shall not be
possible. The protection action and the operator reset shall be recorded by
the DCS.
0.6.18.4
0.6.18.5
Tests
The single components and pre-erected assemblies shall undergo
functional and routine tests in the Contractor's or Sub-Contractor's
workshop. The ready mounted control and supervisory system shall
undergo functional tests on site prior to pulling the plant under steam.
These tests shall take place in the presence of the. Owner's and Engineer's
140
Field equipment
141
into enclosed racks or panels for easy access. Sunshades shall be provided for all
outdoor panels
Individually installed transmitters shall have their own weather proof enclosure of
robust construction "nu be suitable for the proposed environment. All field
equipment terminals shall be wired to a terminal box using screwed connections.
Transmitters shall be provided with all necessary isolating, vent and blow down
valves and facilities shall be provided for the connection of test instruments at the
input and output of each transmitter, to enable calibration to be carried out.
All control, measuring and supervisory equipment (including actuators) related to
the explosion-prone areas shall be of explosion proof, e.g. intrinsically safe design.
0.6.18.6.2 Flow measurements
The primary elements of flow meters shall be standard orifices and standard
nozzles unless otherwise specified.
Their design and performance shall be in accordance with the before mentioned
Standards.
The throats of flow metering nozzles and orifices shall properly be protected
against erosion by means of stellite lining or equivalent means. In case of Reynold
numbers below 100,000 quadrant nozzles or double tapered orifices shall be
provided.
Primary elements such as orifices or nozzles located in steam or high pressure
feed water pipes shall be of the weld-in type. Material, dimensions and installation
of orifices, nozzles and tapping points etc. shall be in accordance with the
specification for the pipes in which they are installed.
Isolating valves shall be provided at the tapping points of the orifices/ nozzles. In
the case of steam flow measurements condensing vessels (steam traps) shall be
provided between the tapping point and the isolating valve.
In case of flow measurements for fluids with pressures higher than 25 bar double
shut-off tapping valves shall be installed. The design and arrangement of tapping
point, piping and valves should be according to VDI/VDE rules 3512 Bl.1 or
equivalent standards.
The material and dimensions of the piping shall conform to those laid down for the
piping concerned. The welds shall be executed in such a manner as to avoid
turbulence them can affect measurement.
In order to achieve exact installation, the vendor supplying the orifice plate or
nozzle for high pressure pipes shall install the orifice plate or nozzle in its own
works in a section of pipe of about 3.5 times the pipe diameter (1.0 x Nil in the
outlet, 2.5 x Nil in the inlet). For orifice plates or nozzles installed in pipes with a
nominal bore smaller than 80 mm, complete meter runs shall be supplied.
Orifice plates and nozzles shall be manufactured of ANSI 316 Stainless Steel
unless specified otherwise.
Orifice plates shall be sized for a d/D ratio not less than 0.20 and not greater than
142
0.70. Higher other than lower d/D ratio are preferred to minimi7.c line restrictions.
All sizing calculations shall be submitted to the Engineer for approval.
Tags on orifice plates shall be stamped with the basic design information (i.e. flow
rate, pressure and temperature of the passing fluid, the orifice diameter and the
pressure differential generated).
Venturi tubes shall only be considered when operating economy requires low
permanent pressure losses.
Rectangular venturi tubes may be considered where other measuring devices
are impossible or impractical (e.g. in large rectangular air duct of boilers).
For flow measurements in LP-systems e.g. water or condensate, orifice plate
installation using slip-on orifice flanges shall be provided. All ori1icc plates for
installation between flanges shall have their own tapings for differential
pressure measurements incorporated in the plate. simple orifice plates with the
tapings situated in the pipe arc not allowed. The flow direction shall be
consistently marked on the orifice or nozzle by means of an arrow.
Steam, gas and air flow measurements at measuring points with variable
temperature and/or pressure should be provided with automatic correction of
flow signal.
All flow transmitters shall begin to measure correctly at a rate of flow of at least
5% of the measuring range. The error limit shall be limited to I % f~ a rate of
flow higher than 10%. The error of the primary elements is not included in this
accuracy.
The root extraction of flow measurements shall be effected electrically within
the transmitters.
All flow transmitters shall be in accordance with Chapter B06.18.6.1
Special conditions may dictate the use of devices such as:
For the measurement of fuel oil flow, turbine type meters or positive
displacement meters shall be used.
Magnetic and ultrasonic flow meters may be used under special circumstances
but prior to their" use agreement must be obtained from the Engineer.
Arrangement of flow measurements
The arrangement of the throttling devices, e.g. the straight length upstream and
downstream from the throttling device shall be according to Standard DIN EN
ISO 5167-1. Bends shall be at a sufficient distance upstream from the throttling
device, particularly when large orifice ratios are used.
When the requirements of the Standards cannot be fully complied within some
cases, then, as an exception, an uninterrupted pipe run of at least lOx Diameter
143
for temperatures up to
for temperatures up to
for temperatures higher than
700C
950C
950C
144
The use of dial type contact thermometers shall be restricted to bearing metal
only. In all other cases thermocouples or resistance thermometers and
electronic limit switches shall be used. Glass thermometers or similar will not
be accepted as contact thermometers.
Insofar as local conditions or extreme temperature do not require otherwise.
Screw-in immersion wells for exhaust gas and air shall meet the following
requirements:
145
146
147
influence of temperature
148
0.6.18.6.6
linearity:
Level measurements
The remote measurements for the liquid level in the boiler drums and banks
with a steam cushion of pressure above atmosphere shall be of the hydrostatic principle by means of a differential pressure transmitter.
For liquid measurements in condensers and tanks with a steam cushion of
pressure below atmosphere level transmitters of displacement type or of
differential pressure type with isolating membranes shall be used. The
membranes shall be installed close to the condenser or tank.
Where detection of discrete levels is required, the simple float operated switch
should be used, however each switch shall have snap action with limited
hysteresis to prevent contact bounce caused by small fluctuations in level.
Switches used for level detection shall provide facilities for testing the
mechanical and electrical operation of the switch without its removal from the
process. Isolation by means or shut-off valve will be allowable during testing.
POI' measurement of large storage tanks, the load indication and transmitting
mechanism shall be located at the base of the tank.
The transmitters shall be as specified under Chapter B0.6.18.6.1.
For special applications such as chemical tanks, techniques such as ultrasonic, capacitance probes, etc. should be considered.
For measurements where a reference leg of process fluid is used. the design
of the system shall ensure that the reference leg is fully maintained at its
prescribed height during all conditions of process level change and changes in
process conditions and the density of the reference leg docs not vary from that
of the process fluid due to. temperature changes or other reasons.
All measurement transmitters for differential pressure shall be provided with:
shut-off valves to be arranged directly at the condensing vessels and
active pressure tapping points
b) valve blocks enabling the transmitter to be isolated from the active
pressure and enabling the transmitter zero point to be checked
c) separate blow-off valves for cleaning the active pressure tubes.
a)
149
type equipped with electric illumination, working in such a way that the water
level is clearly readable as a column over the complete measuring range.
Level indicators showing the level only as a point will not be accepted.
The indicating range of local level indicators shall cover all switching points of
level switches mounted on the tank or similar as a minimum requirement.
On all forms of measurement all parts of the switch, transmitter, etc. in contact
with the process fluid shall be made of material compatible with the process
fluid, Stainless steel shall normally be used for all corrosive duties
0.6.18.6.7
Electrical measurements.
150
name of manufacturer
manufacturer's type reference
serial number
rate input voltage and current, as appropriate
DC output current
overall ratio (e.g. Watts/mA).
The type of transducers selected shall be suitable for use in digital instrumentation schemes and the outputs of all transducers shall have a linear
relationship with the measured quantity. Transducers shall be self-powered,
where possible, or powered from the RTU battery power supply.
Each current input shall be capable of carrying 200% rated current continuously
and shall withstand 10 times rated current for 5 seconds without damage. The
output shall be accurate up to 120% rated output. In addition, transducer inputs
shall withstand 30 times rated input current on each range for 3 seconds without
damage.
Transducers shall withstand for one hour, without damage, a short circuit on the
output terminals when the input circuits arc carrying rated voltage and current.
The error in transducer output shall be not more than 0.5% of full rated output
over as great a part of the output range as possible. For all inputs, the output
error shall not exceed 0.2% due to 10% voltage variation in the
151
voltage circuit input nor exceed 0.5% due to a 10% change in the input
frequency.
The root-mean square ripple current shall not exceed 5% of the maximum signal
current and shall preferably be much less.
The response time to reach and remain above 80% of the final steady value for a
step change in input from zero to a value equal to full rated output shall not
exceed 1 second.
Adjusters shall be provided to allow adjustment of the output current to be made
to compensate for errors of primary circuit transformers. Adjustment may be
continuous or in fixed steps. A range of 2% adjustment in the output current
shall be provided.
Power transducers
For the measurement of three-phase balanced power flows; Watt/Var
transducers designed for reversible real and reactive power flows, except where
specified otherwise, shall be used which have DC current outputs proportional to
the AC real and reactive inputs. The lineary shall be 0.25%.
The transducer output shall be 0 to 10 mA for single direction power flow, and 10 to 0 to + 10 mA for reversible flow, respectively~ representing 0 to 1.2 amps
input current at nominal rated input voltage. The polarity of transducers for
measurement of both forward and reverse power flow shall be such that power
flow into the busbar is positive.
The burden imposed on the primary circuit current and voltage transformers at
full rated input shall not exceed 2 VA and 12 VA respectively.
The additional burden imposed on the primary circuit current transformer at full
rated input when the dc output is open circuited shall not exceed 2 VA, and the
transducer's steady output voltage shall not exceed 25 volts.
Voltage transducers
Voltage transducers shall have a DC output current proportional to the AC input
voltage. The rated input voltage shall be 110 volts AC and the transducer output
shall be 0 to 10 mA representing 0% to 120% of rated input voltage.
The phase angle voltage transducer shall have an inverted linear output of 10 to
0 mA representing an input range of 0 to 240% of rated input voltage.
The burden imposed on the primary circuit voltage transformer at nominal input
shall not exceed 5 VA.
Current transducers
Current transducers shall have a DC output current proportional to the AC input
current. The transducer output shall be 0 to 10 mA representing 0 to 1.2 amps
input current.
The nominal input current rating shall be 1 amp. The effective range of the
152
transducer shall be 0 to 120% of the rated input current and the accuracy shall
be 0.5% at full rated output.
The burden imposed on the primary circuit current transformer at nominal
maximum input shall not exceed 2 VA.
Frequency transducers
Frequency transducers shall have a dc output current proportional to system
frequency. The transducer shall record with an accuracy of 0.25% over the
range 45.00 to 55.00 Hz. The nominal input voltage shall be 110 V and the
output range of 10 mA.
Summators
Where specified or indicated on drawings, a summator shall be provided to
summate the outputs of several transducers. The summa tor output sball be 0 to
10 mA for single direction flow, and -10 to 0 to + 10 mA for reversible flow. The
error of the summator output shall be not more than 0.5% of full rated output
over as great a part of the output range as possible.
Transformer tap changer position indicators
Transformer tap changer position transducer shall have a DC output of current
proportional to the tap position.
The transducer shall have an output range of 0-10 mA representing tap position
1 to maximum tap position. Tap 1 should be at 1 mA and maximum tap at 9 mA.
Due account shall be taken of tap change transfer taps positions which do not
affect voltage output.
0.6.18.6.8 Position measurements
For the continuous remote position indication of valves, dampers etc. also
transmitters with impressed output signal of 4-20 mA shall be employed.
Therefore, electronic position transmitters shall be used.
Position transmitters of the potentiometer type will net be accepted.
Binary position switches shall be of the proximity type.
0.6.18.6.9
Contact devices
Where binary signals cannot be derived from an analog value. binary transmitters
e.g. temperature switches, pressure switches etc. may be used. Indicators with
integrated limit switches are allowed within package units. Preferably limit
switches shall be of the proximity type.
All switches shall be of robust design and reliable performance. The switches
shall have an adjustable switching hysteresis.
The set point and the dead band (reset point) of each switch shall be adjustable
153
from inside the case, over the full range specified. The set point and reset point
shall be indicated 011 the adjusting mechanism.
The switches shall be housed in robust, dust and moisture proof cases having
glanded cable entries and shall be suitable for the ambient conditions local to the
equipment, on which they are mounted.
Contacts of level switches, pressure switches, temperature switches, limit
switches, and of all other pilots shall be of the snap-action type. The creeping
action type will not be acceptable.
Contact devices for interlocking systems shall be separate, i.e. contact devices
serving commonly for interlocking and other purposes will not he 'accepted.
0.6.18.6.10
Vibration measurements
Vibration shall be measured at large rotating or reciprocating machinery for
protection and predictive maintenance. Suitable indications shall be provided in
the Central Control Room for each measurement point and the measurement
shall be suitably alarmed where high vibration levels may cause possible
damage or affect the safety of the power plant.
The vibration monitoring system shall be reliable, accurate, easy to maintain, and
suitable for use in such ambient conditions appertaining to the intended plant
installation.
Where feasible, standardization and interchangeability of components shall be
implemented.
The following criteria shall be used as a guideline for rotating machinery, in order
to ascertain the monitoring points, principles of what signal shall be measured,
what is displayed, and what mechanical conditions entail alarm and/or trip status:
154
0.6.18.6.11
Control valves
0.6.18.6.11.1 General
General requirements for control valves are contained in Clause B06 and further
details are given below.
0.6.18.6.11.2 Valve sizing
Control valves shall be standardized wherever possible and shall be sized for
optimum control. The sizing calculations shall include CV, noise and cavitation
calculations.
Valves bodies shall in all cases match the piping pressure and temperature
rating specifications as a minimum and the operating point on the valve
characteristic, i.e. lift/throughput curve should be within the 60-70% operating
range.
0.6.18.6.11.3 Valve bodies
For normal service duties valve bodies shall be of carbon steel with and
connections flanged raised face, unless process conditions dictate or otherwise
specified. Flange type connections shall in all cases match the piping
specifications as a minimum but never Iess than a pressure rating equivalent to
ANSI Class 300 specification. (See ANSI B36. 10 for full details rating
schedules.)
For liquid services with high pressure drop cage-guided control valves shall be
provided having the plug supported at the critical area.
For severely erosive service the fluid impact area inside the valve body shall be
covered by welded stellite.
For high pressure superheated steam service the complete valve body shall be
of Cr 13 Mo 44 or equivalent.
0.6.18.6.11.4 Plug characteristics
A linear characteristic shall be provided when the pressure drop across the
control valve under all operating conditions is more than 2/3 of the pressure drop
across the valve in the closed position. Unless otherwise approved an equal
percentage characteristic shall he provided for all other cases.
0.6.18.6.11.5 Trim material and stem packing
Control valve trims shall be of stainless steel ANSI 316 or equivalent ns n
minimum where appropriate according to the service, fluid and conditions.
Hardened and/or stellite plug and seal rings shall be used for the following
applications:
erosive service
155
Multi-stage valves shall be used on services, e.g. steam and gas, having
very high pressure drops which would result in supersonic velocity inside a
conventional body and shock waves in the piping creating unacceptable
noise levels.
For liquids the exit trim velocity shall not exceed 30m/sec.
For flashing service the exit trim velocity shall not exceed 22.5 m/sec.
For gas and steam the velocity head in line shall be less than 70 psia.
Supplier shall provide calculations demonstrating meeting the above
velocity requirements.
The maximum allowable noise level shall be 85 dB A or less.
Angle valves shall be provided:
for steam pressure reducing desuperheating stations of the
"combination" type
for erosive service, e.g. slurries
on applications where solid contaminants might settle in the valve body
on hydrocarbon services with tendency for choking.
Ball valves shall be used for on-off and throttling services under moderate
operating conditions.
Where alternative specifications are considered more appropriate then
156
0.6.18.6.11.7 Installation
The installation shall include for upstream and downstream isolating valves and,
and for critical control valves, a bypass valve for each control valve on all
services. Unless otherwise agreed by the Engineer the bypass valve providing
tight shut-off shall have the same characteristics and construction as the control
main valve. Any exceptions or variations to this requirement shall be subject to
the approval of the Engineer. Where a service is subject to pressure above three
bar g a 25 mm vent valve shall be provided, between the upstream and
downstream isolating valves, in order to relieve the pressure to enable
maintenance to be carried out on the control valve. Control valves shall be
adequately supported in all cases and shall be accessible for maintenance. Local
pressure gauges shall be provided at the upstream and downstream of each
control valve.
0.6.18.6.12
Actuators
0.6.18.6.12.1 General
Unless otherwise specified actuators for modulating valves and dampers shall
either be pneumatic or electrically operated. Self contained scaled hydraulic units
may be considered where high thrusts or high speeds of operation are required
but each application shall be to the approval of the Engineer.
Actuators for ON/OFF duty or manually positioned units shall generally be
electrical motor driven, however the use of solenoid types on small valves shall
be allowed dependent on duty.
The various types and sizes of actuators shall be rationalized and as far as
possible each type shall be from a common manufacturer to facilitate
interchangeability and spares.
The operation of all actuators, control valves and driven units, shall be so
arranged as to ensure the safety of the "plant" under failure of control or
actuating supplies.
Unless specified otherwise, the failure of a control signal or actuator power
supply shall either:
a)
b)
With either action the failure mode shall be suitably monitored and the plant
operator informed by some form of alarm.
Where pneumatic actuators arc used, an internal bias spring shall be used to
obtain motive power 10 reach the safe position in the event supply failure
Where the type of actuator offered does not have the appropriate fail-safe
facilities described above then the valve/damper shall have a second
valve/damper in series or parallel as appropriate, designed to provide the correct
157
failure response.
When an actuator is locked or moves to a safe position on failure detection, it
shall not be allowed to return to automatic control without resetting action by the
operator after restoration of the supply/control signal.
The failure response of all actuators in .the event of the loss of the prime mover
(air pressure, oil pressure, electrical power) shall be indicated on the Piping and
Instrumentation (P&I) diagrams, valve Sc11cdules, etc.
All modulating and regulating actuators shall be filled with position measurement
for CCR indication of actuator position. This requirement applied irrespective of
the operating mechanism, whether electric, pneumatic or hydraulic.
All actuators which are controlled remotely from a panel or from the CCR shall
have independent control units and independent remote/local, auto/man
functions where specified or applicable. It is not permitted to gang several
actuators onto one signal output and independent positioning control shall be
provided for each actuator.
Where control requirements call for split range operation, the computing of the
split range shall be carried out externally from the actuator such that standard
signal inputs to the actuator are maintained.
All actuators shall include a mechanical device to show the true position of the
operating mechanism.
All actuators shall have a hand wheel for direct manual operation. The diameter
of the hand whelp and geared effort shall be such that they are reasonably
operable by one man. A lockable mechanical clutch mechanism shall be
provided to inhibit power control of the actuators when the hand wheel is
operated. The disengagement for hand control shall signal remotely to indicate
that the normal operation of the actuator is inhibited.
All actuators shall be provided with a local control facility. which in general will be
used for test purposes only. Such controls may take the following forms, as
appropriate or specified:
a)
Control initiations (i.e. raise, lower, etc.) with lockable local/remote selection
when appropriate either on the actuator, in the direct vicinity of the actuator
or on its associated switchgear.
b)
A portable test facility for injecting the appropriate position demand signal
either at the actuator or drive unit (switchgear or power amplifier).
Isolating actuators shall have short time ratings appropriate to duty cycle type S2
158
10 min. to IEC 34-1, and n maintenance free interval better than 10,000
open/close cycles.
Unless otherwise specified actuators with integral or separate switch units may
be offered. The contactors may be of the mechanical or static (thyristor) switch
type. If a static switch is offered then the switclll1nit and actuator shall be
supplied by the same manufacturer as a complete system.
The following features shall be provided for each actuator:
Switched actuators
Each actuator shall be driven by a duration modulated switched power
signal at the full AC supply voltage. Each shall feature either electromagnetic or mechanical braking. However, the latter will only be accepted
on low power single phase actuators and a brake life in excess of 107
operations shall be guaranteed by the Contractor. They shall not be used
when full travel times of less than 20 seconds are required.
159
160
Where "lock up" devices are provided on those services requiring the actuator to
remain in the position prevailing immediately before an operating medium failure,
the following two methods of "freezing" are acceptable:
a)
The pneumatic system may be locked, but equipment used for this
purpose shall always be installed between a positioner output and an
actuator input.
b)
All pneumatic control equipment, control drives rind control valves, shall be
capable of satisfactory operating on n main air supply pressure of approximately
7 bar g normal down to 5.5 bar g minimum.
On positioners where the output control air is of equal range to that of the input
signal air (e.g. 0.2 to 1.0 bar) they shall be furnished with integral pneumatic
"bypass switch" facilities for applying signal air direct to the actuator.
All positioners and electro pneumatic: converters shall be furnished with three
pressure gauges: air supply, signal input and control air output and an air filter
regulator set. All pneumatic tubing to drives and actuators shall, unless otherwise
agreed to by the Engineer, be in copper which shall be sheathed in PVC.
Where an electro pneumatic converter precedes or is integral with the positioner
then facilities are to be provided for the connections of portable test equipment
for the injection of electrical reference signals or pulses to allow the stroking of
the actuator for test purposes.
All on/off (open/close) actuation systems shall be provided with suitable tamper
proof adjustments for actuator stroking time, independent for the open and close
stroke.
All actuators which are in control loops shall be provided with robust precision
position measuring transmitters for CCR indication.
Solenoid valves for controlling the air to/from actuators shall be mounted on n
rigid mounting frame or plate independent from the actuator. It is not permitted to
mount the solenoid valve on' the actuator, unless agreed by the Engineer.
Solenoid valves shall not be merely supported from the air piping connections.
0.6.18.6.12.4 Solenoid valves
In lines with nominal diameters of up to DN 25, as well as for piloting pneumatic
actuators, suitable solenoid valves shall be used. Valves with power ratings up to
30 \V shall be controlled directly at 24 V DC from the I&C system. For powers
over 30 W, solenoid valves for a 120 or 230 V AC shall be employed. Solenoid
valves shall be fused individually. Electrical connections are made by means of
plug connectors with the mating connector forming part of the scope of supplies
0.6.18.6.12.5 Electro hydraulic actuators
Generally these actuators shall only be used where high thrusts are required
combined with fast operating times and the applications requirements cannot be
met by the standard range of actuators used on the remainder of the contract.
161
The units offered shall be or the self contained, fully sealed types which allow
removal of the complete unit to n clean room for any maintenance requirements.
Units accepting either 4 - 20 mA signals or pulsed input signals shall be
acceptable.
Failure of the internal hydraulic supply shall result in the actuator locking in its
last operating position or stroking to its fail safe position and a suitable alarm
being given to the operator.
0.6.18.6.13 Local instrumentation
All local instruments, necessary for local operation, maintenance and local
supervision have to be delivered.
The scope of supply shall comprise but shall not be limited to:
pressure indicator on the suction and discharge side of each pump and
compressor
pressure indicator at each heat exchanger inlet and outlet (except for sample
coolers)
temperature indicator at each heat exchanger inlet and outlet
pressure indicator upstream of each safety valve
temperature indicator at each bearing oil drain
pressure gauge at each tank or vessel if pressurized
differential pressure gauge at each important strainer or filler.
level indicator for each tank or basin
pressure gauge upstream and downstream of control valves .
pressure gauges at pneumatic actuators for air supply, signal input and control
air output.
All local instruments shall be as far as practicable be mounted free of vibration to
allow a good readability. Wherever required damping elements are to be used.
Local pressure and temperature gauge shall be installed on gauge boards either
grouped or individually depending upon site conditions.
All local indicating instruments and test connections shall be included in the
respective plant equipment as integrated parts. The scope of local indicating
instruments and best connections shall enable the local operator to properly
survey the equipment, and shall also allow to properly carry out all acceptance
and other tests. All Local instruments of main equipment (pumps, motors,
transformers) shall be readable from one side only, accessible for operation and
maintenance.
0.6.18.7
162
Junction boxes
In order to simplify local collection of cables and distribution of signals and to
centralize connections in the plant the junction boxes shall be filled on nil the
necessary
0.6.18.8
0.6.18.9
163
0.6.18.10
Control cubicles
PLC hardware and other associated control equipment shall be installed in suitable
control cubicles. Where ambient conditions are suitable, these cubicles shall be set up in
a protected area, near to the secondary system to be controlled. Should this not be
possible, the cubicles shall be set up in local switchgear rooms or in local control rooms.
The protection class shall be IP 54 as stipulated in IEC-529.
The required control elements and displays (annunciation anti status lights, analogue
displays, switches etc.) shall be so configured that as far as possible they can be viewed
from the associated secondary system. Should it be necessary to place the control and
monitoring elements in the field, these shall be installed in separate, robust housings
(protection c1nss IP 65).
In preference LED displays shall be used. Ease of access and operation of the equipment
shall be ensured.
Where appropriate, visual display unit (VDUs) shall be employed for field operation and
monitoring.
All cubicles shall be adequately ventilated in order that the heat generated by the
equipment mounted there shall remain within the specified limits, even in the case of high
ambient temperatures that may occur in the event of failure of the air-conditioning
system.
Locally installed cubicles shall be suitable for the location in which they are situated and
shall provide adequate protection against dust, moisture or mechanical damage for the
equipment mounted therein. Sunshades shall be provided for all cubicle located
outdoors.
164
Table of Contents
0
xxx
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
xxx
xxx
xxx
xxx
xxx
xxx
xxx
Inspection and Testing
0.7.1
General
0.7.1.1
Workshop manufacturing and pre-assembly
0.7.1.2
Works inspections
0.7.2
Testing during manufacturing
0.7.2.1
Material tests
0.7.2.2
Tests at site
0.7.2.2.1
General remarks
0.7.2.2.2
Hydraulic tests
0.7.2.2.3
Test runs and functional tests
0.7.2.2.4
0.7.2.3
0.7.2.3.1
0.7.2.3.2
0.7.2.3.3
0.7.2.4
0.7.2.5
0.7.2.6
0.7.3
0.7.3.1
0.7.3.2
0.7.3.3
0.7.4
0.7.5
0.8
Abbreviations
165
0.7
0.7.1
test program
test standards
type of inspection and tests
tests which are to be witnessed by third parties
quality control procedure.
Six (6) months prior to the proposed start of commissioning the Contractor shall
submit to the Owner/Owner's Representative:
commissioning test program
commissioning procedures
tests on completion.
Six (6) months prior to commissioning the Contractor shall submit to the
166
167
safety conditions
consideration of the applied standards and regulations
execution of workmanship
conformity with the present state of modern technology.
0.7.2
168
welded joints, stiffening rings, etc., shall be carried out by the Contractor in
compliance with the standards under which the relevant equipment will be
designed.
All castings and forging shall be subjected to X-ray and/or ultrasonic tests before
the start of machining procedures, in order to detect defects as early as possible
and to replace in time defective parts, thus avoiding undue delay in the
manufacture and delivery of plant components. After partial machining in the
Contractor's workshop, further tests may be performed. No repair welding
machining of castings and forgings of major components shall be carried out
without prior inspection and confirmation by the Owner/Owner's Representative. In
case of a rejection, written and certified notice must be given to the Owner/Owner's
Representative, indicating also measures undertaken by the Contractor in order to
cope with the requirements 'of the Contract.
Major steel forgings
Purchase specifications shall clearly state the quality and inspection requirements
and should include, but not be limited to:
a)
b)
c)
d)
e)
f)
g)
Each forging shall be suitably marked with an identification number which shall
transferred throughout all machining stages. The identification number shall be
indicated on all documents relating to the forging.
Repair welding will not be permitted on rotating parts and on other components the
proposal will be subject to approval by the Owner/Owner's Representative.
Rotor forgings
The profile of forgings at the stage of final ultrasonic Inspection should be such as
to minimize the regions where complete coverage is not possible.
Ultrasonic indications should be measured by the equivalent flat bottomed hole or
AVG (DGS) method.
The toughness of rim and core (where applicable) material shall be evaluated by
testing charpy V impact specimens over a range of temperatures and thus
determining the 50% fibrosity fracture appearance temperature.
Allowable indication size and material toughness are interdependent design related
criteria and the Contractor must be prepared, if requested by the Owner/Owner's
Representative's Representative, to justify his proposals by reference to fracture
169
mechanics calculations.
Bores, when provided, shall be magnetic particle inspected and a suitable
intrascope used for examination.
Major steel castings
Purchase specifications shall clearly state the quality and inspection requirements
and should include:
a)
b)
c)
d)
e)
f)
g)
b)
c)
d)
e)
170
171
Dimensions
172
Vacuum test
Vacuum test of pipe shall be carried out for each diameter once at beginning of
production. The vacuum to be applied shall be equivalent to the condition which
occurs during full vacuum. The corresponding derated vacuum for this test shall
be proved by the pipe manufacturer.
Failure of tests on completed pipes
In the event of a specimen not fulfilling the minimum requirements for strain
corrosion resistance, all pipes of that class and diameter which have been
manufactured shall be rejected and shall be rep]aced .entirely.
Any pipe or fitting which fails any of the quality control tests which are to be
carried out on each and every pipe or fitting shall be rejected. In the event of
any pipe failing any of the remaining tests outlined above that pipe shall be
rejected and the relevant test shall be carried out on a further ten pipes of that
class and diameter. If anyone of these ten pipes fails than the manufacture of
pipes of that class and diameter shall cease and the Owner/Owner's
Representative reserves the right to reject all the pipes of that class and
diameter
Thermal insulating materials
Materials shall be tested for bulk density, specific heat, compressive strength, fire
resistance under pressure, service temperature limit in accordance with VDI 2055
or equivalent standards.
0.7.2.2 Tests at site
0.7.2.2.1 General remarks.
The equipment to be supplied under the Contract shall be tested at Site during
erection and initial operation. These tests shall prove whether the equipment
meets the requirements of the Contract and the safety conditions, whether it has
been executed with satisfactory workmanship and whether the equipment is in
'conformity with the prevailing standards and regulations as well as with the
present state of modern technology.
Where manufacture or finishing is done at site, tests and inspections shall be
conducted as a replacement for an appropriate workshop test. The preliminary
check-out and test runs, the trial operation, the initial operation, the reliability test
run and the performance tests shall be carried out by the Contractor's personnel in
the presence of the Owner and the Owner/Owner's Representative.
Acceptance test readings shall be taken with calibrated instruments.
Waiving of any tests shall not release the Contractor of his responsibility to fully
meet the requirements of the Contract.
0.7.2.2.2 Hydraulic tests
Unless otherwise stated in the specifications or in the relevant standards and
codes, hydraulic tests at site shall generally be carried out on complete items of
plant, where applicable. This may, at the discretion of the Owner/Owner's
173
Representative and as far as applicable, include steam, water, air, gas and oil
carrying pipe work.
0.7.2.2.3 Test runs and functional tests
Test runs and functional tests shall be carried out on individl1al equipment where
practicable to prove the reliability and the correct functioning of the component and
its compliance with the stipulations of the Contract.
Rated operating conditions shall be simulated if possible otherwise appropriate
conversion factors shall be applied.
0.7.2.2.4 Visual inspection, checking of dimensions, test instruments
The Owner/Owner's Representative may from time to time make visual
examinations and may check the dimensions of plant equipment and the
conditions under which it is manufactured or erected at the Contractor's or SubContractor's premises to make sure that it complies with the relevant specifications
and drawings.;
Unless the calibration of test instruments and gauges is certified by recognized
statutory institutes, they shall be calibrated at the premises and in the presence~ of
the Owner/Owner's Representative or their authorized representatives. Test
calibration certificates shall be submitted for each test instrument.
0.7.2.3 Manufacturing tests
0.7.2.3.1 Welding
Welding procedures shall be qualified in accordance with the requirements of the
construction code/specification for the item of plant concerned and in the case of
critical plant items the tests shall be witnessed by an internationally recognized
inspection authority.
Welders shall be qualified in accordance with the requirements of the construction
code/specification for the item of plant concerned for all types/positions of welding
he may perform.
A system of positively identifying the work of each welder shall be maintained and
any welder whose work is the subject of multiple rejections shall be required to
undergo a requalification test. Any welder failing the retest may, at the discretion of
the Owner/Owners Representative's Representative be disqualified from further
welding on items under this contract.
Welded fabrications shall be stress relieved when specified by the applicable
standard or for dimensional stabilization prior to machining.
Copies of temperature charts referenced with load items shall be included in the
test certification supplied for the relevant items.
All welds shall be visually examined and shall be of smooth contour, free from
cracks, undercut and other significant defects. Wherever possible the interior of
tubes etc. shall be examined using a suitable optical device where necessary.
174
Fillet welds shall be checked for size using suitable gauges which shall be
available for use on request by the Owner/Owner's Representative's
Representative during an inspection visit.
Non-destructive examination of pressure and vacuum containment welds
Welds shall be non-destructively tested in accordance with the construction
standard applicable to the item of plant. In addition the requirements of the
following Table shall be observed. This table shall also apply in cases where the
standards used for design and construction of an item of plant does not specify the
quality requirements for welds. Fault limitations to be subject of agreement with the
Owner/Owner's Representative's Representative prior to fabrication.
175
Design
factor
(shell)
0.85
Wall
thickness
Inside
diam
(mm)
(10m)
nozzle
Remarks
Fillet
Only applicable to:
Atmospheric systems
(excluded systems, which
handle chemicals, toxics or
flammable media).
10
all
all
10%R
>40
all
100% R
10%M
10%M
40
100
10%R
> 100
100% R
IO%M
10%M
>40
all
100% R
100% M
100%M
30
all
10%R
10%M
10%M
all
> 30
all
100%R
100%M
100%M
all
all
all
100% R
100%U
100%M
all
all
100
100% R
100% M
100%M
> 100
100% R
100% U
100%M
100%U
> 0.85
100% M
176
Type of Steel
Design factor
(shell)
0.85
>0.85
Wall
thickness
(mm)
Inside diam
(mm)
Nozzle
Remarks
Fillet
15
all
30
all
10% R
> 30
all
10% R
10% D
10% D
100
10%R
> 100
100%R
10%D
10%D
all
100%R
100%D
100% D
30
> 30
Legend:R = Radiographic examination
U= Ultrasonic examination
M=Magnetic particle examination
O= Dye penetrant examination
Note:
1.
2.
3.
4.
Where 10% examinations are shown for pipe work under 100 mm diam bore this shall be the circumference of 10% of the welds by each welder selected at random
with a minimum of one per welder.
Where 10% examinations arc shown for vessels or large diameter pipe work this shall be 10% of each weld length and must include all intersections of longitudinal
and circumferential welds.
Where partial exam' at ions reveal rejectable defects, adjacent welds or areas of weld shall be examined. In the event of rejectable defects being found welds shall be
subject to 100% examination.
Welds in clad materials shall be tested in accordance with the requirements of
the base material and the surface of the overlaid welds shall be dye penetrant
tested throughout the length.
177
Weld repairs
Unacceptable defects observed by visual examination or indented by nondestructive testing shall be completely removed by chipping or thermal
gouging and grinding. The resulting excavation shall be crack detected prior
to rewelding.
Details of the original defects and repair shall be recorded.
Repaired welds shall be subjected as a minimum requirement to the same
inspection requirements as the original welds and test records should
indicate that a repaired weld is referred to.
0.7.2.3.2 Pressure testing
All items subjected in service to internal pressure or vacuum shall unless
otherwise agreed be pressure tested in the manufacturer's works and prior
to any internal or external coating.
Hydrostatic testing
All pressure vessels inserts or other parts of such vessels which are subject
to an internal pressure or vacuum during operation shall undergo a
hydraulic or other approved test. Unless otherwise stated in the
specification the test pressure shall be maintained for a sufficient period to
permit complete examination by the inspector.
Should it be necessary to carry out repair welding on stress-relieved equipment, it must undergo a stress-relieving process again. In all such cases the
hydraulic test must be repeated.
Particular attention must be paid to the temperature of water used for hydraulic
testing which shall not be less than 20C. Prior to testing, metal temperatures
shall also not be less than 20C. Where pressure parts 600 mm in diameter
and above are being tested the hydraulic pressure shall be raised to the test
pressure in stages during which the item shall be examined and all defects
rectified before the full test pressure is reached.
Suitable water shall be used as the test media unless otherwise agreed and
test pressures shall be in accordance with the applicable construction
178
standard but if none is specified then the test pressure shall be 1.5 times
the design pressure but not less than an overpressure of 3.5 bar. Test
pressure of vacuum containment items shall be agreed with the
Owner/Owner's Representative's Representative.
The test pressure shall be maintained for sufficient time to permit complete
visual examination of all surfaces and joints and in no cases less than
specified in the applicable construction standard.
The chloride content of water used for testing austenitic stainless steel
items shall not exceed 30 ppm unless immediate flushing with water of this
quality is done after the test.
Pneumatic testing
The Contractor shall apply pneumatic testing in cases where hydrostatic
testing is impractical or undesirable. Safety precautions, test pressures/
duration and degree of prior non-destructive examination of the subject
items shall be agreed with the Owner/Owner's Representative's Representative.
Pnelm1<\tic or gas leak testing supplementary to hydraulic testing shall be
applied in appropriate cases where specified by the applicable construction
standard.
0.7.2.3.3Testing of corrosion protection
Surface coatings
Following tests have to be performed before, during and after coaling:
visual inspection of blasted surfaces according to DIN 55928 part 4,
annex 1
checking of coating material
measurement of air humidity, air temperature and coating area
temperature (determination of dew point)
visual inspection of coating
checking of dry film thickness (DFT)
checking of adhesion.
Galvanized zinc coatings
Surfaces shall be visually inspected. Bare patches, lumps blisters or inclusions of foreign matter shall be cause for rejection.
Zinc coating thickness shall be determined non-destructively in accordance
with DIN 50981 or coulometrically in accordance with DIN 50932. For
coatings with a weight exceeding 900 g/m2 the coulometric test
method specified in DIN 50932 shall be used.
Hard rubber linings
179
181
On-load tap-changers
Voltage transformers
IEC 186
Voltage Transformers
Generators
IEC 34, VDE 0530, IEEE 115, ISO R1680 and VDI 2056
Generator test report
Comprehensive test reports for the generators are to be compiled and
submitted by the Contractor, which shall include:
Description of the test method, equipment used and any limitations of
182
Generator assembled:
three phase short circuit characteristic test and current balance
check
dielectric test
measurement of insulation resistance
measurement of winding resistance and resistance check of temperature detectors
open circuit characteristic test and voltage balance, phase
sequence
check
segregation of mechanical loss and core loss
segregation of stray load loss
efficiency calculation
unbalanced load test for negative-phase sequence and zero se-
183
quence reactance
shaft voltage measurement
oscillographing of verified voltage wave form and harmonic (,lIlalySIS
measurement of vibration
polarization index
tan delta measurement of complete winding
bearing insulation resistance .
Type tests on generator as far as type test certificates are not available
sudden short circuit test at reduced voltage (30%, 50% and 70% of
rated voltage), extrapolated to 100% voltage
equivalent heat run test consisting of windage and friction heat run,
open circuit heat run at 105% rated voltage, short-circuit beat run at
rated line current, open-circuit heat run at rated line voltage
measurement of open-circuit direct-axis transient time constant
noise measurement
moment of inertia
measurement of excitation response time
overall characteristic coupled with generator and A VR cubicle at no
load
184
IEC 439
IEC 529
IEC 337
VDE 0641
VDE 0170/0171
VDE 0660 Part 1
VDE 0670 Part 2
Capacitors
IEC 70
Power capacitors
lEC 80
IEC 103
IEC 143
lEC 358
lEC 384
Primary batteries
Recommendations for polycrystalline semiconductor rectifier
stacks and equipment
Semiconductor converters
185
Telecommunication installations
IEC 215
Safety requirements for radio transmitting equipment
Aerials
IEC 597-2
IEC 169
IEC 492
VDE 0855 Part 1
VDE 101
IEC 298
Protection equipment
Equipment for modular numeric protection systems (e.g. generator, distance, bus
186
IEC 51
IEC 258
IEC 414
Calibration tests
The Contractor shall conduct calibration tests of the following
instruments and equipment:
187
all binary transmitters over the full range including initial setting
one of each type of indication loop with circuit resistance of the loop
increased to a value which is equal to the highest value expected, and
under worst case operating conditions
188
0.7.3
0.7.3.1
Erection tests
General
During erection all required erection tests as well as final erection checks
of the mechanical completion of the systems and part there of have to be
performed.
After successful mechanical completion Mechanical Completion Certificates will be issued.
The activities necessary for mechanical completion shall included but not
be limited to following testing:
visual inspection after unloading at site
checking of completion of relevant systems
completion of buildings and civil works
test of ventilating and air-conditioning units
alignment of rotating equipment coupled on site
safety audit
testing of site welds (non-destructive examinations)
pressure testing, leak tests, tightness tests
checking of pipe hangers, supports, guides, etc.
pipe line and equipment flushing and cleaning
chemical protection of piping systems
checking of coating
testing of cranes and hoists
Electrical equipment tests
The following checks and tests measurements shall be made:
screwed connections for correct assembly
terminals and terminal connections for correct assembly
checking of earthing connections and testing of earthing resistances
measurement of insulation values
verification of neutralization conditions
fire-proof partitioning
marking, inscription, provision of designation plates
rotating-field measurement
189
Electrical equipment
As far as not already covered by the erection tests the pre-commissioning
tests shall cover:
voltage tests
trip tests
functional tests of the equipment
Control equipment
190
0.7.3.3
Tests on completion
Preconditions of the Tests on Completion are the successful completion of
the pre-commissioning checks of all items of the whole system and the
satisfactory completion of the commissioning activities. On completion of
each commissioning activity to the satisfaction of the Owner/Owner's
Representative/Owner/Owner's Representative, the commissioning
schedule shall be signed and dated by the Contractor and countersigned
by the Owner/Owner's Representative.
The Tests on Completion shall prove that the plant is prepared and
adjusted to ensure the correct functioning of the individual components
and of tile complete plant.
After successful completion of the Tests on Completion the "Authorization
to Start Reliability Test Run" shall be signed.
The Tests on Completion shall cover at least following tests:
protection tests
operation of selected turbine train protection devices including
the following as a minimum
fire protection
boiler protection
steam turbine protection
generator protection
transformer protection
auxiliaries
method of alarm/trip condition reset for subsequent starting
operation of auxiliary systems
method of changeover of main equipment to standby equipment
prior to turbine starting (see start-up tests) and during normal
turbine generator operation for lubrication and control oil system
and cooling systems
operation of fire protection systems
isolation procedures
method of isolation of plant equipment for safe shut-down and
maintenance procedures including as a minimum
HV station and unit supplies
LV supplies
oil systems (lubrication and control)
fire protection systems
191
192
0.7.4
The reliability test run will not be deemed to be completed unless the
relevant performance tests have been made.
In the event of interruptions to the reliability test run, for which the
Contractor is responsible, the length of the reliability test run can be
extended by a period equal to the total duration of the interruptions. If
such an interruption lasts more than 48 hours, the reliability test run
shall be restarted, after repairing the defect. The reliability test run
may be interrupted on three occasions, provided that the total hours of
interruption do not exceed 48 hours and that the Owner/Owner's
Representative is notified of the interruption in good time. Minor
adjustments to the control system are permitted with previous
agreement of the Owner/Owner's Representative.
0.7.5
Performance tests
After positive conclusion of the reliability test run period the Contractor
shall demonstrate by means of performance tests that the plant units
and the Plant including related equipment and systems can be tested
to prove the guarantee parameters.
Lower output and heat rate
The overall outputs under differing operating conditions shall be
determined and achievement of the performance guarantees given in
the relevant schedules shall be evidenced.
Performance tests shall be conducted in accordance with following
standards:
193
the boiler
generator
steam turbine
transformer
The curves required for the correction of the power output and
specific heat rate to the site specified ambient conditions shall be
listed in the technical schedules of the Plant performance and gas
turbine performance.
All margins required for instrument inaccuracies and for all other
reasons shall be deemed to be included in the guarantee figures.
Derating curves for the Plant performance shall be submitted by the
Contractor with tender. The curves shall show the Plant's degradation
in power output and heat rate versus equivalent operating hours. The
curves shall be applicable up to and including major overhaul.
All special instrumentation shall be calibrated for the test and supplied
by the Contractor. Meter accuracy shall be as determined mutually by
the Owner/Owner's Representative.
194
0.8 Abbreviations
In general when using abbreviations care shall be taken to prevent confusion
with KKS numbers .
ASC
AC
AVR
COD
DC
DCS
EHV
EMC
ESP
GRP
H.R.C
BV
I&C
IR
KKS
Technischer Oberwachungsverein
(Technical Surveillance Association)
Deutsche Industrie Norm
(German Industrial Standards)
Verein Deutscher Elektroingenieure
(German Electrical Engineers Society)
195
196
Table of Contents
B1.
1.1
General
1.2
1.2.2
1.2.3
1.2.4
1.2.5
1.2.6
1.2.7
1.2.8
1.2.9
Boiler accessories
General
1.3.1.1 Design
1.3.1.2 Steam generator plant modes of operation
1.3.1.3 Fuel
1.3.1.4 Feedwater
1.3.1.5 Steam purity
1.3.2
1.3.2.1 General
1.3.2.2 Steam generator
1.3.2.2.1 Furnace and connection pass for dry slag/ash extraction
I.3.2.2.2 Pressure parts
1.3.2.2.3Superheater (SH) and reheater (RH)
1.3.2.2.4 Economizer
197
1.3.5
198
B1.
1.1
General
Steam generator to be installed shall be of the natural circulation reheat type. The unit
shall be designed for pulverized coal firing (PC firing), balanced operation and out door
arrangement.
The Bidder has to check and to verify all relevant information as the basis for his offer.
1.2
blow-off pipes for safety valves and start-up valve incl. silencer
boiler mountings, valves and accessories:
feed water shut-off valve and feed water control valve with electric drive, check valve
incl. manual. operated control valve as bypass
sampling system for feed water, boiler water and live steam incl. coolers, piping and
valves
199
1(one) continuous blow-down flash tank (atmospheric tank) incl. Cooling system,
blow-off pipe, control valve and necessary equipment
1 (one) boiler drain flash tank with flanges, vent drain and connecting pipes.
1.2.3 Firing and grinding system
coal mills with motor, with shock absorbers, classifiers and special tools; Coal mill
specification: Capacity= 70% through 200 mesh, Hardness Grinding index=75, raw
coal moisture= 15%
mill primary air fan(s) with silencers on inlet and delivery sides with electric motor
seal-air fans with electric motor
PC firing systems including low-NOx burners, PC distribution and delivery lines,
combustion air register, regulating, adjustment and isolating dampers as well all
drives, two PC sampling equipment incl. sieving device for each burner
two PC sampling studs with air scaling connections for each PC pipe
flame detectors for the PC firing system
Automatic Coal mills hard coal/stone rejection system, via denseveyor/ positive
pressure conveyor with 16 hrs storage and related others auxiliary, if necessary
1.2.4 Start-up and back-up firing system operating on diesel fuel oil
Comprising essentially:
flow meters for oil supply and return line and each burner
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oil trays
2 safety catches
2 drive limit stops
plastic rollers to keep off the working platform from the boiler walls
plastic wheels for transporting the working platform outside the boner
plant
The parts of the working platform are to be assembled by plug-andsocket connections.
One electrical equipment mainly consisting of:
switch cupboard at the lifting winch
trip line for the working platform included are 2 conductors for a telephone connection
control panel for the working platform with
2 connections for hand lamps 42 V
connections for the proximity switches of the drive limit stop systems
and the safety catches
.
mercury cut-out to limit the slanting of the working platform
all necessary key buttons, conduit boxes and cross-cables
2 hand lamps, 42 V, 60 W
transfer drum for the trip line
two cantilever arms in Iight-metal construction
two hoisting ropes and two safety ropes (steel ropes)
accessories
2 hooks to fetch the safety ropes
2 movable transfer drums for the safety catches
2 auxiliary ropes to let down the safety ropes from the cantilever
arms into the boiler
3 leading-strops to fasten the working platform at the boiler-walls in
the range of the entrance openings
special tools
lay down construction on the furnace bottom.
1.2.7
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1.2.8
complete steel structure for boiler. coal bunker, lift shaft, pipe and
conveyor bridges and for auxiliary equipment
1 (one) open stairway as connection between platforms (taking into
account permissible escape route lengths)
all necessary access galleries, stairways, ladders and platforms
protection sheds (or hoods) for all equipment located outside such as
fans, actuators, electric drives, etc.
roof and dust proof cladding for tripper conveyor
dust proof enclosure for all conveyor bridges.
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1.3
1.3.1
General
The requirements specified under B0 "General Technical Specification
and General Technical Requirements" are to apply, and, where
applicable, further regulations from other sections of this specification.
The Special Technical Requirements under the Section B 1 refer to
simplifying to boiler and accessories.
1.3.1.1 Design
The steam generator shall be of the radiant, natural circulation (single
drum) water tube type with integrated reheater.
The unit shall be of the balanced draught design, i.e. with forced and
induced draught fans.
The prescribed design and performance data of the boiler plant are listed in
the Technical Data Sheets B1/FB.
It is to have provision for firing 100% of MCR pulverized coal and 35% of
MCR design capacity with fuel oil firing for boiler start-up and low load
backup firing.
The furnace enclosing walls and the enclosing walls of the heating surface
section are welded gas-tight. The gas-tightness has to be tested. The
furnace itself, the radiation pass and the enclosing walls of the convection
heating surface sections are comprised of vertical membrane walls.
In order to compensate for any non-uniformities of flue gas temperature
over the cross-section of the boiler, each of the superheater and reheater
stages are separated into at least two parallel streams. The streams of the
individual stages are diagonally connected to each other.
The temperature control for the superheater and reheater is achieved by
means of spray attemperators which are located in the connection lines
between the stages of the superheater and of the reheater.
In order to permit cleaning of heating surfaces during operation and which
have become fouled by slag or fly ash, soot blowers have to be provided,
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Steam is used as the blowing medium for the furnace walls and
for the convection heating surfaces.
The boiler is suspended from the roof of the steel support structure and
thus allows for thermal expansion downwards during operation. The boiler
enclosure is to be arranged as an extension of the boiler steel structure
which shall be c1added with metal sheets.
Firing system
Coal is supplied to the boiler units via belt conveyors. The coal bunkers are
charged by means of belt conveyors. It is planned that the belt installation
be in one line .
Boiler unit has 4 coal bunkers each with a capacity suffices for 16 hours of
operation at MCR and with design coal. It is planned to construct the coal
bunkers of steel.
By means of the coal feeders, the coal is withdrawn at a controlled rate
from the coal bunkers and supplied by coal feeders to the inlet chutes of the
four coal mills (one standby). In these, the coal is pulverized, dried and
classified. The coal is supplied to the burners via pulverized coal (PC) lines
with distributors. The classifier temperature is regulated by mixing with cold
air.
The main design criteria of pulverizer design has to be:
MCR has to be generated by 3 pulverizers in service, burning design
coal, without supporting oil
MCR has to be generated by 4 pulverizers in service, burning worst coal,
without supporting oil. When one mill is not available for operation due to
maintenance reasons, its output can be substituted by diesel oil.
Further, the diesel oil is used for ignition, cold and hot start-up and for low
backup firing.
The installation of low NOx burners is to be provided. As key measures for
the abatement of NO x emissions by combustion modification, air and fuel
staging. Flue gas recirculation can be incorporated, if necessary.
Air and flue gas system
The air and flue gas system is designed in a double flow path, each for 60%
of MCR. Provision for later flue gas recirculation system for decreasing the
NOx emission has to be provided, if necessary.
Air system
Combustion air is supplied by means of the FD fans, following which the air
flow is separated into primary and secondary air. The primary air is further
compressed by means of the primary air fans, following which part of the
primary air is diverted to provide cold air for controlling the mill classifier
205
temperature. For both the primary and secondary air, steam air preheaters are
arranged upstream of the regenerative heater. With the steam air heater the
combustion air is preheated sufficiently for there to be no danger of corrosion at the
regenerative air preheaters in cold section. Following the regenerative air preheaters,
the primary and secondary air is routed to the, mills or to the burners. Sufficient
measurements for all air flows and all burners will be applied.
206
measures shall be taken to ensure rapid availability after start-up and optimum
load-following behavior.
The reheater outlet temperature shall be kept constant within the load
range from 70% to 100% ofMCR with feedwater injection.
The exhaust gas temperature at MCR when burning coal with 20%
excess air shall be 150C at air preheater outlet.
1.3.1.3 Fuel
The steam generator and its auxiliaries shall be designed for pulverized
coal firing. Diesel oil shall be used only for start-up and back low load up
firing. Typical analyses of coal is given in the Annex.
1.3.1.4 Feedwater
The steam generator of natural circulation water tube type shall be fed with
turbine condensate and a small percentage of make-up water. The
feedwater shall be thermally deaerated and treated with volatile chemicals.
Its chemical properties shall be within the limits of the "VGB Directives for
feed and boiler water of steam generators" (latest edition).
Thorough supervision of feed water entering the steam generator shall be
provided.
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1.3.2
1.3.2.1 General
The steam generator and its accessories shall be designed for outdoor
installation with a suitable weather protection, insulation to completely
protect the boiler and its accessories.
The design of the steam generator and of the auxiliary equipment shall
envisage the life time of the Power Plant under the prevailing climatic and
operating conditions to be 30 years.
All noise emitting equipment shall be duly protected by silencers, sound
absorbing jacketing, insulation, etc. in order to meet the requirements as
specified in Section B06 and B07.
The pattern of the normal load jumps as dictated by the interconnected grid
are sudden due to load shedding and line faults. The Bidder shall describe
measures he has taken in the designing of the steam generator to facilitate
and secure these operating conditions.
Sufficient space shall be provided in the convection pass of the steam
generator for possible correction of the heating surface in case practical
results suggest such corrections to be necessary. The amount of space
shall be consider possible future installation of approximately 10% of total
superheater, reheater, economizer and air preheater heating surfaces.
The design of the steam generator and its auxiliaries shall consider the
possibility of preservation prior to or after commissioning by providing all
necessary connections and provisions as for example
of balanced furnace design with two regenerative air heaters, two FD fans
and two ID fans.
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All stress calculation of the pressure parts shall be allow for the lifetime of
the plant as stated elsewhere with at least 50 shut-down and start-up per
year.
All tubes material shall be fabricated from hot or cold finished seamless
material and shall be ultrasonic tested.
Headers shall be of forged or seamless drawn steel. They shall be provided
with inspection stubs on the ends. Headers and spray attemperators shall
always be located outside of the flue gas stream and shall be fitted with
closure elements to permit their direct inspection without any auxiliary
equipment.
In addition, the spray attemperators shall be installed outside of the sheet
metal casing and easily accessible.
Grey cast iron may not be used in any pressure part.
The steam drum, headers, pipes and tubes shall be of approved
construction and manufacture, the suspension system and seismic
precautions shall be particularly indicated.
Supporting tubes for heating surfaces exposed to flue gas temperatures of
more than 400C shall be cooled by feedwater or steam.
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212
To ensure an effective SH control the final stage shall have a maximum rise
in steam temperature at MCR of not more than 75 K for final SH stage.
Each spray water control station for SH and RH shall be fitted with a least 1
control valve, 1non-return valve, 2 isolating valves and 1 hand-operated
bypass valve.
Besides all measures taken by the Contractor to avoid unbalanced
temperature distribution across the boiler width the Contractor shall provide
and install at least 300 thermocouples as temporary provision well
distributed on evaporator, SH and RH outlet tubes and assure himself by
measurements during commissioning of the plants that at all operating
conditions no unbalanced temperatures exceeding max. allowable wall
temperature of the single tubes will occur.
1.3.2.2.4 Economizer
The boiler shall be equipped with an economizer which shall be designed to
preclude evaporation at any operating condition. Otherwise it must be
ensured that the operation of the boiler shall be possible if the HP feed
water preheaters are out of operation for a lengthy period. Its arrangement
shall be designed to be completely drainable. The water flow shall
preferably be upwards.
The heating surface shall be formed by seamless plain tubes which shall be
fitted in line.
The economizer shall be divided into banks. The height of the tube banks
shall be limited as defined in the Data Sheets B I/FB.
Parts of the first and second layer of tubes with distance less than 1 m to
sootblower have to be equipped with protective shells for avoiding of
erosion caused by soot-blowing.
All fittings, spacers and supporting lugs of the economizer tubes exposed to
the flue gas shall be made of approved corrosion and heat resistant
materials.
The feed connections to the drum shall be fitted with thermal sleeves.
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The design of the buckstays shall consider the expansion of the gas-tight
welded tube walls during start-up and shall not result in additional forces.
The downcomers shall not be heated.
The drum shall be of the welded type with a manhole at each end. The wall
thickness of the drum shell shall be uniform throughout. It shall be amply
sized to ensure adequate steam volume to provide a suitable level control
and to preclude the possibility of carrying over of water during any transient
mode of plant operation as well as to provide adequate space for maintenance work and manual cleaning operation without removing any internal
fittings.
The drum shall be fitted with the necessary internals for the uniform distribution of the feedwater, with sufficient devices for efficient separation of
water from saturated steam.
Access manholes of hinged type shall be provided at each end of the drum
heads.
The drum shall be provided with dished ends and with the required nozzles
for the water and steam connecting tubes, drains, vents, blowdown, installation of safety valves, controls of pressure, temperature, analyzers and water
level. All drum nozzles for valves, fittings and mountings shall be welded to
the drums. All internal and external attachments welded to the drum shall
be made before final treatment.
The connection between drum and downcomers shall be well distributed
over the length of the drum. Entry of downcomers into the drum at the
dished ends shall be avoided. The downcomers shall be designed with
ample in cross-section-and shall be arranged at an unheated position to
avoid any disturbance of the circulation.
The feed connections to the drum shall be fitted with thermal sleeves:
The drum shall be provided with all suitable internal fittings such as:
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215
13.2.2.7 Headers
The headers shall be of seamless forged manufacture or solid drawn construction. The method of connecting the tube elements to headers shall be
by means of welding.
All distribution headers shall be adequately sized. To enable visual inspection of the internal space during maintenance periods, conveniently caps
on header panel sections shall be provided at sufficient locations to
facilitate such internal inspection. The closure of these must be of a
permanent type, either strength welded or seal welded. For headers,
where this inspection can easily be done by cutting pipes (e.g. overflow
pipe header), the inspection caps may be omitted.
The drum on headers shall be provided with shop welded tubular stubs of
the set-on type and thicker than the minimum calculated tube thickness.
These shall project a sufficient length to ensure that the welding of the
tubes will not affect the material of the drum and headers.
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217
The safety valves at superheater outlet shall always lift before the safety
valve on the drum opens. The superheater safety valves shall have such
capacity that the superheater cannot be overheated when also the drum
safety valves are blowing. The safety valves shall be of the spring loaded
type.
One blow-off station consisting of one throttle and one shut-down valve
connected in series with the relating electric actuators shall be installed in
the hot reheat line. The capacity of this station shall be determined in
accordance with the following requirements:
operation of the station during start-up until achievement of pressure on
which the LP bypass reducing stations enter into operation (if required)
in case of non-availability of LP bypass stations, a start-up until synchronization of the turbine shall be possible.
1.3.2.2.9
Miscellaneous mountings
For cold and hot reheat pips leading to the turbines, pressure test locks
shall be installed in the vicinity of the steam generator so that it will not
be required during a pressure test of the boiler, to block the supports of
the whole piping system.
If the pressure and temperature of the interconnecting steam line to be
provided is not sufficient for the sootblowers, fuel atomizing and other
necessary purposes, the boiler shall be provided with its own reducing
valves in adequate number and size.
An adequate number of thermocouples and fixings shall be provided to
measure the superheater outlet header, inside and outside temperature
as temperature difference for monitoring of thermal events which may
have an influence on headers life time. Drum metal temperature
difference measurements shall be supplied.
The corresponding number of blowdown and drain valves for the drum,
furnace wall bottom headers, for superheater and headers shall be
provided, each set including two valves of an approved bore and type
arranged in series.
The necessary vents for venting the economizer, drum and
superheaters, reheaters shall be included. Nozzles and isolating valves
and test connections for all remote and local pressure indicators shall be
supplied.
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one high and one low level water drum alarm (each independently
connected to a pair of branches)
one independently working low water safety feature for boiler trip
the lower limit of indicating range of the water gauges shall be at least
30 mm above the uppermost pass and at least 30 mm below the
minimum water level
all level gauges shall be provided with a retaining device, so that at
bursting of glass the boiler does not need to be shut-down.
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221
load washing with process water. The system shall include all supply
pipes, pumps dosing system, discharge pipes, dust separator complete
with internals, discharge ducts and pumps (if required) from the dust
separator.
Drainage pipes of air heaters washing system shall be provided with
double shut-off valves and drain valves in between, in order o exclude
the intrusion of water into the dry ash removal system. The same shall
apply also for other drainage points where dry ash and washing water
will be discharged into the same piping system.
1.3.3
223
the burners which are not in operation have to be foreseen for avoiding
damages caused by furnace heat.
It is essential that the Plant shall be dust tight in every respect and all
bearings and working parts shall have dust proof housings.
For monitoring the flames of the PC firing system, flame detectors shall
be provided. Which in the event of the failure of its associated burner
group will not be effected in its action by extraneous light or spurious
radiation from the furnace. The offer shall be accompanied by a detailed
description and drawing of the combined burners and a reference list.
The ignition and backup firing system shall be designed for the fuels and
load range as laid down in the prescribed design data, without
consideration of the PC firing equipment. The number and arrangement
of the combined ignition and backup burners shall meet the
requirements of the PC burners.
The pulverizing and firing system shall be adaptable to varying fuel
qualities in such a way that on the one hand a stable firing of worse
fuel sorts is possible and on the other hand no slagging of the furnace
will occur when burning higher qualities of fuel.
Each ignition and backup burner shall be fitted with a pure gas-electric
ignition device and gas bottle station, its own flame detector, a
combustion air control damper and all other auxiliaries connections and
slop tank shall be provided.
Piping to the ignition and backup burners shall start at the inlet of the
isolation valve outside of the boiler area, be routed to all burners, and
shall contain all safety relevant equipment, fittings and burners valves
and accessories. For each burner, two quick acting safety shut-off
valves with intermediate drains to the slop oil tank shall be provided.
Explosion protection of the electrical equipment belonging to the coal
grinding and firing system shall be in compliance with the requirements
of the NFP A code or recommendations or other similar standards.
1.3.3.1
Coal bunker
Each pulverizer has to be fed from one coal bunker and one feeder.
The bunkers shall provide the necessary counter pressure by means of
a minimum coal level against the pressure in the coal mills.
The design of the bunkers shall guarantee a controlled, continuous and
undisturbed feeding of the mills. This should be achieved by giving a
due consideration to the properties of the stored and selected of a
suitable form and suitable outlet openings.
Each boiler unit has 4 coal bunkers. The bunkers shall be provided with
a total reserve corresponding to a minimum of 16 hours of operating at
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225
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1.3.3.2
Coal feeders
The raw coal is to be fed even distributed to the centre of the mills by
means of encapsulated plate conveyors. The coal feeders shall be
designed dustproof and pressure-tight (gauge pressure of 0.5 bar). The
coal feeders are to be designed with enough margin in capacity compared
with the coal mills.
All sides of the casings of the plate conveyors - including the shaft ducts
must be absolutely tight against dust escape. The front and side walls, discharge box must be at least 4 mm thick. The scraper floor must have a
thickness of 8 mm or more.
It is to be ensured by means of the suitable choices of coal bed thickness,
conveyor speed and paddle shaft speed that coal feeding is effected
continuously in every load range. The .coal feeders have to be equipped
with an coal bed thickness indicator.
The plate conveyor is to be of a solid and wear-resistant construction so
that it can be operated throughout its entire service life without constant
repair work being necessary.
In order to prevent corrosion to the roller chains of the coal feeders, an air
seal supply with gate valve is to be connected at the outlet of every coal
feeder. Pipes and valves belong to the scope of supply of the Contractor.
Steplessly variable drives with remote adjustment are to be provided as
variable speed transmissions.
The coal damper, coal fall shaft in the feeder discharge section and the
bunker passage to the feeders are to be lined with stainless steel.
In addition, the mill feeders are to be equipped with needle weirs, height
levelling frames (stainless steel) coal bed thickness controllers, pendulum
plate, tension station and automatic oil Iubrication equipment of for the
conveyor, paddle and scraper shafts, Belt or chain cleaning device, one
inspection door (0.5 m x 0.5 m) above coal feeder and at front and rear
side, chutes between feeders and mills, complete scraper equipment and
complete air seal equipment. \
Dumping of coal from the feeder to the mills shall be done vertically or
227
nearly vertically.
1.3.3.3
Coal mills/pulverizers
The pulverizers and the firing plant shall match the boiler plant overall
layout and shall be designed so that all operation requirements including
start-up and shut-down, also transient at turbine trip, emergency boiler
shut down, or failure in the internal power supply can be covered safely
and without damage.
The coal pulverizer shall be suitable for pressurized operation in
conjunction with primary air fan.
The pulverizers shall be equipped with adjustable classifier system
(separator).
The system shall operate as a continuous process and, within the
specified design limitations, the coal feeding shall be varied as rapidly
and as widely as required by the combustion process.
It shall be possible to be operated the pulverizers and firing plant stable
and safely between 30% and 100% boiler MCR.
At all partial load conditions it shall be assured that each burner has the
same and controlled fuel/air ratio.
The coal supply, pulverizing and burning system shall be arranged as
independent path from the bunkers, coal feeders, pulverizers, pipe work,
to the burners.
The pulverized coal system shall be supplied completely with
accessories as specified and as required for a complete unit and to
secure safe, reliable and efficient operation.
The pulverizer shall be of Low speed Horizontal Ball mill (2 inlet 2 outlet)
type of proven design and of pressurized operation type. Coal mill shall
be designed by considering Coal Hard Grove Grindibility index (HGI) 75.
The feeding of the coal into the pulverizer shall be centric through the
classifiers. Each pulverizer has to be equipped with an automatic
operating steam smothering system.
Manhole covers and inspection hole covers at pulverizers and fans shall
be designed so that absolute dust tightness can be guaranteed. The
inner mill casing has to be manufactured without dead comers.
The pulverizer gear shall be easily exchangeable in such a way that
during necessary gear repair an exchange of the gear is possible
without dismantling important parts of the pulverizer casing.
All pulverizers shall be equipped with adequate and insert gas protection
fire-fighting system by steam.
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1.3.3.4
1.3.3.5
230
The individual pulverized coal pipes behind the distributors shall be provided with shut-off devices which upon shut-down of one mill shall be
closed for avoiding the recirculation of hot flue gases.
Each coal pipe has to be equipped with air sealed test opening (approximately 500 mm in diameter) to extract pulverized coal for measurement
of grain size and coal distribution. Provisions for galleries in this area
are to be made.
The dust coal pipes from mills to burners shall be as short as possible
and arranged as straight as possible.
Changes of mills load shall not cause any disturbance of the gas and
coal dust flow in the pipes.
Pulverized coal pipes shall be from steel piping or sheet with sufficient
wall thickness and all necessary protection measures against wear and
tear. Each PC pipe has to be equipped with two coal extraction studs for
sampling. The extraction studs have to be equipped with an air sealing
device for preventing the PC leaving the PC pipes during sampling.
1.3.3.6
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1.3.3.7
1.3.3.8
Each valve combination for diesel fuel oil has to be carried out as duplex block
and bleed valve set.
The fuel oil strainers shall be of the cage type with a maximum gap width of 0.5
mm on the suction side and 0.08 on the pressure side.
The strainer assembly shall include integral flow switching gate valves, external
valve position indicators, differential pressure gauge, steam tracing and valves
for drains and vents.
The oil pumps shall be of the rotary screwed type. The horizontal pump units
shall be coupled directly to the driving motor. Each pump shall be fitted with a
pressure relief valve preventing over-pressure in the pump casing. Pump and
motor shall be mounted on a common base plate.
Spindles of the pumps shall be approved material nitrided and ground. The
design of the pumps shall take into account the increased oil temperature in the
casing.
The pump casings shall be at least of cast steel. Cast iron is not acceptable.
The pumps must be designed and suitable both for continuous or intermittent
operation. They must also be ready for immediate service even after a
prolonged period of standstill, without any special measures being necessary.
Suitable cleaning and drain piping of the systems to the slop-tanks have to be
supplied.
The arrangement of the whole equipment shall allow access to all valves and
instruments.
Integral piping for diesel oil, cooling air and compressed air shall comply, with
the requirements of this specification.
Besides the remote control system it shall be possible to operate the burner
from local box near the burner with minimum employment of the remote control
system. The change-over from remote control to local control shall be done by
key switch for each burner located on the control room panel.
The remote control system and the interlocking system as well as the closed
loop control shall be provided under Chapter B9 in these Tender Documents.
Therefore the firing system also shall meet the requirements of Chapter B9
(Instrumentation and Control Works).
1.3.3.9 Diesel oil storage tank and unloading station
All the equipment for the diesel fuel oil system shall be of the outdoor design.
Scope of supply/ installation shall include but not limited to the following:
One (01) diesel oil storage tank (tank capacity 2000 m3);
Diesel oil unloading station [Two (02) diesel oil unloading pumps including
valves, pipings, filters and others as per requirement];
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developed. The vent intake shall be protected by a screen with a mesh width of
not more than 5 mm. The clear screen area shall be at least 125% of the vent
nozzle area.
A 100 mm high kick-plate, tightly welded around the entire tank perimeter and
acting as a gutter is to be arranged on the tank. top edge. For each tank at
least two rain downpipes, connected to the kick-plate and provided at their
bottom ends with a 45 bend, are to be provided.
Each tank. is to be equipped with a device for local and remote level indication.
All level indicators at tanks shall have scales which indicates meters and
millimeters. Corresponding volumetric tables must be made available also. This
device shall be equipped with at least three adjustable limit contacts to initiate
alarms or signals at given levels (low, high, maximum).
Each tank shall be provided with an overfilling protection device (level switch)
which shall respond when the maximum permissible level is exceeded by
initiating an alarm and switch off the filling pump of the oil truck.
The maximum limit contact of the level indicator shall also protect the tank from
overfilling by initiating an alarm.
The surface preparation, interior and exterior coating application, shall be done
in accordance with the requirements set out in Chapter BO "General Technical
Specification". Inside painting shall be applied only to the tank bottom and one
meter height of the shell above bottom.
In the dimensioning of all attachments on the outside of the tank, such as
sockets, manholes, measuring instruments, etc., allowance shall be made for
an insulation layer with a thickness of approximately 100 mm. The insulation
shall meet the requirements set out in Section B06 (General Technical
Requirements).
A pipe extending 2 - 3 m into the tank is to be flanged inside on to the bottom
discharge connection piece. The end of the pipe is to be provided with a bend.
The bend shall extend into a pour-in bowl, the upper end of which shall
terminate at the level of the sounding plate. The clear inlet area. of the pour-in
bowl shall be at least 2 times the outlet nozzle area.
1.3.3.10 Slop oil tank
The slop oil tank may be supplied wither as rectangular tank or as a horizontal
cylindrical tank. All necessary connections, manholes, drains and ventilation
systems are to be provided where required and made easily accessible.
The tank is also to be equipped with a local contents indicator having a sensor
arrangement to issue an alarm when the tank is full. Also to be provided is a
further level switch arranged to sever as dry-running protection for the pump
and to annunciate when the tank is empty.
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1.3.3.11 Filters
For the diesel oil pump group, one duplex filter shall be provided on the
suction side.
The duplex filter shall be equipped with a change-over device which allows
change-over under full load conditions without operating trouble
Each slop oil pump shall be protected by a single filter arranged in the suction
line. Each filter shall mainly consist of the filter bowl with cover and removable
filter insert.
All the filters shall be fitted with a differential pressure indicator equipped with
transmitters for electrical remote indication and alarm.
Filter covers are to be fastened by hinged bolts.
Filter bowls are to be equipped with stripping connections and valve.
Consideration is to be given to maximization of useful screen area to keep
initial pressure drop as low as possible
The switching point of the differential pressure gauge shall be freely settable
Filter casings must be at least of cast steel. Cast iron is not acceptable
1.3.3.12 Pipelines, foam pourer
The pipelines shall be designed according to the requirements of Section B06
(General Technical Requirements).
A pipe emptying system shall be provided for the entire pipework system, so
that pipes which are out of use for longer periods can be emptied and do not
require continuous heating.
Each foam pourer is to be allocated a foam generator which shall be fitted in
the immediate vicinity of the foam pourer.
The foam generators and foam pourers shall be made of process water
resistant and heat resistant materials.
The foam system for the oil tank shall be capable for foaming the complete
internal surface of oil.
Components made of plastic, plastic coatings, rubber or other materials which
in the event of fire, as a result of the effect of heat could prejudice the operation
of the foam generators or the foam pourers must not be used.
The pipes and valves of the foam system shall be made of corrosion resistant and heat resistant materials. Stainless steel or approved equivalent
236
materials shall be used. The nominal pressure of the foam system should
with adequate reliability be above the maximum possible operating pressure.
1.3.4
The auxiliary steam boiler fired with diesel fuel oil has to be provided if
necessary to supply steam to the steam turbine unit during the start-up
period. For an outdoor installation a respective weatherproof implementation has to be foreseen.
The number, type, capacity, steam parameters and arrangement of the
auxiliary steam boiler shall be decided by the Contractor.
Demineralized water will be used as boiler make-up water which is supplied
from the demineralization water plant.
The boiler used as the auxiliary boiler has the characteristics of frequent
start-ups, large changes of load, quick start-up, long periods between
maintenance, start-up at any time and operating reliability; being a
packaged completely assembled and then dispatched to site.
Because of characteristic difference between start-up boiler and normal
boiler, the water of this boiler can be drained completely and a nitrogen
blanketing protection connection shall be provided.
The plat form and gallery of boiler shall possess enough strength and
stiffness shall be proved at operation, monitoring or maintenance locations.
The boiler shall be provided with the necessary observation ports, manhole
for maintenance and explosion vents.
The drum shall be provided with safety valve, vent valve, exhaust piping
237
and a motor driven valve, and a silencer shall be provided at the outlet
header of the superheater.
Connections for drum water level and furnace pressure measuring shall be
provided. Local instruments and remote instruments (in the control room)
shall be used for drum water level measuring, and the pressure,
temperature and flow rate shall have indications in the control room.
The boiler shall be provided with one set of forced draft fans, feedwater and
oil pumps. The steam pipe lines of the auxiliary boilers shall be connected
together and also with the extraction of the steam turbines. So that it is
possible, while the auxiliary boilers are shutdown, to start-up the second
steam turbine by the first, which is already in operation.
1.3.5
238
Minimum requirements
Unit
Data
1. Thermodynamic Data
Steam generator
Max continuous rating (MCR)
bar
145
0C
535
0C
535
MCR
60 -100
MCR
70-100
MCR
30
mbar
+ 70
MCR
0-35
approx.. 207
walls/ducts
C
kg/s
bar
Feedwater quality
Feedwater quality in line wtth VGB Directives for boiler, boiler
water and steam from water tube boiler Operating at pressure of 68
bar and up (Iatest edition)
Chemical mode of Operatiion1alkaline as per VGB Directive
pH-Value
8.0 - 8.5
Flue Gas
150
350
B1/FB1
239
Minimum requirements
Unit
Data
2. Performance in Service
Intended operating regime
operating hours per year
total cold starts per year
cold starts (after 48 h shutdown) per year
warm restarts (a1tsr 8 h shutdown) per year
hot restarts (after 2 h shutdown) per year
n/a
-
% MCR/ min
% MCR/ min
8500
10
30
100
20
6
4
and 70 bar
from OC/bar
up to OC/bar
50/1.0
450/70
Warm start
from OC/bar
to OC/bar
300/50
500/100
min
Hot Start
from OC/bar
to OC/bar
450/120
535/145
min
min
240
Minimum requirements
Unit
Data
400
380 x 425
12
m /h
mm
m/s
1.8
1.2
mm
mm
%
-
plain tubes
in-line
100
80
10
on both sides
Directly down
stream of
evaporator
mm
mm
800
60
m
m
-
pieces
-
1.8
1.2
2 pass 3
stages
crosswise
2
inline
mm
100/200
mm
55
on both
sides
10
%
0
75
B1/FB3
241
Minimum requirements
Unit
Data
m
m
1.8
1.8
2-pass
crosswise
pieces
mm
mm
mm
mm
%
in line
100
70
400
70
10
on both sides .
PC direct firing
gas-side vacuum
high volatile
bituminous coal
Annex
Annex
MJ/kg
42
0- 35
B1/FB4
242
Minimum requirements
Unit
Data
20
steel structure
operation
hours
24 at MCR
Excess air
Maximum excess air in furnace. for coal firing (guarantee
coal) between 60 % and 100 % MCR.
coal bunkers
1:5
bar
3.5
n-1
Pulverizers
Minimum interval between two scheduled Overhauls of the
mills
hours
8,000
10
m/s
18
delivery head
110
capacity
121
B1/FB5
243
Minimum requirements
Unit
Data
%MCR
60
Type
Type control
Type of drive
Maximum speed
Sealing air fans
min-1
Minimum number
Safety margins
delivery head
capacity
Type
%
%
Type of control
Ingestion temperature at design point
Type of drive
Maximum speed
design temperature +
5O 0K
radial
inlet guide vane
variation mechanism
30
electric motor (direct
type)
1000
min-1
110
121
radial
inlet guide vane
variation mechanism
30
electric motor.(direct
drive}
1000
%MCR
%MCR
delivery head
capacity
n-1
1:5
%
%
110
121
B1/FB6
244
100% MCR
60% MCR
MSL
Feedwater temperature at
100% MCR
60% MCR
Minimum requirements
Unit
Data
C
C
%MCR
0
C
C
100% MCR
60% MCR
kg/s
kg/s
100% MCR
60% MCR
kg/s
kg/s
t/h
100% MCR
60% MCR
100% MCR
60% MCR
%
%
0
C
C
60% MCR
100% MCR
C
C
100% MCR
60%MeR
MSL
%
%
%
B1/FD1
245
Bidder/Contractor
Unit
Data
100% MCR
MW
MW
100% MCR
kg/s
60% MCR
kg /s
MSL
kg/s
bar
100%MCR
60% MCR
MSL
C
C
C
%MCR
100% MCR
60% MCR
kg/s
kg/s
MSL
kg/s
100%, MCR
60%MCR
MSL
B1/FD2
246
Bidder/Contractor
Unit
Data
100% MCR
pc.s
60% MCR
pc.s
MSL
pc.s
kg/h
Operating data
Note:
All data refer to MCR and guarantee conditions
Water/steam flows
'.
Feedwater
kg/s
Live steam
kg/S
attemperator 1
kg/s
attemperator 2
kg/s
kg/s
bar
Drum /evaporator
bar
superheater outlet
bar
Water/steam temperature at
Economizer inlet
Economizer outlet
Drum/evaporator
Supporting tubes
C
C
Superheater 1 inlet
Superheater 1 outlet
Attemperator 1 Inlet
C
C
0
C
Attemperator 1 outlet
Superheater 2 outlet
Atlemperator 2 outlet
Superheater 3 outlet
C
C
C
C
B1/FD3
247
Bidder/Contractor
Unit
0
C
0
C
0
C
Reheater 2 outlet
Flue gas temperatures
After supemeater 3
After reheater 2
After superheater 2
After reheater 1
After superheater 1
After economizer
After regenerative air preheater
At stack inlet
Operating times
Data
C
C
C
C
C
0
C
0
C
0
C
C
0
C
0
min
0
C
min
min
Drum temperature
min
0
C
bar
min
min
0
bar
min
min
B1/FD4
248
Bidder/Contractor
Unit
Data
min
bar
Drum level
Excess air
0
0
mm
%
%/ min
HP steam pressure
HP steam temperature
bar
0
C
Drum level
mm
Excess air
Technical particulars
Boiler steam/water system, Furnace
Projected heating surface
MW/m
MW/m
Material of risers
mmxmm
mm
mxmxm
Water volume
Volume of water from economizer inlet up to drum center line
m3
m3
B1/FD5
249
Minimum requirements
Unit
Data
Steam drum
Manufacturer
Cylindrical length
Internal diameter
mm
mm
Plate thickness
mm
m
3
m
-
Safety valves
Manufacturer
Type
% MCR
bar
Capacity
% MCR
bar
Set pressure
Hot reheat line safety valves
Number
Capacity
Set pressure
Hot reheat steam blow-off station
Number
Capacity
Continuous bailer blow-down flash tank
Cylindrical height
Outside diameter
Blow-down rate
Boiler drain flash tank
Cylindrical height
Outside diameter
Flow rate
% MCR
bar
% MCR
mm
mm
kg/h
mm
mm
kg/h
B1/FD7
250
Bidder/Contractor
Unit
Data
Platforms
Elevation of operating platforms
Elevation of auxiliary platforms
Boiler insulation and brick lining
Max. temperature at outer face of insulation
Total heat loss of boiler
Design heat flux density
Refractory lining material
m
m
0
C
kW
W/m2
Denomination (type)
Manufacturer
Max. service temperature
Operational life time
Components which will be brick lined
Bricksetting material
0
C
h
-
Denomination (type)
Manufacturer
Form of delivery
Refractories
Operational rife time
Components for which Bricksetting will be applied
Sootblowers
--
Numbers of sootblowers
Type
Soot blowers for economizer
pcs
pcs
Type
Soot towers of RH
Numbers, of sootblowers
Type
pcs
B1/FD8
251
Unit
pcs
-
pcs
mm
t
mm
pcs
kg/h
kg/m3
mm
mm
bar
kW
Design
Coal
Coal mills
Number of mills
Manufacturer
Type / Model
Capacity per mill. max. after 3.000 operation hours
Capacity per mill at MCR (n mills in operation)
Capacity per mill at MCR (n-1 mills in operation)
Fineness of grinding (oversize on 0.09 mm sieve at 550)
Temperature downstream of mill
Hot air mass flow rates per mill
Data
Worst
Coal
pcs
kg/s
kg/s
kg/s
%
0
C
kg/s
B1/FD9
252
Unit
Data
Design Coal Worst Coal
mbar
kg/s
0
kW
t
kg/s
-
kW
kV
min1
.
pcs
m3/h
mbar
0
kW
rpm
pcs
m3/h
mbar
0
C
kW
rpm
B1/FD10
253
Bidder/Contractor
Unit
Data
kg/h
-/pcs
mbar
%
kg/s
pcs
t
pcs
-/MW
kg/S
bar
pcs
pcs
m3
m
m
t
pcs
t/ h
bar
kW
kV
min1
bar
B1/FD11
254
Unit
Data
mm
mmxmm
m3
pcs
Kg/s
pcs
Kg/s
B1/FD12
255
256
257
2 (two) evacuation units for the steam side with steam/air ejectors, complete
with vacuum condensers, piping, valves, fastenings, etc,.
3 (three) half load main condensate pumps complete, each with motor drive
and minimum flow device.
258
1 (one) emergency stop valve and 1 (one) reducing valve), complete with the
associated actuating and control equipment, piping from the station(s) to the
cold reheat line/to the condenser and from the feedwater/main condensate
line to the injection points.
Control and monitoring equipment
All control, governing, measuring and monitoring equipment, instrumentation
necessary to match particular design arrangements of the apparatus and
units, including
electro-hydraulic turbine governor
jump and rate limiter
monitoring and protection system complete
instrumentation and monitoring
Generator and electrical auxiliaries
1 (one) synchronous AC generator with complete cooling system as
follows:
internal closed-cooling cycle with air-to-water coolers (incl. one stand by
cooler) as preferred solution, or alternatively
internal closed-cooling cycle with water cooling directly through stator
winding and rotor winding and internal closed-cooling cycle with air-towater coolers (incl. one stand by cooler) for remaining parts,
complete compounded excitation system (static or brush less rotating
system) (the Bidder shall mention the reason why he did choose what)
and A VR with power factor control,
generator control panel,
generator star point and terminal cubicles,
complete generator busducts up to generator step-up transformer and unit
auxiliary transformer, including isolators, surge arrestors, voltage and
current transformers, etc.,
generator and unit protection, synchronization, measuring, metering and
monitoring equipment,
associated equipment including CO2 fire protection, pipework, control
etc.
2.2.2 Feedwater pumps
For steam generator 3 (three) feed water pumps , 62.5% capacity each
including flow control devices, two in operation and one as stand-by,
complete with electrical drive, nonreturn valve, hydraulic fluid couplingt
base plates, ,drive motors etc. and speed increasing gear.
For each pump set:
259
260
2.2.5 Vessels
Cold condensate tank
2 (two) cold condensate tanks, complete.
Atmospheric flash tank
2 (two) atmospheric flash tanks, complete
Drain condensate tank
2 (two) drain condensate tanks, complete, including required drain
condensate pumps Tank, vessels where these are not already included in
the other sections of the specifications.
261
2.3
2.3.1 General
The requirements specified in no under section 'General Technical Requirements' are to apply and, where applicable, further regulations from the
other sections of this specification.
The turbine generators and the respective associated equipment are to be
able to be operated without any restriction and any limitation in time at each
load between no-load and maximum load.
Grey cast iron will not be accepted in general. If there should be grey cast
iron contained in a series-manufactured small part which is under consideration, the express approval of the Owner/Owner's Representative's
Representative is necessary.
Stub pipes on the casings and larger constructional parts must have a
minimum wall thickness of 5 mm; the minimum nominal bore is 20 mm. If
flanges are provided, these are to be at least of nominal pressure 25 bar.
The control valves are to be operated in each case with auxiliary energy.
Direct acting control valves will be accepted only for gland steam controller.
262
For all rotor blades, only fully machined or pre-forged and mechanically
machined designs are permissible. For the first rotor blade stage only
milled shrouds are permitted (shroud band integral to the blade and formed
by . machining). The low pressure rotor blades are to be provided with additional edge protection, where necessary. The turbine stages operating in
the steam region are to be provided with sufficient water drains.
Rotor
The coupled critical speeds of the turbine and generator rotor must lie
outside the range from 85% to 120% of the nominal speed. The rotor is to
be statically and dynamically balanced in the factory.
It must be possible to re-balance the rotors on site without particular difficulty. The fixed parts of the steam turbine plant must be free of any resonance which might disturb the operation .
In the design of the rotor, all notches, sharp inner edges or excessively
small radii are to be avoided so that fatigue failures are excluded. All
internal radii arc to be provided with a high quality surface finish.
Bearings
Basically, the bearings are to be designed as horizontally split plain bearings. The thrust bearings must be capable of taking load from both sides
and be self-aligning. They must be axially adjustable.
It must be possible to check the thrust bearing wear during operation.
Earthing brushes are to be provided at the turbine side bearing of the
generator to protect the bearings. Similarly the necessary bearing and pipe
insulation must be provided to give protection against eddy currents. In
order to prevent oil leaks, suitable bearing seals such as oil thrower rings
are to be provided.
It must be possible to dismantle the bearing shells without removing the
turbine casings or dismantling the generator.
Gland steam
Gland steam must not be discharged into the turbine hall. The labyrinths to
be provided should have spring elements if possible. It must be possible to
inspect the outer labyrinth through a removable cover without having to
open the turbine.
The gland steam system is to be provided with a gland steam and vapour
condenser and vapour suction fans. The materials to be used for the gland
steam condenser shall be of stainless steel material.
263
Turning device
Hydraulic or electrically driven turning devices may be employed. The turning
device must disengage automatically as soon as the turbine speed exceeds the
turning speed. Automatic engaging of the turning device must be foreseen
remotely from the central control room and manually from local position. A
manual turning gear provision should be included for the black periods.
If jacking oil pumps are used they are to be interlocked so that turning without
jacking oil supply is precluded. Interconnection between the lubricating oil
supply and turning operation is to be ensured by automatic interlocks.
Couplings
If toothed couplings are employed, these are to be provided with forced oil
lubrication. All parts of toothed couplings are to be fully machined. Coupling
hubs and sleeves are to be individually balanced, statically and dynamically, at
a speed corresponding to the operating speed. For the design the short circuit
shock has to be assumed at least 8 times the nominal torque on the drive
coupling for at least 100 times. If necessary, this value is to be corrected
upwards after the torsional critical speed calculations for the total plant and the
actual generator short circuit torque are known.
264
Oil vapour suction fans and oil separators are to be provided. The possibility
of unacceptable concentration of the oil vapour must not exist at any point of
the oil system.
All oil-carrying parts must be separated from equipment subjected to hot
steam so that premature ageing of the turbine oil and the danger of fire is
excluded. The oil pipes must be run in separate oil ducts away from the
cables.
The oil pipes must be seamless and connections between oil-carrying parts
must be welded or flanged. Flange connections of the oil pipes outside oil
ducts and turbine oil room must be encapsulated. The fastening of the oil
pipes must be such that excessive vibrations are excluded. Oil drain points
are to be equipped with double stop valves. It must be possible to shut off
the control oil circuit separately.
The auxiliary oil pumps should he arranged on the oil tank. The auxiliary oil
pump must be able to start automatically in the case of a drop in oil pressure. If positive displacement pumps are employed, pressure relief valves
must be provided in each case for the full flow quantity. To avoid an
unallowable drop in pressure during switch over of oil pumps, a pressure
accumulator is to be installed in the oil system (if necessary).
The DC emergency oil pump has to be connected electronically in a failsafe
way. It has to be ensured by proper means so that the pump is always
working in emergency cases. Off-command from the central control room
shall only be possible in case of turbine standstill.
The oil coolers are to be provided with a withdraw able tube bundle. If2
coolers are installed; they must be switch able during operation without
interruption of the oil flow and must be easy to clean. The coolers are
connected to the closed circuit of the plant auxiliary cooling water system.
The materials used for the oil coolers shall be equivalent to the materials
specified for the gland steam condenser.
The oil filters in the lubricating oil main circuit and in the control oil circuit are to
be arranged as duplex filters which can be switchover without interruption.
In addition, an oil separator (preferably of the centrifuge type) with all auxiliary
equipment is to be provided for at least 3% of the circulating oil flow. The
separator shall be capable of being used both in operation and when the
turbine is out of service. Those parts of the oil separator in contact with fluid are
to be manufactured from stainless material. Dirt and all solid particles greater
than 5 microns are to be removed in the oil separator. However, oil additives of
any type should not be removed from the oil. It is necessary that an oil vapour
extraction must be provided for this equipment. The oil separator delivered shall
be of the self-cleaning design.
The different oil systems are to be made easily distinguishable by a clear
arrangement and different colouring.
A suitable sampling device shall be provided for the oil tank.
265
The scope of the system should include the lube oil transfer pump and motor,
clean and dirty storage tanks and lube oil conditioning equipment. All piping
from the lube oil storage tanks to the lube oil conditions, to the main turbine
reservoir and the lube oil conditioner to the rooftop vents is included.
2.3.4 Insulation
In order to avoid a possible penetration of oil, insulation with an oil-tight hard
cover is to be provided for the turbine. Damaging heat radiation on to the
foundations must be avoided.
Asbestos insulating material will not be accepted.
Hot sections which cannot be insulated, such as for example observation
openings, are to be provided with a corresponding contact protection.
All external thermal insulation shall be of the blanket type and be capable of
removal and replacement for overhaul purposes without damage. Thermal
insulation shall be provided, where appropriate, to prevent adjacent concrete
surfaces from reaching excessive temperatures.
2.3.8 Condenser
266
The design of the condenser shall comply with the design data of the
turbine generator. In dimensioning the heat exchange surface it must be
assumed that all the load cases must be met even if 10% of the condenser
tubes are blocked. Under-cooling of the condensate is to be avoided. The
pressure design on the steam side must at least cover the range from full
vacuum to bar gauge and, on the water side, at least 3 bar gauge.
The water side of the condenser is to be divided into two independent
halves. Each half must be so dimensioned that the turbine generator can be
operated with corresponding decreased load while the other half is out of
action. The condenser has to meet the requirements of the main cooling
water system with respect to material. The Contractor must show that
sufficient experience with the chosen material is available; in particular
reference shall be made to the expanding of the tubes into the tube plates
and the welding of the tube plates to the condenser shell.
Dangerous vibrations of the condenser tubes must not occur during operation. Therefore a corresponding number of carbon steel tube support plates
must be employed. If necessary, baffles are to be provided to protect the
tubes. The holes in the tube plates and tube support plates shall be accurately drilled, renamed and chamfered on both sides to facilitate assembly
of the tubes. Sufficient space is to be provided for withdrawal of the
condenser tubes.
Each half of the water chamber shall contain venting and water drain
connections of adequate size. Sufficient and manually actuated venting at the
cooling water side in case of sudden outage of the main cooling water pumps is
to be provided. The water side of the condenser is to be designed so that
satisfactory functioning of the continuous condenser cleaning equipment is
ensured.
The water side of the condenser is to be designed so that satisfactory
functioning of the condenser cleaning practice by chemicals is ensured.
The arrangement of the condenser must be such that no unacceptable forces
can be exerted due to thermal expansion, over-pressure or. the filling of the
steam space with water.
In addition, the condenser must be suitable for accepting all drains occurring
during start-up or operation.
A suitable number of manholes with internally held covers is to be provided on
the steam and water sides of the condenser having at least a nominal bore of
500 mm. Furthermore, means of observing the vulnerable condenser tube
regions must be provided.
The capacity of the hotwell shall correspond to a condensate flow of at least
2.5 minutes during full load condenser operation. The complete control loop for
controlling the hotwell level including minimum condensate flow and control
valves is part of the condenser. Local pneumatic control devices are not
267
accepted.
AIl connections in the vacuum area must be welded.
268
The installation height of the pumps and the NPSH value of the pumps are
to be matched to one another so that there will be sufficient suction head
even under the most extreme operating conditions.
269
Particular attention will be given to the insulating and securing of the rotor
winding and its connections to avoid vibration and the possible failure of
either conductors or its insulation. Rotor retaining rings will be thoroughly
tested before application to the generator rotor (ultrasonic penetrate
inspection).
An earthing brush has to be fitted at a suitable position on the shaft, which
is free from contamination by oil etc. Brush changing should be possible
safely and easily while the generator is operating. Where necessary
suitable precautions shall be taken against harmful flow of shaft currents by
the provision of insulating bearings. Insulation provided for this purpose has
to'" be designed to withstand a test voltage of 2 kV AC.
Generator bearings
The bearings shall be of the metal sleeve type and designed so as to be
readily accessible and replaceable without the removal of the rotor.
All bearing oil wells shall be provided with visual oil level indicators and
ready means of checking oil flow, filling and draining.
Thermometer pockets must be provided on each sleeve bearing with a dial
type thermometer with adjustable alarm contacts to provide. warning of
excessive oil temperature ..
Bearings dependent on lubricating oil has to be provided with a complete
and approved lubricating oil system capable of maintaining the continuous
operation of all parts of the machine, without undue heating, at all loads,
together with the necessary equipment to provide suitable lubrication during
normal start-up and shut-down, emergency shut-down, barring and all other
conditions. The system for the generator will be part of that for the prime
mover and automatically maintained.
Generator excitation system
Provision shall be made for testing the excitation equipment without the
operation of the main generator.
A brush less rotating diode type (RE) of excitation system or a terminal-fed
static excitation system (SE) may be supplied, provided the Bidder/Contractor can prove this is his standard system and there is proven and extensive
experience on installations in similar locations to the Site.
A block diagram of the complete excitation system has to be supplied
together with the constants of the transfer functions for the control and
stabilizing circuits. The time constant of the exciter shall also be included.
The over-current capability for the generator shall be 150%, 30 s.
The nominal exciter response has to be not less than 0.5 s1.
270
The continuous rated current and voltage of the main exciter has to be not
less than 110% of the generator excitation current and voltage required to
maintain rated output at the terminals of the generator. The ceiling voltage
must not be less than 200% of maximum continuous rating.
Rotating exciters have to be of the enclosed ventilated type. IP54. They will
be directly driven by the generator.
Anti condensation heaters shall be provided in the air circuits of the exciter.
The leads from the heaters has to be brought out to an isolator located
close to the bed plate with suitable interlocks provided to energise the
heaters with the generator at stand-still.
Ventilating air for rotating AC exciters should be closed circuit cooling.
incorporating an air-to-water heat exchanger. and shaft mounted fans.
Generator exciter
Rectifiers for RE system
The rectifier bridge will comprise a simple three phase full wave configuration. Each bridge arm shall consist of a number of diodes in parallel per arm
with suitable protection incorporated.
Particular attention should be paid to the full load and field forcing requirements of the generator in addition to the protection of the diodes.
The repetitive peak reverse voltage rating of the diodes in each arm of the
rectifier bridge shall be greater than the maximum reverse voltage
appearing across an individual diode by a factor of at least 2.0. The
maximum reverse voltage appearing across the rectifier bridge will be
determined from a calculation of the induced voltage following a faulty
synchronization.
Suitable surge suppression equipment shall be provided across the rectifier
bridge if necessary to afford overall protection of the rectifier against
excessive over voltages
In order to protect the diodes when connected in parallel. either each diode
should be protected by an H.R.C. fuse together with individual R-C circuit
suppression and diode failure indication or. if the Bidder/Contractor can
demonstrate that individual fuse protection is not required. consideration
will be given to incorporating such fuse protection in the AC leads from the
exciter. Preference will be given to those schemes uti!ising diodes of
sufficiently high peak reverse voltage capability such that the requirement
for individual diode R-C circuit suppression may be elimin;1ted.
The diodes in the rectifier bridge has to be continuously rated such that
generator full load. field forcing, fault conditions and a reserve capability of
at least 20% can be carried with one failed device per bridge section. A
diode failure detection device is required to monitor all diodes forming the
271
272
the standby AVR channel will be continuously monitored, and system operation
and protection shall be unaffected by transfer of control from one channel to
another.
273
274
9 positions
1 position
1 position
18 positions
1 position
1 position
2 positions each
2 positions.
Each indicator must have adjustable settings for initiating a high temperature alarm which shall be independent of the temperature indication selected.
The leads from the temperature detectors have to be brought out to a
terminal box on the generator in a position which is accessible during
normal operation of the set. All temperature detectors shall Rave the same
characteristics. A multi-point temperature indicator with selector has to be
mounted in the central control room.
Generator cooling equipment
The generator cooling system must be complete and include all necessary
275
coolers, fans, pumps and control apparatus as required for safe and
efficient operation of the plant and has to comply with the requirements of
IEC 34-3.
As cooling systems the following has to be provided:
Internal closed-cooling cycle with air-to-water coolers (incl. one stand by
cooler) as preferred solution, cooling classification of complete generator
IC7A1W7,
or alternatively
internal closed-cooling cycle with water cooling directly through stator
winding and rotor winding together with internal closed-cooling cycle with
air-to-water coolers (incl. one stand by cooler) for the remaining parts,
cooling classification of generator stator and rotor windings IC3(W7)W7
and of remaining parts IC7A1W7.
If H2 cooled Generator is proposed, Contractor has to supply, install 2x 100%
capacity H2 Generator, 02 nos. of H2 compressor (for H2 storage bottles), H2
storage bottles, on line H2 analyzer, H2 dryer, Co2 system etc.
The generator coolers etc. must he sized so, that rated generator output at
class B operation can be mainlained with 10% of the tubes blocked. The
cooler and isolating valves have to be arranged to permit easy isolation and
cleaning of individual sections after shut-down. With one cooler section
withdrawn, the operation of the generator can be continued at rated generator output, utilizing the thermal limits of class F.
The cooler tubes shall be mounted and supported to allow for the effects or
expansion and vibration. Any necessary apparatus required to withdraw the
air coolers or permit repair has to be provided. Water leak detectors must
be provided for all coolers, which will initiate an alarm in the event of a leak
occurring.
CO2 equipment
CO2 systems have to be provided, including the individual CO2 bottle
storage close to each generator, the bulk CO2 storage plant (outside
machine house) and all required equipment for satisfactory operation, such
as piping to the generator housing and to the bulk CO2 storage plant,
:valves, vaporizer, fittings, hangers, supports, control and supervision.
Generator main connections (GMC)
The GMC's are to be designed ns self-cooled isolated-phase busduct system
protected against contact and designed for indoor and outdoor installation. The
complete GMC system must be provided with the necessary current and
voltage transformers, earth switches, star point connections for the generator,
overvoltage capacitors. isolating links li)r the unit auxiliary transformer and all
required fittings and internments.
276
The basic circuit of the GMC's and the instrument transformers and other
equipment is shown in Annex B8-2. All the necessary controls, regulating,
measuring and monitoring instruments including meters are to be provided
locally and/or in the central control room.
The GMC's are to be designed for the thermal and dynamic maximum
short-circuit currents occurring. All supporting and other constructions both
inside and outside the GMC, where not made of aluminum. must be made
in a hot-dip galvanized design. In the GMC-branch busduct to the unit
auxiliary transformer isolating links are to be provided in the single-phase
busbars. Anti condensation heaters are to be provided in each separate
GMC section.
GMC generator star point
The star point is to be made directly behind the generator bushing type
current transformers provided for this purpose. This high voltage section is
to be enclosed by a cubicle unit with solid metal walls. The earthing transformers as required by the generator stator protection system may be
arranged also in this cubicle if applicable.
GMC connection cubiclcs
Along the indoor run of the GMC's, all further auxiliary items such as
voltage transformers, overvoltage capacitors, earthing isolators, etc. are to
be housed in steel sheet cubicles.
GMC current and voltage transformers
All current transformers (CT) and voltage transformers (VT) are to be
provided in accordance with lEC 144 respectively lEC 186.
A tripping time of live seconds is to be taken as a basis for the thermal
stability of the transformers in the GMC's. The current transformers will be
or the toroidal type, cast resin insulated.
GMC transformer and cubicle connections
The generator step-up transformers and unit auxiliary transformer are to be
connected in a way that, in the event of any short-circuit forces, no harmful
deformations can occur.
The distances between the individual transformer bushings and therefore
the spacing and height of the main generator busducts arc to be selected
so that both repair and maintenance work can be carried out without any
difficulty.
In the case of three-phase terminal cubicles arc-proof partitions are to be
provided between the phases for both the generator and the transformer
connection.
277
278
279
280
Turbine speed greater than maximum [at least two (2) independent speed
checks for 110/112% with the possibility of testing during continuous
operation]
281
Strainers should be included in the suction lines to protect the pumps from
damage under all operating conditions. The strainer mesh size should not
exceed 0.4 mm. The strainer and strainer body must be matched so
th:.1lthe full area of the strainer is utilized. The free area of the strainer must
he at least equivalent to 5 times the cross-section m-ea of the
corresponding suction pipe.
The rotor design shall be sub critical.
282
283
nesses for the feed tank and deaerator shal1 have a corrosion allowance of
at least 3 mm. The tank must be suitably stiffened to safely withstand Cull
vacuum.
All valves and fittings directly above the feedwater tank must be accessible
from platforms.
284
The LP feed heaters shall be of standard horizontal tube-plate type with Utubes. A welded-on hotwell shall be provided for water level control (if
required). The material of the tubes shall be of stainless steel.
All pipe collections and all connections on the vacuum side shall be welded.
Valves and other fittings exceeding nominal size of 25 mm which are
continuously or intermittently under vacuum shall be provided with seal
water connections.
Shell and tube bundle shall be equipped with effective baffle plates and
protection at the steam and drains inlet. Particular care shall be taken for
proper air extraction so that no air pockets can form inside the heat exchangers.
HP feedwater preheaters
During low-load operation of the turbine, when the pressure in HP
feedheater is no longer sufficient to drive the condensate into the feedwater
tank, the drain is led to the condensate drain tank (if necessary via a flash
tank) via a low-load drain control system. The automatic switchover of the
drain from the feed water tank to the storage tank and vice versa should be
done dependent on the pressure difference between HP heater and feed
water tank considering a suitable hysteresis characteristic.
Adequate provision must be made to protect the turbine against the
backflow of water from the HP feedheaters. If the water level rises excessively the feedwater line must be automatically by-passed and
simultaneously the motorized shut-off valves and the emergency check
valves in the bleed lines upstream the feedheaters are to be closed without
tripping the turbine.
It must be possible to operate the feedwater bypass valves of the HP feedheaters either manually or automatically. Automatic operation should be by
means of separate level monitors in the HP feed heaters. The operation of
the bypass valve shall not initiate turbine trip.
In case of pipe burst in the HP heaters the 2 out of 3 high level trip shall
initiate immediately the isolation of the HP heaters and bypassing the
feedwater.
The safety valve to be provided on the shell side of the HP feedheaters
must be capable of discharging the max. leak rates of the emergency shut
off valves.
The HP feedheaters shall be designed according to ASME and shall be AS
ME stamped heaters.
All connections must be welded. The feedwater tubes must be
manufactured from high-strength steel. Adequate provision must be made in
the design for the possible expansion of the tubes and internals under the
285
2.3.19 Tanks
Drain condensate tank
The drain condensate tank must be dimensioned for the maximum volume
of condensate arising from the atmospheric flash tank and tundish drains.
The inside tank overflow line is to be so dimensioned that the maximum
inflow of condensate can be discharged without the outflow velocity in the
line exceeding 0.8 m/s. The tank is to be of the horizontal cylindrical type
and mounted as low as possible so that an adequate head exists for all
infeeds.
The condensate level in the drain tank shall be automatically maintained
constant by means of control valve on the pressure side of the condensate
drain pumps. A common line for tank overflow and tank draining is taken to
the hot drainage system. The condensate-coming from the flash tank has
to be introduced into the tank below the lowest condensate level by way of
a pipe with nozzles. The pipe is to be fixed inside on the tank bottom and
must have a clear discharge cross section of at least 2.5 time the pipe
cross section.
Atmospheric flash tank
The atmospheric flash tank is a vertical cylindrical tank which must be so
dimensioned that the steam and condensate are properly separated and
can be separately discharged. The condensate will be discharged to the
drain condensate tank, the steam' to the atmosphere. The condensate
fed to the atmospheric drain flash tank can be run through common
collecting pipes with tangential inlet into the atmospheric flash tank.
Only condensate at approximately the same temperature and pressure can be
combined to a common header. the collecting pipes are not to be arranged at
the same height on the tank circumference.
286
In normal cases one pump will be in operation. The second pumps shall
start automatically if the operating pump trips.
The pump motors arc to be so designed that even with 25% overload the
pumps will not be switched off. Pumps and driving motors arc to be supplied
on a common base plate.
The installation height of the pumps and the NPSH value of the pumps are
to be matched to one another so that there will be sufficient suction head
even under the most extreme operating conditions.
2.4
Technical Schedules
The following technical schedules comprise part of this specification. The data
and requirements specified in the respective forms arc to be adhered to and
the missing data of forms arc to be completely filled in. The completed
technical schedules arc to be submitted with the Bid.
B2/FB Performance and Design Data
B2/FD Technical Data by Bidder
287
Unit
Data
Turbine
Reheat condensing
steam turbine
Turbine type
Number of turbine casings
MW
250 + 10%
According to IEC
recommendations
latest edition
104
-0/+3
Frequency
Hz
50
-3 to +3
-4
-5
minimum 6
max. 10
m/s
2.2
Design pressure
bar
full vacuum
110
m/s
mm
without limitations
Condenser
1.5 or according to
requirement of
sponge ball
cleaning equipment
17
B2/FB-1
288
Unit
Data
Generator
Rated voltage at generator terminals
kV
Select between
(11 - 15.75) 5%).
Rated frequency
Hz
50
cos phi
0.80
cos phi .
%
0.92
17
0.50
kV
12 - 17.5
Operating voltage
kV
Rated frequency
Hz
Select between1115.75
50
kV(peak) 75 - 95
kV
50
Type of ducts
Single-phase.
self-ventilated
1
0.5M5
5P20
110/ 3,110/3
0.5/0.2
Rated voltage
kV
12 - 17.5
kV(peak) 75.-95
kV
Earthing switch
28 - 38
B2/FB-2
289
Minimum Requirements
Unit
Data
Design pressure
120% of respective
maximum turbine bleed
pressure and full
vacuum
Max. turbine low load
temperature
Design temperature
C'
LP feedheaters
Design pressure of LP feedheaters (steam side)
120% of respective
maximum turbine bleed
pressure and full
vacuum
HP feedheaters
Design pressure of HP feedhealers (sleam side)
120% of maximum
operating pressure
Maximum operating
temperature plus 20 K
120% of maximum
delivery head of the
feedwater pumps at
minimum flow and cold
conditions
2 x 100%
B2/FB-3
290
Bidder/Contractor
Unit
Data
MW
bar
kg Is
kg/s
bar
Exhaust moisture
rpm
Steam Turbine
Manufacturer
Type
Casings
Number of casings
Casing design HP
Casing design IP
Casing design LP
Rotors
mm
LP shaft
mm
B2/FD-1
291
Bidder/Contractor
Unit
Data
Blading
HP regulating stage:
Type of wheel
Mean blading diameter
mm
bar
HP/IP blading:
Type of H.P./I.P. blading (impulse/reaction)
Number of stages
Length of blades last row
mm
mm
LP blading:
Type of LP blading (impulse/reaction)
Number of stages
Length of blades last row
mm
mm
m2
Materials
LP nozzles
LP rotor blades
(HP-steam; reheat-steam)
Casing of HP-steam governor valves
292
Bidder/Contractor
Unit
Data
rpm
rpm
rpm
mm
Type
Actuator
Reheat-steam governor valve
Number of valves
Size
mm
Type
Actuator
Bleed steam emergency shut-off valves Type
Manufacturer
Type
Bearings
Number of journal/thrust
bearings Type: Journal
Thrust
Maximum oil outlet temperature
B2/FD-3
293
Bidder/Contractor
Unit
Data
Dimensions
Total length of turbine generator
Length of foundation
Width of foundation
Height of foundation
Weights
Heaviest part to be handled by crane
warming-up time
min.
min.
min.
warming-up time
min.
min.
min.
warming-up time
min.
min.
min.
Turning device
Method of operation
rpm
Drive
Rating
kW
B2/FD-4
294
Unit
Data
Materials:
Tubes
Shell
Gland exhauster
Number of exhausters
Type
Rating
kW
Oil Supply
Tank capacity
m3
I/h
bar(g)
Drive
Speed
rpm
-/%
-
Rating
kW
Speed
rpm
Type
B2/FD-5
295
Bidder/Contractor
Unit
Rating
kW
Speed
rpm
Data
Type
Rating
kW
Speed
rpm
Type
Rating
kW
Oil cooler
Number of coolers
Erection (horiz.lvert.)
Cooler length
mm
Materials:
Tubes
Shell
Oil separator
Manufacturer
Type
Heat rating
kW
Rating of drive
kW
B2/FD-6
296
Bidder/Contractor
Unit
Type
Grade of filtration
Data
bar(g)
Type
Rating
Speed
kW
rpm
-
Grade of filtration
Condenser
Total number of condensers
Manufacturer
Type
Arrangement
kg/s
m3/h
K
bar
kJ/m2sK
m2
B2/FD-7
297
Bidder/Contractor
Unit
mm
mm
mm
Data
-/mm
Materials:
Tubes
Tube plates
Shell
Water boxes
Hotwell capacity
minutes
Number/capacity of pumps
Manufacturer
Type
Nominal capacity
m3/h
Delivery head
Motor rating
Closed valve head
kW
m
Speed
rpm
Type of bearings
/ %
Designation of system
Designation of system
B2/FD-8
298
Bidder/Contractor
Unit
Data
Vibration. high
Fire protection
Generator protection
Vibration Measurement
Manufacturer
Designation of system
Method of operation
B2/FD-9
299
Unit
Data
Material of tubes
/%
-
Synchronous generator
Applicable standards
Manufacturer
Type
Protection class
MVA
cos phi
cos phi
MW
Rated voltage
kV
Rated frequency
Hz
Rated speed
rpm
kA (peak)
kWs/ KVA
kV
kV
B2/FD-10
300
Unit
Data
mm
m
kw
V
A
V
A
V
KW
%
m
m
Total width
Generator weights
Stator weight
Rotor weight
Transport weight complete generator
-/t
t
t
t
B2/FD-11
301
Bidder/Contractor
Unit
Data
Hz
msec
El
Number of cabinets
Auxiliary voltage
kV
Rated frequency
Hz
Rated current
kV(peak)
kV
kA(peak)
kA
B2/FD-12
302
Bidder/Contractor
Unit
Data
metering
protection
Secondary voltage of voltage transformers
metering
protection
voltage regulation
Earthing switch
Manufacturer
Rated voltage
kV
Rated frequency
Hz
Rated current
kA(peak)
kA
kV .
kV(peak)
yes/no
Protective capacitors
Type
Number of capacitors
Nos.
Rated voltage
kV
Rated frequency
Rated capacity
Hz
nF
dB(A)
B2/FD-13
303
Bidder/Contractor
Unit
Data
t/h/%
t/h/%
Feedwater pump
Number of pumps /each pump capacity
Manufacturer
Type
Minimum capacity
No. of stages
Type of journal bearings
Method of axial thrust hydraulic compensation
Type of axial bearings
Type of bearing lubrication
Oil supply from
Type of glands or seals
Closed valve head
Materials:
Pump casing
Shaft
Impeller
Total power requirement of feed pump sets when the
turbine is running at MCR
-/%
m3/h
m
kW
VOITH,
Germany
m3/h/m3/h
m/m
kW
304
B2/FD-14
Bidder/Contractor
Unit
%
Data
..
Coupling
Type
Maximum allowable transmitted load
kw
Manufacturer
Type
Materials:
Pump casing
Shaft
Impeller
m3/h
Delivery head .
Power requirement of one pump set at motor terminals
Coupling
Type
m
kw
kw
B2/FD-15
305
Bidder/Contractor
Unit
Data
Type
Rated power
kW
Rated voltage
kV
Rated speed
rpm
Rated efficiency
Starting time
sec.
Protection system
Insulation class
Type of bearings
Type of lubrication
Type
Mode of operation
kg/s
mm
mm
Materials
Shell (where applicable)
Internals
B2/FD-16
306
Bidder/Contractor
Unit
Data:
Feedwater tank
Manufacturer
Nominal capacity
m3
m3
Outside diameter
mm
Total length
mm
Materials:
Shell
Internals
Operating weight
kg
kg
bar
bar
Manufacturer
Type
Heat rate
kJ/s
kJ/m2sK
Drain side
m2
mm
Total length
mm
mm
mm
Materials:
Tubes
Tube plate
Shell
Weight
kg
B2/FD-17
307
Bidder/Contractor
Unit
Data
Manufacturer
Type
Heat rate
Heat transfer coefficient (outside diameter) condensation/drain
Terminal temperature difference
Steam side
Drain side
Total heat exchanging surface (outside diameter)
Shell outside diameter
Total length
Tube outside diameter
Tube wall thickness
Materials:
Tubes
Tube plate
Shell
Weight
kJ/s
kJ/m2sK
K
K
m2
mm
mm
mm
mm
kg
Manufacturer
Type
Heat rate
Heat transfer coefficient (outside diameter) condensation / drain
kJ/s
2
kJ/m sK
Drain side
Total heat exchanging surface (outside diameter)
K
2
m
mm
Total length
mm
mm
mm
Materials:
Tubes
Tube plate
Shell
Weight
kg
B2/FD-18
308
Bidder/ Contractor
Unit
Data
kJ/s
m2
mm
Total length
mm
mm
mm
Materials:
Tubes
Tube plate
Shell
Weight
kg
Manufacturer
Type
Heat rate
kJ/s
Drain side
m2
mm
Total length
mm
mm
mm
Materials:
Tubes
Tube plate
B2/FD-19
309
Bidder/Contractor
Unit
Data
kg
m3
Installation level
Capacity of pumps
Manufacturer of pumps
kW
B2/FD-20
310
311
B3.
3.1
General
Existing coal handling system capacity is 300 MT/ hr which is being used
for existing 2 x 125 MWe units.
Existing Coal handling system is receiving coal from the adjacent coal
mine mouth with storage arrangement in the Power Plant coal yard,
transportation and storage in coal bunkers.
The raw coal from the coal mine to the coal storage area is transported
by a single line conveyor belt system. For the transportation of the
crushed coal from the coal storage area up to the coal bunkers of
existing 2 x 125 MW e units, a double line belt conveyor system is being
used.
A Coal Processing Plant to remove iron, hard materials, waste & large
size coal and to control moisture of coal (within the limit of 10%) shall be
provided at the upstream of existing Magnetic Separator with necessary
modification of relevant coal conveyer system.
A single line coal conveyor belt system with two (02) crusher units shall
be provided from the upstream of existing crusher unit to the new coal
yard with necessary modification of relevant coal conveyer system.
A coal conveyor belt system shall be provided in between new coal yard
and old coal yard.
Extension of existing two coal supply belt conveyors shall be provided from
existing unit no. 2 to the new 250 MW unit complete in all respect to feed
coal to the coal bunkers of the 250 MW unit.
3.2
312
Dryer
Processed coal weighing belt scale etc.
3.3
3.3.1 General
The following factors shall be taken into account on system design and
equipment selection:
safety
reliability
maintainability
minimize indoor and outdoor environmental pollution
standardization of components.
The scope of design and supply of coal handling system include all the
313
314
315
done by front end loaders and loaded to underground hoppers for further
feeding to downstream conveyors of inplant coal handling. Required number
of front end loaders shall also be supplied. Number of front end loaders
shall be adequate to feed the conveyors at 110% MCR of boilers.
The inplant conveyors capacity shall be adequate to fill the boiler bunker in
8 hours operation.
The coal storage areas shall be provided with necessary fire water system
and compacting/dust suppression system.
Covered storage to cater to about 4 days MCR requirement shall be
provided as part of the total coal storage area. The covered storage shall be
constructed with structural steel supports and metallic sheet covering. Size
and arrangement of the covered storage shall be such that it shall not
hamper stacker movement/operation.
316
tripper arrangement shall be given for bunker filling. This system shall
also include bunker sealing arrangement, bunker ventilation system and
traveling tripper conveyor.
Necessary bunker flooring shall also be included.
317
Minimum Requirements
Unit
Data
kg/m3
0.65
kg/m3
1.0
1.1
1.0
hours
m/s
4
2.0
1 x 100%
1 x 100%
1 x 100%
coal crusher
2 x 100%
2 x 100%
magnetic separator
1 x 100%
belt scale
1 x 100%
2 x 100%
mg/m3
0.5
"
B3/FB-1
318
Bidder/Contractor
Unit
Data
Manufacturer
Belt widlh
mm
Height of borders
mm
Handling capacity
kg/h
Belt velocity
m/s
Material of belt
Drive power
kW
Coal crusher
Number
pcs
Manufacturer
Type
Capacity
t/h
Screen dimension
mm
mm
Motors:
manufacturer
type
rating
kW
rated voltage
kV
speed
rpm
Number'
pcs
Location
Rated power
kW
B3/FD-1
319
Bidder/Contractor
Unit
Data
Weighing scale
Type
Manufacturer
Capacity
kg
Accuracy
location
Tripper conveyor
Manufacturer
Type of construction
Number
length
pcs
m
Capacity
kg/h
Width
mm
Belt velocity
m/s
kg/m3
B3/FD-2
320
321
Table of Contents
B4. Air and Flue Gas System
4.1
General
4.2
4.2.1
4.2.2
4.2.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
4.3.7
4.3
322
B4.
4.1
4.2
4.2.1
4.2.2
Flue gas ducts with reinforcements and support structure. isolating and
regulations dampers with electric actuators expansion joints, Venturi
measurements devices, etc. consisting of raw gas duct with ash hopper
between the steam generator out- let and the regenerative air preheater
323
inlet duct, from the regenerative air preheater exit to the inlet hood of the
electrostatic precipitator (ESP), clean gas duct from the exit hood of the
ESP to the induced draft fan (ID fan), common duct between ID fans and
further to the stack inlet
4.3
2 (two) ID fans (with special type impeller blade considering 100% ash
with flue gas causing no damage or unbalance) including electric motor,
forced lubrication system
all necessary isolating dampers (for all ID fan, Coal mill, ESP, flue gas
recirculation fans for plant running maintenance) and regulation dampers
with electric actuators. expansions joints
all measures necessary for damping out vibrations and for noise
attenuation including silencers.
4.3
4.3.1
General
The air flue gas system shall be of the balanced draft type and designed
in two parallel lines. The system shall be completely gas tight.
All the equipment shall be of the high efficiency aerodynamic design
silent in operation vibration free and must guarantee complete safety in
service. All fans shall be dynamically balanced in the factory.
324
4.3.2
325
operation with two (2) regenerative air heaters but one (I) FD fan
respectively one (1) ID fan
326
regenerative air preheater will be possible. The flue gas damper in the
bypass shall be suitably interlocked to avoid that the maximum
permissible temperature of stack will be exceeded.
Due attention shall be paid for the material selection of the flue gas duct in
which during continuous operation the flue gas will be stagnant.
Selection of ducts and dampers within the air and flue gas system shall be
done so that the wet washing of one regenerative air preheater will be
possible. while the boiler will operate on partial load with the other air
preheater in operation. Nevertheless the Contractor has to guarantee
continuous operation of the regenerative air pre heaters without wet
cleaning for the duration stated under "Guarantees" (Guarantee data
sheets BO/FG).
In general, the air and flue gas ducts shall be interconnected by welding.
Only in places where maintenance or repair is required (dampers,
expansion joints, fans, etc.). flanged connections may be provided.
Air boxes for burners shall be designed so that at least each row will be
fed separately.
Connection between boxes for burners and the membrane wall shall be
done by steel expansion joints.
All ducts which are not insulated shall be suitably cleaned and painted for
resistance to corrosion. ducts and flues requiring thermal insulation shall
comply with the requirements of this specification.
327
4.3.3
328
4.3.4
329
The air heater shall be equipped with a 100% bypass at the air side.
Condensate shall be led back to an appropriate point in the feedwater\
condensate system through a trap and a control tank. All steam and drain
piping control and isolating valves. and all other fittings shall be provided
in order to satisfy the above requirements.
Drain condensate pumps of the vertical barrel type shall be provided.
Heating coils shall be easily removable for cleaning and maintenance.
The steam supply can be taken from suitable bleed points on the turbine
(see Heat Balance Diagram). During start-up the steam can be taken from
the auxiliary steam line. The condensate shall be cooled in a cooling stage
at the air inlet to at least 80C when working at MCR.
Drain connections (blind flanges or screwed plugs) shall also be upstream and down-stream of the steam air preheater in the bottom of the
air duct (not only in the steam air preheater frame).
Condensate pipes shall be valved so that the condensate can be returned
to the unit from which the steam is coming from.
The air temperature control shall be performed by means of steam now
control. located at the inlet of the steam air preheater.
330
coolers and all other equipment required for the safe and efficient
operation of the Plant. .
The heating elements shall consist of low alloy steel sheets of not
less than 0.5 mm thickness and shall be properly packed in baskets.
The heating elements shall be spaced and compactly arranged within
sectors of the cylindrical housing, but they shall be kept at a fixed
distance from each other. The individual elements shall be partly or
entirely corrugated or modulated to give a turbulent flow of the gases
and air.
The hot and cold end elements shall be arranged in casings with
removable compartments and the design shall allow for the removal
of the cold and hot end element
baskets through access doors
provided in the AH housings.
At least 300 mm in height of the cold heating elements shall be
enamelled in order to achieve longer service life. The cold end
elements shall. be properly packed in baskets and a sufficient
number of access door provided for easy and fast replacement. The
Tendered shall give full particulars of the material and estimated
performance of the intermediate and low temperature sections and
the frequency of material replacement. Electrical hoist with runways
etc. for maintenance and replacement shall be provided.
Each AH has to be equipped with two drives. The main drive is to be
an electric motor through a gearbox or a hydraulic motor. A standby
motor drive to the same gearbox or hydraulic motor shall be
provided. The drive is to be complete with a self contained lubricating
system which shall include a water cooling system facilities for
manual rotation and rotation monitor of signal that the AH is in
operation shall be provided.
For on-load cleaning integral steam soot blowers for cold and hot
side shall be arranged. The blowing pressure shall be designed with
respect to the thickness of the heating elements. The Contractor shall
take the steam for soot blowing from a source within his limits of
supply. Steam blowing equipment. bearings and other parts which
so require. shall be air sealed to avoid infiltration of corrosive flue
gases.
The sootblowing device has to be designed for the most effective
cleaning of the AH heating surfaces.
The AH shall be equipped with fire extinguishing devices including
fire alarm equipment display panel. The AH elements shall- be
arranged for water washing and all necessary washing equipment
shall be supplied.
The necessary drainage troughs hoppers, pipes, valves shall be
331
supplied.
Adequate sealed and illuminated inspection windows for inspection
during operation and removable door and access ways for
maintenance and repair shall be provided.
If as a result of electrical black-out there is a total failure of the
cooling water supply. the bearings must be capable of performing
without cooling and be safeguarded against over-temperature. An oil
bearing temperature measuring equipment shall be supplied to judge
the oil temperature.
Possibility of hot end and intermediate AH element inspection and
replacement shall be provided (openings with removable covers in
the ducts above the air heaters. internal beams or hooks for lifting the
elements).
External hoist with trolleys and beams to extract the elements or
sufficient length, electrically operated, shall be provided.
Initial thickness measurement of cold end elements has to be carried
out as spot-checks before commissioning that corrosion resistance
can be proved after 6.000 operation hours by measuring the sheet
thickness again for operational informal ion.
The seals between the primary and the secondary portion shall be
designed like those between the secondary portion and the flue gas
ducts. i.e. with moveable. multi-part, radial sector plates, capable of
following automatically the rotor deformation as well as with shell
seals likewise moveable. Both. the radial and the shell seals shall be
readjustable from outside during operation.
Ten (10) thermocouples up to a local control box shall be supplied for
each AH to judge the cold end element temperature to avoid cold end
corrosion .
The external surfaces shall he insulated in accordance with the
requirements of this specification (see Chapter B06).
4.3.6
332
4.3.7
333
334
335
Unit
Data
Air flows
m3/s
m3/s
m3/s
m3/s
m3/s
m3/s
m3/s
m3/s
Stack inlet:
wet/dry (m3 at 0 0C, 1013 mbar)
m3/s
m3/s
Air pressure
FD fan outlet
mbar
mbar
mbar
Primary side
Secondary side
mbar
Primary side
mbar
Secondary side
mbar
Before burners
mbar
Combustion chamber
mbar
Before superheater
mbar
Before economizer
mbar
mbar
Before ESP
mbar
B4/FD-1
336
Unit
mbar
mbar
mbar
Data
mbar
Air temperatures
Ambient
Primary part
Secondary part
C
C
Pulverizer inlet
Forced draft fans
Manufacturer
pcs
Number
Type of construction
m/s
mbar
pcs
%
kW
FD fan motor:
Manufacturer
Power
kW
Related voltage
kV
Speed
Cooling water consumption
rpm
kg/s
B4/FD-2
337
Unit
Data
Type
Number
Type of bearing
Fan speed
rpm
Inlet temperature
Manufacturer
Number of steam air preheaters
pcs
m2
kg/s
bar
kg/s
bar
Tube material
Fin material
Pitching of fins
Thickness of fins
mm
mm
t
Weight
Regenerative air preheater (RAH)
Manufacturer
Number
Type
pcs
-
Heat exchanged
MW
m2
m
B4/FD-3
338
Unit
mm
mm
kg/s
kg/s
kg/s
kg/s
t
Data
Rotational speed
mm-1
Manufacturer
Type
Rating
Rated voltage
kW
kW
Speed
min
-1
Manufacturer
min
min
kg
kg
-
B4/FD-4
339
Unit
Data
Washing medium
kg/s
Type
pcs
kg/s
Number
Flow rate
Induced draught fan (ID fan)
pcs
Manufacturer
Type
kg/s
mbar
kg/m3
%
kW
Efficiency at MCR
Max. allowable flue gas temperature
Type of controller
Gearbox manufacturer
Type
Range of control
Manufacturer
Type
Rating
Rated voltage
kW
kV
Speed
min-1
kg/s
B4/FD-5
340
Bidder/Contractor
Unit
Data
Type of construction
Number of fans
pcs
3
m /s
Capacity of each
m /s
Static head
mbar
Manufacturer
Power
kW
Rated voltage
kV
Speed
Cooling water consumption
rpm
kg/s
Number of ESP
pcs
pcs
m2/m3/s
Collecting electrodes
Type
Thickness
mm
-
Material
Number per treatment zone
Effective height
m2
Pitch
mm
2
2
B4/FD-6
341
Unit
Data
Discharge electrodes
Type
Thickness
mm
Material
mm
pitch
mm
mm
Type of rectifier
Discharge electrodes
Frequency or rapping
Steel casings
Thickness
mm
mbar
mm
Hoppers
Number of dust hoppers per precipitator
kg/m
mm
B4/FD-7
342
Unit
Type of rapping
Data
g/m3
CO2 content
Gas temperature
dry
m3/s
wet
m3/s
%
g/m3
furnace outlet
g/m3
ESP inlet
g/m3
mg/m3
P/o
mls
Treatment time
Draught loss
s
mbar
kW
t/h
B4/FD-8
343
344
General
5.2
5.3
345
B5
5.1
General
The design and supply of the ash handling system shall include all ash
handling equipment necessary to remove the ash from following sources:
5.2
5.2.1
346
complete ash conveying system starting from ash/slag crusher outlet up to the
bottom ash silo inlet including belt conveyor tripping conveyor (or shuttles)
driving units complete with gear and motors
protection devices corner tower und transfer stations (if necessary), supporting
structure together with galleries stairs, gangways, cladding of steel structure.
structural members Il)r fixing lining appliances for dismantling of various components
bottom ash silo including lining, steel support structure, shut-off gate,
loosening and discharge equipment, hopper, all mechanical, electrical and
control equipment associated with the silo
protection facilities to protect equipment against the adverse effect of process
water
drag link conveyor below the bottom ash silo
truck unloading facilities
hydraulic ash discharge including mixing vessel.
5.2.2
ash hoppers under the second flue gas path (if any) regenerative air
preheater and ESP including one manually operated shut-off valve and one
automatic opening gate for each hopper
complete electrical trace heating system to all hopper, ash chutes, rotary
locks, cellular wheel sluices
jet conveyors for each extraction hopper together with compressed air cock
and fans for jet conveyors (one 100% standby) including base frames electric
motors. Sound attenuation facilities (silencers. sound insulation)
all interconnecting pipe work and valves for jet conveyor air
all connecting pipes from the jet conveyor up to the intermediate fly ash
bunker
Intermediate fly ash bunker, together with cyclone separator for waste air
purification; electrically or pneumatically actuated gates to be installed under
the bunker and electric heating facilities for heating of the bunker hoppers
ash pressure vessel conveyors (one in standby) consisting of pressures
vessels ash inlet valve air intake valve control and vent valves drainage
valves pressure nozzles and all sensors actuators and instruments for
functional group control
rotary air compressors inclusive bed plates anchoring bolts coupling electric
motors, silencer, air suction, filters non return valves, safety valves, air
coolers air storage tanks. all necessary instruments and sound attenuating
insulation (if required)
fly ash silo waste air filters of the bag filter type, including filler with bunker
mounting collar, rappers with actuators, suction and scavenging air fans,
inclusive coupling and motors
all necessary interconnecting pipe lines and valves between ash pressure
vessel conveyor, intermediate bunker, fly ash silo rotary air compressors blowoff silencers
.
fly ash silos including lining, steel support structure, with bottom fluidizing
equipment (fans, gates, pipes, hopper, all mechanical electrical and control
347
5.2
5.3
5.3.1
General features
The design of the fly ash and bottom ash (slag) handling system shall be based
on the following considerations:
The ash and slag disposal are (ash settling pond) will be located inside the boundary of the Power Station. There for transportation or ash and slag shall be made by
suitable conveyor systems. Silo discharge facilities for bagging (50 kg bag) and
truck Ioading has also to be provided.
The location of storage and loading facilities (silos, bunkers. etc.) shall allow a
centralized handling or fly and bottom ash irrespective or the design/system
variant chosen. The arrangement of these facilities shall not interfere with the
operation area of the boiler.
All possible measures shall he taken to protect components which are coming into
direct contact with process water against its adverse effects (use of material, etc).
The ash handling system shall be designed and constructed in view of a "dust
free" operation.
The ash handling system shaII be operated fully automated.
Fly ash shall be collected from the flue gas pathes of the steam generator (if
applicable), the air hoppers and from the hoppers of ESP. It shall be envisaged
to conveyed as much as possible fly ash with pneumatic conveyors. A dense
lean phase dry pneumatic system (e.g. air slide) under each fly ash hopper to
convey the fly ash to the fly ash silo shall be installed.
The discharge of the ash resulting from some of the above points into the
bottom ash removal system will also be accepted, provided the ash
temperatures necessitate it for safety requirements.
348
5.3.2
349
way that the wet slag can be cooled in the water basin and extracted by
conveyor equipment without a problem at all boiler loads and the total coal
range.
Floating ash/sing is to be prevented by means of a corresponding arrangement of
water spray.
One submerged scraper conveyor is to be arranged under each ash/sing chute of'
the boiler furnace. The submerged frame in the water basin must guarantee an
absolutely tight seal against air ingress into furnace.
The drag link scraper ash/slag extractor shall be of the semi-wet type. The lowest
part of the conveyor shall be located under the furnace hopper. Consideration shall
be made with regard to the relative expansion of the furnace and the drag link
scraper and to exclude the intrusion of false air via the extractor into the boiler.
Bottom and side walls of the extractor shall be lined to avoid excessive erosion.
The quenching water shall be injected into the conveyor in the part were the slag is
falling into the water bath in order to smash the big pieces of slag.
The removable submerged scraper conveyor is to be manufactured in welded
plate construction with profile stiffening brick lining cooling water overflow basin
including water discharge pipe (including draining equipment).
The drive motor of the conveyor chain is to be connected to a hydraulic item and
via elastic coupling to a step-down transmission. By means of a continuously
variable adjustable gear the conveyor speed shall be adjustable to the respective
quantities of ash/slag as to minimize wear.
The capacity of auxiliaries shall be selected under the consideration that for load
changes the ash flow may reach three times the ash now at normal continuous
operation. Due to the above the conveyer shall be equipped with drive with
variable speed and with safety clutch.
The slag extractor shall be equipped with a device enabling to change over from
dumping on the conveyor belt to dumping into a small hopper from which the
bottom ash can he taken over by a trolley.
Suitable openings for inspections shall be provided.
5.3.2.1 Crusher
The crusher shall he provided with dust proof shaft passages. Casing doors shall
with quick look for checking and exchanging wear pans.
The shaft shall be supported from both sides in amply sized and dust proof self
aligning roller bearings.
For conveyors or short length, fixed installed tension devices may he used while
for conveyors of longer length tension carriages or equivalent self-regulating
350
351
Belt scrapers shall be arranged at the discharge pulley and, if necessary, for
tail pulleys.
Material and construction of covering plates between upper and lower discharge
hoods and product guides shall be chosen in view of optimum sliding behaviour
of the product, avoidance of clogging and limitation of noise. Material shall be
stainless steel, reinforced fibre glass or equivalent. Rubber aprons for guidance
shall be provided.
Gears shall be of the lip on type. Flexible or hydraulic start-up couplings
(depending on requirements) shall be used.
Retention assemblies such as limit switches, true run switches, belt monitors,
lanyard switches shalI form part of the mechanical equipment of the
conveyor plant
352
worm conveying system using process water. For fly ash silo fly ash fluidization
shall he provided.
The following requirements have to be considered by the Contractor:
all the pressure vessel conveyors, conveyor lines and switch points are
to be provided for 100% quantity at five conveyor cycles per hour
the exhaust air filter unit-located on the intermediate bunker (if necessary) is
to be supplied redundantly
all the bends and loops in the conveyor lines to the fly ash silo are to be
provided with wear protection lining (fusion-cast basalt)
.
all the service and instrumentation air stations are to be designed
redundantly in total
the service air for low pressures up to 1.5 bar is to be generated by rotary
piston blowers; the service air for higher pressures and the instrument air
are to be generated by screw type compressors. All the compressors must
be completely designed as dry running compressors
'
air receivers and adsorption dryers are to be connected down stream of the
screw type compressors; air heating is 10 be provided for the rotary piston
blowers (if necessary)
all the units are to be provided with a sufficient number of inspection, poker
holes and drain holes
all fly ash pipes have to be equipped with tube connections (studs) and
valves for blowing fee the pipes in case of blockages
all hopper gates, ash chutes, rotary locks, air conveying chutes, etc. are
to be equipped with electrical heating systems (if necessary)
all ash silos have to be equipped with anti-bridging devices
all fly ash conveying equipment, the complete exhaust air filter unit as well as
the piping with heated air are to be provided with insulation as well as
insulation cover plates
exhaust fans connected down stream of the exhaust air fillers are to be
equipped with vane controllers to keep the vacuum in the ash silo constant
a sufficient number of duct isolating valves are to be installed in the air
slide system so that certain chute sections can be closed for repairs
during operation
fine meshed grates above the duct cloths installed in the air slide are to be
provided.
fans and blowers must be designed with two bearings
shafts of dust conveying units must in addition to the usual seals, also be
provided with grease seals to avoid dust exit (with arrangement of
bearing and seal in and housing).
353
354
355
This also includes all the piping to the jet conveyors as well as their continuation
to the fly ash silo, respectively intermediate bunkers including all fittings and the
jet conveyors.
The compressed air stations are to be designed in accordance with state-of-theart technology, including for example standby quick throw-over switches, dryers,
storage basins and condensate discharge lines as well as electrical binary and
analog measurement equipment.
.
356
Unit
Data
as per Annex
MCR of boiler
1.1
1.0
combustion chamber
25
15
90
days
days
Net storage capacity of the intermediate fly ash bunker corresponding to the
ash production at MCR
hours
Net retaining capacity of the hoppers of the ESP corresponding to the ash
production at MCR
hours
Capacity of bagging system and truck loading devices shall permit the
emptying of the bunker content within
hours
m/s
2.0
1 x 100%
Ash/slag crusher
1 x 100%
1 x 100%
1 x 100%
1 x 100%
2 x 100%
1 x 100%
2 x 100%
2 x 100%
2 x 100%
2 x 100%
B5/FB-1
357
Unit
Data
Operating data
Data shall be filled in for guarantee coal at MCR
Ash resulting from:
furnace
kg/h
nd
kg/h
kg/h
ESP
kg/h
kg/h
kg/h
kg/m
kg/m
kg/m
kg/m
kg/m
kg/m
kW
m /h
kg/h
kg/h
kW
m /h
kg/h
kW
kg/h
B5/FD-1
358
Bidder/Contractor
Unit
Data
Design Data
Bottom ash handling system
Submerged link scraper slag extractor
Number
pcs
Type
Conveying capacity
Turndown range
Gradient of the inclined section
Type of chain
kg/s
-
m/s
m
m3
manufacturer
type
speed
quantity
Weight of conveyor
Content of sediment in the water
Water content in ash/slag at extractor outlet
Crusher for ash/slag
Manufacturer
Type
Number
Capacity
Power demand
Bulk density
Screen dimension
Final grain size
kW/ kV
rpm
kg/s
kg/h
t
mg/l
%
pcs
t/h
kW
kg/m3
mm
mm
B5/FD-2
359
Bidder/Contractor
Unit
Data
Motors
manufacturer
type
rating
kW
rated voltage
kV
Speed
Min-1
Belt conveyors
The Bidder/Contractor shall fill in the following data for each
belt conveyor.
Type
Manufacturer
Belt width
mm
Height of borders
mm
Shaft centres
Handling capacity
kg/s
Belt velocity
m/s
Drive power
kW
Type
Net volume
Overall dimensions (length/width/height)
m/m/m
Inclination of bottom
Material
shell
--
bottom lining
--kg/h
B5/FD-3
360
Bidder/Contractor
Unit
Data
pcs
Type of gates
Size of gates
Number of jet conveyors
Conveying capacity
pcs
kg/h
Conveying distance
pcs
Type of gates
'"
Size of gates
pcs
Conveying capacity
kg/h
Conveying distance
ESP hopper ash removal
Number of hoppers
m
pcs
Type of gates
Size of gates
pcs
Conveying capacity
kg/h
Conveying distance
pcs
Manufacturer
m /s
Discharge pressure
mbar
Motor speed
rpm
Rating
kW
C
B5/FD-4
361
Bidder/Contractor
Unit
Data
Number
Heat rate
Heating surface
Air inlet temperature
Air outlet temperature
MW
m2
0
Type
Net volume
Overall dimensions (length/ width/ height)
m3
m/m/m
Number of compartments
Inclination of bottom
Type of outlet gates
Material
Shell
bottom (lining)
Manufacturer
Number
kg/h
Conveying distance
m /s
Air pressure
bar
Rating
kW
Speed
rpm
B5/FD-5
362
Bidder/Contractor
Unit
Data
pcs
m3/h
bar
Rating
kW
m3
m/m/m
0
shell
bottom (lining)
m3/h
c
pcs
m3/s
Discharge pressure
mbar
kW
kW
kW
%
B5/FD-6
363
Bidder/Contractor
Unit
Motor speed
rpm
Motor rating
kW
Data
pcs
Worm length
Product to be handled
Conveying capacity
kg/h
Number of inlets
pcs
Rating
kW
Motor speed
rpm
Material:
casing
worm
kg/s
pcs
-
Type/arrangement
kg/h
Speed
min
Rating
kW
-1
Material:
impeller
casing
pcs
Manufacturer
Type/arrangement
kg/h
B5/FD-7
364
Bidder/Contractor
Unit
Speed
min-1
kW
Rating
Medium handled
Data
Material:
impeller
casing
B5/FD-8
365
Water
Storage
Systems
and
Treatment
366
General
6.2
6.3
6.4
Technical Schedules
367
B6.
6.1
General
This specification covers the design manufacturing and supply of the
complete water storage and treatment system for the entire specified
power plant.
Discharge water from coal mine after required treatment will be used as
cooling water and the existing deep tube well water will be used for potable
water & demi water production of the proposed 250 MW. At present approx.
1200 MT/ hr is discharged from the Coal mine. Coal mine discharge water
quality is mentioned below:
Sl no.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Test Item
PH
Conductivity
Iron (Fe)
Silica (sio2)
Suspended Solid
Turbidity
Total dissolved solid
Chloride (Cl)
Hardness
Unit
8.35
360 s/cm
0.95 mg/l
37.5 mg/l
187 mg/l
3.2 NTU
157 mg/l
9.6 mg/l
2.66 mmol/l
The water storage and treatment system of this section includes the
following parts
Cooling water
Coal mine discharge water receiving system from coal mine discharge
water tank, Clarifiers (2 x 1200MT/ hr), Settling water tank (capacity 5000
m3), Pumps, Coal slurry tank, filters, chemical dozing system, Clear water
tank(capacity 2000 m3), Cooling water supply system, Interconnection with
the existing cooling water system.
Drainage system must be incorporated with all tanks/ reservoirs and
clarifiers.
Demineralised water
Raw water receiving arrangement from existing deep tube well system,
Raw water tank (1000 m3), Filters (Fe-Mn filters, Multimedia filters,
Cartridge filters), Clear water tank, RO plant ( 2 x 60 m3/ hr), Decarbonator
(tank capacity 2 x 200 m3), Mixed bed ion exchanger, pumps, Demi water
tank (2 x 1000 m3), Demi water supply system, Interconnection with the
existing demi water system.
368
6.2
6.2.1
6.2.2
369
6.2.3
6.2.4
6.2.5
6.2.6 Dosing system for condensate. boiler feed water and cooling water
conditioning
370
371
Boiler blowdown
Condensate polisher outlet
Economizer inlet
Main steam
372
2.
3.
4.
5.
6.
Condenser hotwell
Condensate polisher outlet
Economizer inlet
Main steam
Boiler blowdown
6.2.7
6.2.8
373
6.2.9
The pre-treated chemical polluted wastewater shall be discharged to the ash pond.
All waste water discharge to the environment shall comply with the
Environmental Quality Standard of Bangladesh. Annex shows the relevant
standard values effluent. Additional equipment to comply with these
regulations shall be considered in the scope or supply and services.
6.2.10
Chlorination system
The scope of this system includes the chlorine feed system to chlorinate
the cooling water of Power Plant at the cooling water towers and to
chlorinate the potable water system. One (01) sodium hypochlorite (Naocl)
plant (free chlorine concentration shall be minimum 1%) having minimum
capacity 10 ton/ day shall have to be provided.
374
6.2.11 Laboratory
The laboratory installations and equipment shall be installed for routine
control of
service water
water-steam-condensate water
waste water and
coal and ash
oil
Name of instruments
Quantity
Remarks
01 (one) pc
2
3
Atomic Absorption
Spectrophotometer (AAS)
Spectrophotometer (Digital)
Spectrophotometer (Analog)
01 (one) pc
02 (two) pcs
pH meters (Digital)
03 (three) pcs
02 (two) pcs
03 (three) pcs
02 (two) pcs
02 (two) pcs
03 (three) pcs
375
Sl.
No
10
02 (two) pcs
11
02 (two) pcs
12
02 (two) pcs
13
02 (two) pcs
18
19
Pour pointer
02 (two) pcs
20
21
22
23
24
25
26
Electron Microscope
Contamic kit (for oil sediment test)
Decicator (big size)
Incubator
Autoclave
Computer (Inter Core two dual Core)
Temperature meter (for pump motor)
01(one) pc
01(one) pc
04 (four) pcs
01(one) pc
01(one) pc
01(one) pc
02 (two) pcs
27
28
29
30
01(one) pc
01(one) pc
02 (two) pcs
02 (two) pcs
01(one) pc
01(one) pc
02 (two) pcs
14
15
16
17
31
32
33
Name of instruments
Quantity
01(one) pc
02 (two) pcs
02 (two) pcs
02 (two) pcs
02 (two) pcs
Remarks
Chemicals
The types and quantities of chemicals supplied shall he calculated in such
a way that all necessary analyses can be carried out to permit
uninterrupted laboratory operation.
Normal solutions for titrimetric analysis to be in the form of prefabricated
vials for later dilution (type; Merek Titricol or equivalent).
The quantities of all chemicals must be sufficient for the analytical
supervision of the power plant during commissioning period, warranty
period & LTSA period. The purity of the chemical substances must be in
accordance with the requirements of the various analytical methods to be
performed.
376
15
20 (twenty) pcs
different size
20 (twenty) pcs
16
20 (twenty) pcs
17
20 (twenty) pcs
18
19
20 (twenty) pcs
20 (twenty) pcs
377
Laboratory furniture
The following laboratory equipment shall be included in the scope of
supplies as a minimum:
work benches with artificial resin surface for titrimetric analysis. proof
against chemicals and heat with drawers and cabinets in the floormounted units
complete compressed air reducing and filtering device for oil-free and
dust-free
When furnishing the laboratory, there may he no gaps left in the working
surfaces. Adequate numbers or control elements for water, electricity,
compressed air supplies etc. shall he provided and so arranged that they
can be easily operated.
Adequate provision shall be made for storage space liter glass equipment
chemicals, etc. and likewise there shall he adequate working surfaces and
stowage surfaces for analysis equipment.
Spare parts.
Spare parts for the warranty period and LTSA period are to be included
in the price schedules.
6.3
378
6.3.1
379
Starting
Stopping
Selection of a particular step and
Repeat of each step of the program
380
6.3.2
Conditioning plants
The dosing units shall be fully skid-mounted units. The concentrated
chemicals ammonia and hydrazine supplied shall be diluted to a 1 to 2%
solution by mixing with demineralised water. The solid phosphate shall be
diluted to a 3 to 5% solution in a separate mixing and dosing station.
Dosing pumps shall be of the reciprocating metering type
Appropriate piping or adsorption devices of the ammonia conditioning
station shall ensure no ammonia gas leakage.
The dosing station for hydrazine shall be designed and erected in full
compliance with regulations for storage and handling of hazardous
substances.
6.3.3
381
6.4
Technical Schedules
The following technical schedules comprise part of this
specification. The data and requirements specified in the respective
forms are to adhered to and the missing data of forms are to be
completely tilled in. The completed technical schedules are to be
submitted with the Bid.
382
Bidder/Contractor
Unit
Data
m / hr
no.
m3
no.
m3
no.
3
m
no.
No. of clarifiers
no.
m3 / hr
no.
no.
m3 / hr
m3 / hr
No.
m3
No.
3
m /h
kW
.
B6/FD-1
383
Bidder/Contractor
Unit
Data
No.
Net capacity
Material
Raw water pumps
Number of pumps
No.
Rate of delivery
m /h
kW
Material: Housing/impeller
Raw water pumps (other consumers)
Number of pumps
No.
Rate of delivery
m /h
kW
Material: Housing/impeller
Clear water storage
Number of tanks
No.
m /h
Material
Demineralisation water plant
Number of lines
No.
m /h
m3
Regeneration time
Regeneration mode
Chemical consumption
kg/cycle
kg/cycle
m /cycle
Conductivity
Silica
S/cm
mg/I
B6/FD-2
384
Bidder/Contractor
Unit
Data
Number of filters
Throughput:
Material
m /h
Minimum/Maximum
Diameter
mm
mm
No.
mm
N m3 /h
No.
Degasifier
m3 /h
No.
m /h / bar
mm
Material tower
mm
.
No.
Rate of delivery
Mixed bed exchanger
Number of mixed bed exchangers
Throughput:
Minimum/Maximum
Exchanger capacity:
Operating capacity
Exchanger material quantity
No.
m3/h
Cation
eq
Anion
eq
of cation resin
of anion resin
Cation
Anion
eq/IE
eq/IE
I
I
m/h
m/h
Design pressure
Diameter
bar
mm
Cyl. jacket
mm
length Total
height
mm
mm
B6/FD-3
385
Bidder/Contractor
Unit
Data
No.
I
No.
Number of pumps
No.
Type of pump
Rate of delivery
I/h
Material
%
I
B6/FD-4
386
Unit
Data
No.
Number of pumps
No.
Type of pump
Rate of delivery
Material
I/h
-
No.
Rate of delivery
m /h
kW
-
Air blower
Number of blowers
Rate of delivery
No.
Nm3/h
Delivery head
Bar
kW
No.
Rate of delivery
m3/h
kW
-
No.
Diameter
mm
Cylindrical height
mm
Material:
.
B6/FD-5
387
Bidder/Contractor
Unit
Data
Chemical handling
Hydrochloric acid system
Number of storage tanks
No.
Capacity
mJ
Diameter/cy!. height
mm
Material
Caustic soda system
Number of storage tanks
No.
Capacity
Diameter/cy!. height
mm
Material
Waste water treatment system
Sump pumps
Number of sump pumps
No.
Pumping rate
m3/h
Material
Intermediate storage basin/tank
Capacity
Material
Diameter/cy!. height or length/width/height
mm
Discharge pump
Number of pumps
No.
Pumping rate
m3/h
kW
Malerial
Neutralisation tank
Number of tanks
No.
Capacity
mJ
Diameter/cy!. height
mm
Material
Power consumption agitator
kW
B6/FD-6
388
Unit
Data
Discharge pump
Number of pumps
No.
Pumping rate
m /h
kW
Material
Settling tank
Number of tanks
No.
Capacity
m'
Surface area
Material
Sludge dewatering
Type of sludge dewatering
Conditioning station
Medium: Ammonia solution
Number of dosing stations
No.
m'
Material:
Tank
Agitator
Pipes, Valves
No.
Pumping head
bar
I/h
Material:
Head/Piston / Diaphragm
Medium: Hydrazin
Number of dosing stations
No.
No.
m'
Material:
Tank
Pipes, Valves
No.
l/h
Material:
Head/Piston
B6/FD-7
389
Bidder/Contractor
Unit
Data
Medium: Trisodiumphosphate
Number of dosing stations
No.
No.
3
Material:
Tank
Agitator
No
m /h
Rate of delivery
Material:
Number of lifting and tipping devices
Capacity of dosing lank
Material:'
No.
m'
Tank
Pipes. Valves
No.
I /h
Material:
Head/Piston
Diaphragm
No.
No.
Material:
Tank
Agitator
No.
Rate of delivery
m /h
Material:
Number of lifting and tipping devices
No.
m3
Material:
Tank
Pipes, Valves
No.
I/h
Material:
Head/Piston
Diaphragm
B6/FD-8
390
Bidder/Contractor
Unit
Condensate system
Net treated water volume per cycle of each ion exchanger line
m3
Chemical consumption:
Regeneration time
Data
Regeneration mode
Chemical consumption:
kg/cycle
kg/cycle
m3/cycle
conductivity
Cartridge filter
Number of filters
No.
Throughput:
m3/h
Material
Type and material of cartridge
Cation exchanger
Number of exchangers
No.
Throughput:
m /h
Minimum/Maximum
Exchanger capacity:
eq
l
eq/IE
m/h
m/h
Design pressure
bar
Diameter
mm
mm
Total height
mm
Anion exchanger
Number of exchangers
No.
Throughput:
m /h
eq
Minimum/Maximum
Exchanger capacity
Exchanger material quantity
I
B6/FD-9
391
Bidder/Contractor
Unit
Data
Anion exchanger
Total exchange capacity max.
eq/IE
m/h
m/h
Design pressure
bar
Diameter
mm
mm
Total height
mm
No.
Number of pumps
No.
Type of pump
Rate of delivery
Material
I/h
-
No.
Number of pumps
No.
Type of pump
Rate of delivery
I/h
Material
No.
Rate of delivery
m'/h
kW
Material: Housing/impeller
B6/FD-10
392
393