Documente Academic
Documente Profesional
Documente Cultură
Development Board
Technical Requirements
Volume 1 of 2
B0 General Specification
0.1 Subject of Specification
0.2 General Auxiliary Systems
0.2.1 Purpose of the Plant
0.2.2 Site conditions- environmental conditions
0.2.2.1 Location of site
0.2.2.2 Transportation and access road for site
0.2.2.3 Meteorological condition
0.2.2.3.1 General
0.2.2.3.2 Rainfall
0.2.2.3.3 Temperature and humidity
0.2.2.3.4 Earthquake
0.2.2.3.5 Wind
0.2.2.3.6 Flood water level condition
0.2.2.3.7 Geological conditions
0.2.3 Layout
0.2.4 Configuration
0.2.5 General technical requirements of the Plant
0.2.5.1 Design requirements
0.2.5.2 Outline description of generating facilities
0.2.5.3 Main powerhouse including control building
0.2.5.4 Civil
0.2.6 Mode of operation
0.2.7 Environmental conditions and emission control
standards
0.2.7.1 Environmental conditions
0.2.7.2 Ambient standards and emission standards
0.2.8 Fuel
0.2.8.1 Characteristic of coal
0.2.8.2 Ash
0.6.5
0.6.6
Vibration
0.6.7
Standardization of makes
0.6.8
Accessibility
0.6.9
Signs
0.6.16.4
0.6.16.4.1 Responsibility
Required documents
0.6.16.4.2
0.6. I 6.4.3
Welding procedure
qualification
Personnel qualification
Welding process
0.6.16.4.4
0.6. 16.4.5
0.6.16.4.6
0.6.16.5
0.6.16.6 Insulation
0.6.16.7 Vessels, tanks,
heat exchanger
0.6.17 Electrical equipment and
works
0.6.17.1
0.6.17.2
0.6.17.3
0.6.17.4
0.6.17.5
Standards
Standard
Climatic
voltages
conditions
Inductive interferences
Color code system for
switchgear, for local
switching measurementcontrol-signaling
cabinets and for mimic
diagrams
tion
0.6.18.7 Racks, junction boxes
0.6.18:8 Control cubicles
0.6.18.9 Programmable logic
controller
0.6.18.10 T ransmitter racks and
piping
0.7 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
remar
ks
0.7.2.2.2 Hydraulic
tests
0.7.2.2.3 Test runs and
functi
onal
tests
0.7.2.2.4 Visual
ins
pec
tion
,
che
cki
ng
of
dim
ens
ion
s,
test
inst
ru
me
nts
0.7.2.3 Manufacturing tests
0.7.2.3.1 Welding
0.7.2.3.2 Pressure
testin
g
0.7.2.3.3 Testing of
cor
rosi
on
pro
tect
ion
Section B2: Steam Turbine Plant with Condensate and Steam System
Annexes
General Specification
for
the
trouble-free
operation
of
the
unit
procurement,
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.
area
nearby
is
this
coal
mine
including
its
township
Parbatipur
is
about
by
car
needs
separate
approximately
large
scale
indus-
hours
at
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
site.
road
is
connecting
Dinajpur,
Phulbari,
Parbatipur,
Saidpur
and
materials
is
done
by
shall
fix
up
the
transportation
possibilities
in
detail
for
the
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 acomparatively 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
Dinajpur
Max.
Temp. in
'88 (0C)
Rangpur
Min.
Temp. in
'88 (0C)
January
24.9
11.6
Feb.
27.5
14.2
March
33.5
April
Mean.
Temp.81
- 88 (0C)
18.4
Mean
Hum.'81
- 88 (%)
Max.
Temp. in
'88 (0C)
Min.
Temp. in
'88 (0C)
Mean.
Temp.8
1
- 88 (0C)
Mean
Hum.'8
1
- 88 (%)
70
25.3
11.7
16.8
79
70.9
61
29.0
145
19.0
71
13.5
25.4
54
33.7
12.6
23.6
63
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
Octobe
r
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
72
26.0
14.1
18.3
81
Annual
32.4
17.9
71
31.8
19. 1
24.5
79
19.6
25.6
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.
Monthly average prevailing wind speed (knots and direction/lknot = 0.514 mis)
Rangpur (1979988)
YE
AR
197
9
198
0
198
1
198
2
19&
3
198
4
198
5
198
6
198
7
198
8
JAN
SPD DIR
3
FED
MAR
D
I
R
N
SP
D
APL
S
P
D
6
DI
R
NN
W
SP
D
MAY
JUN
SP
D
DI
R
SP
D
D
I
R
S
JUL
SP
D
DI
R
S
E
S
E
n.
a.
N
E
N
E
N
E
N
E
N
E
NN
E
N
E
N
E
S
E
S
E
4
5
5
4
4
4
S
N
E
w
N
E
N
E
N
E
S
E
AUG
D
I
R
S
E
S
E
n.
a.
S
E
S
E
SP
D
S
E
E
S
E
S
E
5
4
n.
a.
5
3
6
5
5
5
D
I
R
S
E
S
E
n.
a.
S
E
S
E
S
E
S
E
S
E
S
E
S
E
SEP
SP
D
5
OCT
NOV
D
I
R
S
SPD
DIR
3
N
E
N
E
N
E
SPD
DIR
SP
D
S
E
N
E
N
E
N
E
N
E
N
E
N
E
N
E
N
E
N
E
N
E
3
n.a
.
3
4
n.
a.
N
E
4
4
3
5
4
2
2
Monthly average prevailing wind speed (knots and direction/1 knot - 0.514 m/sj
YEA
R
JAN
SPD
DIR
198
1
198
2
198
3
198
4
198
5
198
6
198
7
6
3
FEU
SP
D
N
W
N
W
N
W
MAR
APR'
SP
D
DI
R
N
W
DI
R
SP
D
MA\'
SP
D
DI
R
N
E
IUN
SP
D
DI
R
N
E
JUL
SP
D
DI
R
N
E
AUG
SP
D
DI
R
N
E
S
E
6
3
SEP
D
I
R
N
E
E
NO\'
DI
R
SP
D
D
I
R
N
SP
D
DI
R
SP
D
W
N
E
SP
D
S
E
N
E
N
E
N
E
N
E
S
E
ocr
S
E
E
2
2
2
2
3
198
8
N
E
N
E
2
4
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.
: Importance factor
(1.5 for important facilities, 1.0 for others).
2
5
Geological conditions
The stratigraphical sequence
into the following groups:
has
been
divided
on
purely
litho
logical
grounds
-Upper (Pliocene)
- Lower (Pliocenelate Miocene)
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:
2
6
Cohesion (kN/m3)
30~85
Permeability:
9.79 x 10 - 5 - 5 X 10 - 7 m/s
Ph:
6.8 - 7.4
o
CO
CO
119
b)
17~ 11.6
Tila
formation,
with
the
average
thickness
of
107
is
divisible
The upper unit: average 65 m in thickness, of micaceous gray sands and gravels
with occasional bands of silt and clay. The lower unit; approximately 40 m in
thickness, of orangebrown, slightly micaceous sandstone, generally finer than the
upper unit with more frequent thin beds of slit and clay.
The geotechnical
and
hydrogeological
characteristics
upper Dupi Tila formation are summarized as follows:
of
the
upper
part
Shear Resistance
Angle
24.5
Undrained multistage
Consolidated drained
62
2 - 4
2
Unconsolidated undrained
16
27.5
"3i
o
130
These tests were carried out on undisturbed samples of cohesive materials such as silt or
clayey silt of the Upper Dupi Tila formation.
2
7
of
the
Permeability
No
permeability
test
has
been
permeability of this formation is
judging from its soil composition.
carried
out
for
considered larger
this
than
formation.
However,
the
that of Madhupur Clay,
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
consideration of
easy maintenance,
interfaces to the power grid.
be
proposed
access, short
by
links
the
Contractor
for
piling and
under
cabling,
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
the Plant.
fired
boiler
with
turbine
generators
represent
the
core
components
of
is
to
be
optimized
by
the
Tenderer/
expenses
2
8
and
Redundancy concept
Due
to
the
block-wise
structure
of
the
Plant,
propose
only
1
x
100%
implementation
of
very
cooling
water
pumps,
compressors,
etc.,
but
by
no
water system.
These
moderate
investment
solutions
can
Contractor
proves
with
corresponding
spare
that
overall
an
optimum
economic
solution
will
100% solutions are preferable.
be
parts
result;
the
costly
means
Tenderer/Contractor
major
equipment
for
the
boiler
may
like:
feed
accepted
if
the
Tenderer/
and
maintenance
proposals
otherwise
3
x
50%,
or
2x
unplanned outage time of power unit shall not exceed 1.7% of the time in a
calendar year
Unit is available during 99.2% of the time in a calendar year.
250 MW Net
80%
38.0% (minimum)
output
/input
0.2.5.3 Civil
2
9
The area of the Power Station for protection against flooding is considered to befilled 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
fences and gates.
the
park
shall
be
separated
from each
other
and
the
Plant
by
shall be
operation
the
Plant
shall
be
based
on
the
following
operation
and
dispatching
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
the
admissible
air
pollution
is
required
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.
3
0
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
Item
0.7
Barapukuria
soil
CaO
Na20
K2 0
0.2
2.2
0.2
Barapukuria
soil
6.5
12.
CM
pS/c
CO
0
B203
427
K+
mg/kg
Na
+
201
b3+
mg/kg
0.1
0.2
0.2
1.0
<0.
1
3
1
0.2.8 Fuel
0.2.8.1 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
Hydrogen
Oxygen
Nitrogen
Sulfur
83.0%
5.1%
9.4%
1.7%
0.77%
99.97%
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%
Ash fusion temperatures of seam Vi (mean C)
(reducing atmosphere)
Initial Deformation
l,400C
Hemispherical
l,400C
Flow
1,400C
Water supply of the Power Plant will be covered by Coal mine discharge water
(for normal use) and deep tube well water (during emergency case to meet at least
50% of total requirement). To cope with the water requirements of Power Plant
consumers it is necessary to install water treatment and storage facilities. The
design of the storage facilities shall consider especially start-up and routine
maintenance periods in the Power Plant and water treatment plant.
Chemical polluted wastewater and sewage wastewater has to be treated to
comply with the relevant wastewater emission standards. Chemically polluted
wastewater shall be discharged after treatment to the ash pond
The waste water from the ash pond shall be discharged to the Tillay river. The
water which will be discharged to the Tillay river shall be treated also. This water
shall be suitable to be used in the park for fountains as well as for irrigation
purposes.
Section B1
Section B2
Section B3
Section B4
Section B5
Section B6
Section B7
Section B8
Section B9
Auxiliary Systems
Electrical and Associated Works
Instrumentation and Control Works
Section B10
Section B11
Section B 12
Civil Works
Workshops, Stores and Vehicles
the
by
the
Contract
refer
to
the
All fees required due to a split-up into multiple applications shall be covered by
the Contractor.
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
material costs for site inspections
declaration of conformity with Bangladesh requirements and markings for
all machines
Owner/Owner's Representativeing design of complete supplied equipment
including interface coordination
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
covers, as far as possible aggregated to common groups of on operating
level.
all connection elements, screws, bolts, nuts, including gaskets and seals as
necessary.
check
their
of
required
rehabilitation
existing
where
they
structures,
plant
lie
the
within
components
scope
of
and
supply,
systems
or
and
definition
of
required measures in good time if they lie outside of the scope of supply
all base frames, mounting plates, grouted in parts, rag bolts, covers, etc.
all couplings and coupling guards for electric motors and other drives
all
lifting
(cranes,
equipment
hoists,
and
hoists
monorails,
(for
etc.),
repair
work
electrically
where
operated
loads
if
exceed
lifting
or
50
kg)
lowering
heights exceed 8 m
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
complete primer and top coatings conforming to color code, clarified with
the Owner/Owner's Representative/Owner/Owner's Representative
all corrosion protection and electric trace heating for outdoor installations
(e.g. gas ducts, etc.)
complete
labeling
Representatives
of
all
system
and
plant
components
in
plain
according
language
to
(English
the
and
Owner/Owner's
Bangla)
and
initial
lubricant
filling
test
run,
the
Owner/Owner's
and
minimization
of
sufficient
lubricant
Representative,
lubricants
types
up
for
by
to
commissioning
screening
Provisional
and
Taking
and
reliability
coordination
Over
of
with
the
relevant Unit
provision
of
all
connections
and
temporary
pipe
work
for
flushing of all other lines including disposal of the effluents; protection with
steam
purging
of
the
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
insurances.
complete installation material, that is wiring, cabling and piping material, all needed fastenings, conduits, brackets and other supports, including the cable trays
lightning protection
clarification
of
all
logic
interconnections:
sequence,
interlocking,
protection,
0.3.3.4 Civil
Soil investigations
site fill
plumbing
flooring work
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)
transport insurance
customs clearance
transportation to site
unloading at site
0.3.5 Documentation
reference lists for delivery and installation of plants of similar type and size
time
schedule
for
Owner/Owner's
Representativeing,
deliveries,
dimensioned
drawings
and
sectional
views
of
the
principal
plant
components
general
operation
shutdown
descriptions
including
of
individual
description
procedures,
of
systems
start-up,
tendencies
and
shutdown
showing
descriptions
and
the
emergency
behaviour
of
of
lists of spare parts for warranty period, lists of spare parts for LTSA
period
Generator
Detailed descriptions/references of the main components such as:
excitation equipment
cooling system
Boiler
Description for the equipment offered giving information about:
NOx, CO, S02, etc. emission characteristic for coal operation versus load at
full load
Drawings
dimensioned
general
arrangement
of
boilers,
turbines,
ash
extraction,
pumps,
fans,
el.
precipitator,
mills,
conveyors,
transportation,
etc.
ducting
including
guide
vanes
and
expansion
joints,
damper,
isolator,
platforms,
stairs,
ladders
and
stack,
workshops,
chemical
laboratory
,
stores,
administration building, entrance, fence and all other structures
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.
tentative start-up diagrams for cold start, warm start and hot start
material
diagram
temperature
and
showing
and
maximum
highest
material,
steam
admissible
dimensions,
temperature,
material
temperature
highest
design
and
exhaust
material
design
gas
temperature
pressure
for
variation of steam temperatures over the heating surfaces, stating materials employed
Electrical system
description
of
the
power
supply
system
for
DC/AC
systems(24
DC
detailed
explanations
to
be
given
for
the
DC
and
provided
control system architecture showing all components provided for this Power
safe
AC
principle
to
be
availability
redundancy concept
reference list for the DCS with indication of plant type, system architecture
and size of the system
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.
operating
and
equipment
maintenance
and
facilities
manual
(first
with
issue
description
months
and
before
instructions
start
of
for
all
commissioning
and second issue before trial run (2 weeks) - OMM for approval
overall
time
schedule
commissioning
construction
for
broken
works,
design,
down
stating
for
dates
manufacture,
the
for
supply,
principal
completion
plant
of
assembly
components
any
preparatory
and
and
work
II
all
from
arrangement
drawings
of
the
principal
components
with
ducts
and
platforms
layouts .
piping
of
and
instrumentation
pipelines
and
valves
schematics
and
stating
isometric
materials,
drawings,
)nominal
including
diameters,
lists
nominal
details
of
electricity,
required
steam,
auxiliary
chemicals,
energy
sources
instrumentation
and
air,
consumer
working
consumables
air)
(e.g.
with
condition
before
execution
thermodynamic diagrams
welding
procedures
of the welding
(for
workshop
and
site),
to
be
approved
for
all
lifting
operations
(repair,
maintenance,
etc.)
lifting
plan
has
to
be
detailed
arrangement
equipment
(flash
drawings
tank,
of
etc.)
all
equipment
complete
with
including
pipes,
cable
all
auxiliary
tracing,
steel
electric motors
starting
curves
(torque
of
motor
and
driven
machine,
time,
speed)
for
all
reports
of
cable lists
lightning
protection
plans
with
details
of
measuring
locations
EMC concept with coordinated over voltage protection (NEMP level is not
and
required)
arrangement
drawings
showing
exact
location
of
fire
alarm
devices
if
applicable
general arrangement drawings of the required cable trays, cable laying plans
dimensioned
drawings
and
erection
drawings
for
generator,
transformers,
dimensioned
cubicles,
drawings
voltage
of
switching
regulation
cubicles,
cubicles,
generator
excitation
and
cubicles
star
etc.,
point
including
equipment configurations
short
circuit
calculation
and
determination
of
protection
relay
settings
for
kV
substation.
All
the
equipment
is
overall protection and metering diagrams for the whole protection equipment
will
use
Construction
Power
from
the
existing
33
list of subcontractors
set
of
all
relevant
standard
specifications
to
which
manufactured
list
of
instruments
reference drawings
including
code,
measuring
range,
alarm
and
limit
values,
list
of
control
valves
including
operating
and
design
data,
materials,
makes,
Owner/Owner's
actuators),
Representativeing
control
dampers
drawings
(including
of
control
actuators),
valves
orifices,
(including
nozzles,
venturi
nozzles
diagram
of
control
system
architecture
showing
all
components
provided
for
logic diagrams
list of recorders
general
site
plan
of
the
entire
site
showing
all
buildings
and
installations,
architectural
arrangement
drawings,
design
layouts
and
itemized
drawings
architectural
drawings
of
each
floor
(plants,
sections)
including
all
necessary
whole
(existing,
arrangement
planned)
drawings
with
all
of
supply
the
and
external
disposal
plants
of
facilities,
the
site
roads
and
as
vehicle
access
and
floating floors/systems
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.
Final
Preliminary
In weeks
In weeks
Requirements
the
Documents
inventory
computer
Program
Specification
i.e.
complete
Test
Plan
describing
and
Procedures
how
describing
Documents
the
program
1
9
23
1
9
23
39
inventory
program
is to be tested
Complete user manuals describing
how the user will run the program
29
33
and
65
20
after availability
of maintenance
instructions of
the
corresponding
suppliers
87
43
23
17
39
26
taking over
taking over
Maintenance assembly and adjustment
,
drawings ^ ,
before
As-built drawings
. . ,
provisional
taking over
at provisional
.,
taking over
for
twenty
one
(21)
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,
advise
the
Owner's
personnel
in
trouble
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.
a) two sets of special tools and gauges required for the maintenance c1fthe Plant
b) one set of special lifting and handling appliances required for the
schedule
for
the
The Contractor shall provide all runway beams, trolleys, lifting blocks, special
slings etc. necessary for the safe and efficient handling and maintenance of the
works. Particular attention shall be paid to high level equipment such as
deaerator. Electrically operated hoists and runway trolleys shall be provided for
all lifts in excess of 2.5 tons.
The tools and appliances with the appropriate storage racks, cabinets and boxes
shall be handed over to the Owner/Owner's Representative at the time of taking
over.
Where the Contract includes site erection, any special tools or appliances
required solely for erection shall be provided by the Contractor for his own use
and shall remain the property of the Contractor.
0.3.8.3 Consumables
Lubricants and greases
All lubricants proposed for the Plant operation shall be suitable for all operatingand
environmental conditions that will be met on site.
All oils and greases shall where possible be readily available in the country of
installation.
The number of oils and greases shall be kept to a minimum. For each type and
grade of lubricant recommended the Contractor shall list at least three equivalent
lubricants manufactured by alternative companies.
The Contractor shall supply the first fill of lubricants for the Plant, and shall
provide at the provisional Taking Over sufficient lubricants and greases
necessary for the efficient operation and maintenance of the Plant at full load 24
hours per day for a period of 24 months (Warranty period).
The Contractor shall also supply lubricants and greases necessary 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.
Chemicals and other consumables
The contract includes the provision of all chemicals, reagents, resins, and other
consumables required for testing, commissioning and setting to work of each
section of the Works.
The Contractor shall provide all chemicals, and other consumables required for
the efficient operation and maintenance of the plant at full load 24 hours per day
for a period of 24 months for each section of the works from the date of the
provisional Taking Over.
The Contractor shall prepare a list of these consumables giving
necessary for each section of the works and the recommended suppliers.
quantities
The Contractor shall deliver to site sufficient quantities of consumables in his supply
to allow for running of the Works prior to the issue of the Temporary Taking Over
Certificate. The delivery of the remainder of the consumables shall be programmed
to suit the operational requirements and space availability within the various stores.
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.
0.3.10 Options
Deleted
0.4.1
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:
0.4 Interfaces
Interface
2x125 MW plant.
fuel
with
the
One
separate
nos.
of
coal
of
existing
coal
yard
shall
have
coal conveyor system.
Another
installed
yard.
coal
from
coal
conveyor
of
coal
conveyor
belt
crusher
unit
from
crusher
unit
upto
to
be
installed
conveyor
new
belt
coal
One
coal
processing
shall
have
to
be
stream
of
Weighing
scale
modifying coal conveyor system.
shall
yard
Plant
installed
of
existing
with
the
new
by
have
to
to
old
(Sorter
at
Coal
the
mine
02
upstream
coal
modifying
be
coal
machine)
down
by
busbars
AC
the
terminal
cubicles
of
signals
for
extension
signals of future diameter extensions
(400
system)
required
status
and
V,
for
number
and
interfacing
DC
future
of
protection
of
and
PABX
building
Coal
source
cooling
communication
systems
raw
water,
industrial,
water
racks
building
potable
cooling
protection
within
cubicle
data
and
230
within
exchange
telephony
kV
Power
mine
discharge
water
of
raw
water,
water.
Proper
chemical
required.
Deep
well
water
will
backup. Deep wells having capacity 50% of
V24/28
at
switchyard
terminal
control
Plant
control
will
be
the
potable
industrial,
treatment
is
be
used
as
..
to
existing
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).
Declaration by Bidder
(Form, to be completed by the
Bidder)
Deviation from Tender
Document (Form, to be
completed by the Bidder)
B0/F-1
B0/FA-1
Design Data
BPDB. BarapukuriaGuarantees
Power Plant 250 MW
Section B0: General Specification
Price Sheets (In Part A)
Declaration by Bidder
Time Schedule
Declaration by Bidder
ctionfor
B0: General Specification
Bidder:
Bid Number:
B0/F-1
B0/FD-1
Bidder/Contractor
B0/FG-1 to 14
Bidder/Contractor
B0/FZ-1
Bidder/Contractor
Unit
Data
Steam turbine
Construction
Maintenance
Civil Contractor
Compressor Station
Emergency diesel
B0/FD-1
Guarantee Schedule
BPDB, Barapukuria Power Plant 250 MW
6 B0/FG-1
0
Unit
kW
kJ/ kWh
at 100%
Load
(H-100% )
at 75% Load
(H75%)
at 50% Load
(H50%)
Days
Hours
Hours
Hours
Hours
Hours
Output"
and
"Net
Heat
Rate"
are
mentioned
in
General
condition,
6 B0/FG-1
1
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
6 B0/FG-1
2
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
turbine
generator.
Maximum
effective
measured at bearing housings:
operation
vibration
of the
velocity
"good", according
to VDI rule 2056
dB{A)
85
dB{A)
75
dB{A)
55
dB{A)
60
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
m3/h
m3/h
6 B0/FG-1
3
Minimum Requirements
Unit
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
Data
kJ/kg
kJ/kg
C
%
-
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
Minimum Requirements
Unit
Data
kg/s
bar
C
MW
kJ/kWh
MW
6 B0/FG-1
4
Total
auxiliary
consumption
(excluding
excitation power and transformer losses)
operation (Condition A)
generator
at MCR
MW
Drwg.No.
Minimum Requirements
Unit
Data
mbar/min
8,000
mg/m3
mg/m3
6 B0/FG-1
5
mg/m3
leaving the EP
CO2 drop (dry) between combustion chamber and
regenerative air preheater outlet at MCR
BPDB, Barapukuria Power Plant 250 MW
%
Minimum Requirements
Unit
Data
12,000
general
20,000
8,000
refractory
8,000
general
16,000
8,000
%of
MCR/mi
n
%of
MCR/mi
n
%MCR
35
1:5
Load changes
6 B0/FG-1
6
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
6 B0/FG-1
7
Bidder/Contractor
Unit
Data
constant load
load variation
10
bar
145
constant load
bar
load variation
bar
a) Live-steam temperature:
b) Live-steam pressure:
6 B0/FG-1
8
Bidder/Contractor
BPDB, Barapukuria Power Plant 250 MW
Section B0: General Specification
Design Data and Guarantees for I&C Equipment
c) Reheat steam temperature:
Un
it
Data
constant load
load variation
10
m
m
m
m
mb
ar
mb
ar
%
O2
%
O2
25
50
3
8
0.4
1.0
bar/
o
C
load variation
bar/
o
C
3/ 10
dB
(A)
85
1.5/5
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.
6 B0/FG-1
9
Bidder/Contractor
Unit
Data
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
Bidder/ Contractor
Unit
Data
m3/h
m3
h
h
kg/cycle
kg/cycle
kg/cycle
kg/cycle
pS/cm
<0.01
mg/I
mg/I
mg/I
mg/I
<0.02
<0.003
<0.02
<0.01
Bidder/ Contractor
Days after
effective
Date
Date
B0/FZ-1
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
0.6.1
0.6.2
General requirements
Standards and codes
0.6.3
Plant
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
equipment
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
Personnel qualification
Welding process
0.6.16.4.6
0.6. 16.4.7
0.6.16.5
safety
Table of Contents
0
xxx
0.1
0.2
0.3
0.4
0.5
0.6
works
0.6.17.1
0.6.17.2
0.6.17.3
0.6.17.4
0.6.16.6
Insulation0.6.16.7
Vessels, tanks, heat exchanger
0.6.17
Electrical equipment and
Standards
Standard voltages
Climatic conditions
Inductive interferences
0.6.17.5
Color code system for
switchgear, for local switching
measurement-control-signaling cabinets
and for mimic
diagrams
0.6.17.6
equipment
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
Measuring systems/transmitters
Flow measurements
Temperature measurements
Pressure measurements
Analyses measurements
Level measurements
Electrical measurements
Position measurements
Contact devices
0.6.18.6.10
0.6.18.6.11
0.6.18.6. 12
Vibration measurements.
Control valves
Actuators
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
design,
as they
in this
of the
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
facilities:
shall
be
considered
in
the
design
and
engineering
of
the
Plant
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.
as required for
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.
recent
relevant
codes,
All materials and equipment supplied and all work carried out as well as calculation
sheets, drawings, quality and Class of goods, methods of inspection, specific design
features of equipment and parts and acceptances of partial plants shall comply in
every respect with the following technical standards, codes and regulations .
Statutory safety regulations for equipment items (e.g. for noise preventions).
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.
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.
with
international
oil
grease
paint residues
splatters
mill scale
welding splashes and
Welding slag.
Sharp edges have to be rounded off.
Contamination caused by salts, acids and alkali solutions shall be eliminated by
rinsing with water up to a pH value of 6-8.
The preparation of substrates
according to proposed standards.
shall
be
carried
out
on
the
basis
of
the
specifications
coating
of
concrete
is
required,
concrete
shall
be
allowed
to
cure
Transport and erection damages, as well as damages which result out of additional
welding have to be repaired as soon as possible. The damaged areas have to be
derusted with rotating or steel brushes, abrasive wheels, abrasive blasting according
to the chosen standards.
has
to
have
different
color
shade
in
The last finish coat has to be applied in the specified color shade, to be agreed by
the Owner/Owner's representative.
The interval between applying the different coats has to follow according to supplier's
precautions. Each layer has to be cleaned and released from spray dust before the
next layer will be applied. Prior to applying a further layer, the last one has to be
repaired. All coatings have to be applied without retarding.
Following application procedures are allowed:
at works
by airless spray, roller or brush
at site
by roller or brush or airless spray.
When applying coating systems by roller, rollers have to be of kind and quality
which make an appropriate application possible.
Control areas in accordance with the coating supplier's instructions have to be
applied. For this procedure, a schedule for control areas has to be prepared by the
Contractor and coating supplier which corresponds with the requirements of the
warranty agreement.
Number and performance of the control areas have
the chosen standards and have to be documented in writing.
to
be
done
in
accordance
with
No application may take place neither when the relative humidity will not be within
the given limit nor in case of fog, dust, rain, snow or hail or when it can be assumedthat 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
2
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
surfaces shall be protected by suitable tape wrapping
copper,
copper
alloy
or
aluminum
oating Systems
Surface location
Temp.oC
Surface
preparation
up to 120
SA 2.5
vessels, tanks
INDOOR
up to 120
SA 2.5
vessels, tanks
OUTDOOR
Coating
systems
No.of
coats
Generic type
Primer
Zinc-Epoxy
80
Finish
80
Primer
Zinc-Epoxy
80
1-2
2-Comp.Polyurethane
Intermediate
Finish
160
16
50
50
29
Piping, tanks, etc.
INDOOR and OUTDOOR,
Insulated
up to 120
SA 2.5
Primer
Zinc-Epoxy
50
up to 120
SA2.5
Primer
Zinc-Epoxy
80
Finish
2-Comp.Polyurethane
110
11
50
50
24
1
Primer
Finish
INDOOR
Zinc-Epoxy
Epoxy High Solid
oo
SA 2.5
00 LO
up to 120
80
10
18
oating Systems
Surface location
Piping, reactors
Temp.oC
> 120
Surface
preparation
SA 2.5
Coating
systems
Primer
No.of
coats
1
Generic type
Zinc Ethysilicate
OUTDOOR
Insulated
SA 2.5
Stacks
OUTDOOR
< 120
Steel surfaces
<200
200 - 450
1
Primer
Zinc Ethysilicate
75
2
SA 2.5
Finish
Primer
Silicone Acrylic
Zinc Ethysilicate
50
75
Finish
Silicone Aluminium
25
When Finish
Coat is
required, such
as sea climate
with chloride
exposure
125
Un insulated
Galvanized surfaces
up to 120
Medium
temp.oC
up to 60
Mechanical
cleaning from
contaminants
and zinc salts
by means of
washing or
steam or
sweep- jetting
blasting with
fme sand
Prime and
1
Finish
Glassflake reinforced
Coat in
High Solid Epoxy.
Additional 1 x Finish Coat 2-Comp. Polyurethane, 50 pm, when exposed to UV and colour One
retention is required or when exposed to weathering.
SA 2.5
500
0.6.6 Vibration
Unless otherwise stated or agreed by the Owner/Owner's
Owner/Owner's representative each rotating machine has
requirements for vibration magnitude (criterion I) designation
by ISO Specification 10816 or equivalent for the respective
the vibration magnitude is greater than stipulated as "zone
representative has the right to reject the concerned equipment. .
representative or ; the
to comply with the
as "zone A" stipulated
group of machinery. If
B", the Owner/Owner's
throughout shall
be
made
to
gauge
and
be
interchangeable
All equipment performing similar functions shall be of the same type and
manufacture, to limit the stock of spare parts required and maintains uniformity of
plant and equipment to be installed.
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
geometrical form, color and meaning with the chosen standards.
Signs for plant identification during the
Owner/Owner's Representative approval.
erection
is
comply
period
are
weather-resistant
in
construction,
subject
and
of
to
the
sufficient
89
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.
90
Quantity
Name of Unit
Length
Millimeter
Symbol
mm
Mass
Kilogram
kg
Time
Second
Temperature
Degree Celsius
Temperature Difference
Kelvin
Electric Current
Ampere
Luminous Intensity
Candela
cd
Area
Square meter
m2
Volume
Cubic meter
m3
Liter
Force
Newton
Pressure (absolute)
Bar
bar
Kilopascal
kPa
Millibar
mbar
Stress
N/mm
Velocity
mls
Rotational speed
rpm
3
Flow
m /d
m/h
kg/h
L/s
t/h
kg/m
Kg/Nm
meter
Torque, moment of force
2
Newton meter
Nm
kgm2
Joule
J/K
Calorific value
J/m3
J/g
Watt
W/m2
Thermal conductivity
W/mK
Dynamic viscosity
Quantity
Sym
91
Kinematics' viscosity
m2/
s
N/m
Surface tension
Concentration
Electrical conductivity
Frequency
ppm
^S/
m
Hz
Electric charge
Coulomb
Electric potential
Volt
Vim
F
Electric resistance
Ohm
Conductance
Siemens
Magnetic flux
Weber
Wb
Tesla
A/m
Luminous flux
Lumen
lm
Illuminance
Lux
Ix
Thermal resistivity
Energy
Kilowatt hour
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".
,i
steel
All aspects of platforms, stairways, ladders and other access ways shall comply
with the requirements of applicable 'standards.
92
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
following
design
requirements:
in-fills
of
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.
Lubricating
connected
points.
should
cable
be
and
limited
pipeline
to
wall
margin
penetrations
of
93
at
are
least
to
10K
not to be
screwed-type
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)
a.
Structural steel
(B)
b.
c.
a.
(C)
b.
Torque shearing bolt
c.
Ordinary bolt
Electrodes for arc welding
(D)
(F)
Reinforcing bars
Further, the Contractor shall submit at the. same time the basic draft of the
cleaning procedure and of the treatment of wastes.
Not less than six months prior to the commencement of any site cleaning, the
Contractor has to submit programs covering all procedures, lists of chemicals,
calculations which quote the velocities, temperatures handpipework forces and
movements imposed during site cleaning.
All necessary equipment, provisions, chemicals etc. are to be provided by the
Contractor.
All tests, analyses, etc. as required arc to be performed by the Contractor.
Besides this, the Contractor shall take over all responsibility for the treatment and
disposal of wastes according to the local law and to the satisfaction of the
Owner/Owner's representative.
The date at which cleaning of plant equipment will be carried out at site shall be
notified to the Owner/Owner's representative at least 20 days in advance.
The Contractor shall take all necessary precautions to ensure that the internal
surf.1ces of all plant are kept clean and free from injurious matter during erection.
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.
shall
be
fitted
to
the
casing
and
impeller
where
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
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
available under all operating
employed. The NPSH values
conditions -lowest atmospheric
of the pump, and highest
margin of normally greater
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,
throughput.
the
pumps
are
to
be
fitted
with
devices
to
ensure
minimum
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
lubricated bearings shall be equipped with constant level oilers.
level
indicators.
Non
they
be
pressure-oil
Pumps characteristics
When several pumps arc
unrestricted parallel operation.
installed
for
the
same
service,
shall
suitable
The pump flow/head characteristics shall be such that within the operation
the head will continuously increase with decreasing flow, maximum head
off head) being at least 10% higher than the duty point head.
for
range
(shut
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.
with
discharge
relief
valve
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.
necessary
for
Pockets in pipelines shall be avoided wherever possible and all lines are to be
provided with fittings, valves and/or traps arranged in such a way that the pipes
may be completely drained when desired.
Each mechanical component requires its identification coding number.
practice
of
the
After drying, inspection and conservation, wooden plugs, metal or plastic caps
shall be securely fitted to the ends of each pipe to prevent the ingress of dirt
and to protect flanges and pipe ends from damage during transportation and
storage.
It shall be the Contractor's responsibility to remove from Site all chemicals and
debris accumulated during the chemical cleaning process. Any damage caused
as a result of the process shall be made good by the Contractor at his own
expense, therefore an adequate insurance cover shall be a necessity for such a
contingency.
max. velocity
Steam lines:
High-pressure live steam lines (PN > 64)
Intermediate-pressure steam lines (PN
25140)
60 m/s
40 m/s
35 m/s
25 mls
Vacuum lines
80 m/s
20 mls
0.5-2.5 m/s**
3-5 m/s
1.5 m/s
3.0 m/s
Fuel lines:
Coallair lines
25 m/s
1.0 m/s
discharge
Air Lines:
2.0 m/s
20.0 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, 8, 10, 12, 14, 16,
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
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 accordance 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
2401, or equivalent, the drainage and ventilation facilities
double valves.
All
vents,
drains
pressure/temperature
points with covers.
or
dump
shall lead
PN > 40
shall be
as in DIN
fitted with
points
with
more
than
10
bar/1000 0C
operating
to the flash tanks and into funnels at visible
Guidelines for the design and construction of pipe work and accessories
Design and
correspond
standards.
construction of
to the present
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).
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.
The installed pipe work with its supports and other components shall not
obstruct
gangways
(min.
1000
mm
wide),
maintenance;
escape
routes
etc.
Overhead piping shall have a minimum vertical clearance of 2.3 meters, in
pump rooms 2.45 meters and 6 meters above roadways.
Main pipe ways shall be designed to accommodate 20% more lines than is
required for the initial installation. When designing sleeper ways, allow space
for adding 20% additional sleeper width.
Pipe spools for HP steam, feed water piping and all steel pipes > DN 50
shall
be
cleaned
internally
prior
to
delivery
by
shot
blasting
(no
sand
blasting) at the workshop with iron particles to SA2 1/2 or by acid cleaning,
and shall be property protected against corrosion.
Pipe ends
temporarily
installed.
The
Contractor
shall
submit
a
detailed
description
of
proposed
steam
blowing and other cleaning procedures for all pipelines, and no part of this
work shall be started until these procedures have been approved by the
Employer. Temporary silencers shall be provided for this.
The
Owner/Owner's
Contractor to modify
obtain acceptable results.
The
contractor
shall
furnish,
install
and
dismantle
hangers, anchors, etc. required for cleaning all piping system.
To the extent that hot fluids can accumulate in pipe sections isolated for
maintenance
purposes
(including
control
valves
with
injection
water),
drains
with hand-operated shut-off valves are to be provided for the safety of the
personnel
(block
and
bleed
systems)
.
Furthermore
the
Contractor
shall
safeguard
the
piping
systems
against
over-pressurization
caused
by
thermal
expansion of blocked-in fluids by adequate means.
Welding ends of all piping must be carefully prepared before welding. The type
of butt welding ends of valves, control devices, orifices, etc. shall be specified by
the Contractor and must be given to the manufacturers of these components in
due time prior to their start of work if necessary/post weld heating treatment. If
there are differences in the wall thickness and/or different materials of piping
and valves with butt-welding ends, the necessary transition pieces must be
provided by the manufacturer of the valves
and
branch
connections of
underground
piping
during
installation
if
the
connecting
pipe
is
representative
any of his
reserves
the
right
cleaning .procedures if
all
shall
not
to
found
be
sealed
immediately
require
the
necessary to
temporary
For
pipes,
quality
Socket welds are not permitted for lines above DN 50, for corrosive medialines or for lubricating oil
lines.
After completion of the weld joint, the welder must mark with indelible
crayon his
work was
welders.
in
a
which the
record of
The
Contractor
shall
provide
suitable
thimbles
and
flashing
where
pipelines
pass through floors and walls. Floor thimbles shall be installed to provide 90
mm projection above the finished floor surface.
A
for
all
piping
systems
DN
>
80
with
The
piping
stress
and
flexibility
analysis
standards.
Recalculation
must
be
taken
actual weight and dimensions.
shall
be
based
on
the
relevant
into
consideration
as
built
condition,
Pipe
materials,
bends
and
applicable material standards.
be
fittings
shall
tested
in
accordance
with
the
Constant support hangers and spring hangers shall be equipped with a means
of
locking
the
springes)
against
movement
during
erection,
hydrostatic
testing
etc. The use of counterweights in substitution for support spring assemblies will
not be permitted.
Support spring hangers shall be of the enclosed spring type, and shall have an
embossed on factory load indication scale showing the hot (operating) and cold
(ambient)
positions.
Each
spring
assembly
shall
incorporate
an
adjustable
hanger rod coupling to permit load adjustment. All support springs shall
be
designed
to
permit
at
least
10%
field
load
deviation
from.
the
factory
calibrated load.
The supporting force provided by variable support type spring hangers shall not
change by more than 20% between the cold and hot positions, and supports of this
type shall not be used at any point where such a change in supporting force cannot
be safely permitted. Variable support spring hangers shall incorporate springs with
maximum working range Iength in order to reduce the overall length of the
assembly.
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
start-up
checks
pipe
the
shall
hangers
following
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
shall be protected from corrosion by catholic protection and a system
wrapping to be applied in the workshop.
The design of the catholic protection system(s) shall
and authorized company under consideration of the following:
be
executed
by
corrosion
of tape
specialist
the calculated current required is too low may suitable sacrificial anodes be
used for protection,
of
welding
execution
docs
instruction for issue and return of welding auxiliary materials their drying and
warming, storage and identification
record of performed welding and repairs by welding, their test results and the
welder or welding operator who made them
to
have
the
welding
of
the
test
welds
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.
thicknesses
the positions
inspection plan and test procedure for testing of weld edges and complete
weld.
Prior to start of welding, the welding schedule and test procedure shall be
available at workshop respective site.
and return of
required, their
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
The Contractor shall issue a heat treatment plan showing the temperaturetime diagram
and
a
sketch
with
the
temperature-measuring
points
<Illd
describe the manner of temperature control.
Welding after final stress relieving is basically prohibited. The relevant piece
shall undergo a new stress relieving process if any welding has been
performed afterwards.
adequately indexed
the
Owner/Owner's
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 Valves, Steam traps, condensate drainers, safety valves, control valves
The Contractor shall design and supply all valves and their accessories.
required for the safe, efficient and sound operation and maintenance of the
plant based on the appropriate standards. They shall comply as a minimum
with the design criteria of the relevant piping.
For reasons of plant standardization, the Contractor shall co-ordinate types
and makes of all valves in his supply and that of his sub suppliers.
Design, construction, fabrication and testing of the valves shall be in
accordance with the approved standards. The stipulations of this section will
take precedence if these are more stringent than the approved standards.
All valves shall be suitable for the media and for the service conditions an~
those performing similar duties shall be interchangeable.
All valves shall conform as a minimum to the PN 16 pressure rating.
Basically the following types of valves shall be used:
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)
agreed,
all
valves
shall
be
fitted
with
the
spindle
in
upright
All valves shall be closed in a clockwise direction when looking at the face
of the hand wheel. The valves shall have rising spindles and non rising
hand wheels. Plastic valve hand wheels will not be accepted.
HP and large size gate valves to be opened
be equipped with pressure equalizing valves (globe valves).
under
differential
pressure
shall
valves
shall
be
equipped
with
throttling
control
and
with
parabolic
used
must
comply
accordance with the
for
cones
with
the
relevant
stanrequirements to be met
operation
purposes
it
may
be
The max hand wheel force of 25 deka Newton must not be exceeded.
All block valves DN
manual
override.
The
which can be locked.
500 arc to
actuators
arc
be
to
Preferably
electrical
actuators
shall
be
installed.
for fitment to valves and floor-stands with hand
and
provision
to
switch
over
from
electrical
to
versa (see chapter actuators).
For
pneumatic
or
hydraulic
actuators
Fail-safe functions shall be incorporated.
similar
actuators with
control
points
Actuators
shall
be
suitable
wheels for manual operation
manual
operation
and
vice
requirements
must
be
fulfilled.
The Contractor shall furnish and install steam traps at each low point.
steam
trap
installation
shall
include
a
permanent
strainer,.
upstream
downstream globe valves and a globe valve as free drain. Steam traps
be supplied with weld ends.
Drain traps shall be provided with inlet and discharge valves, vents
controlled
bypasses
and,
when
discharging
into
a
closed
header,
be provided with discharge non-return valves.
Steam traps shall preferably be of the thermodynamic
multistage nozzles selected to suit the service conditions.
or
Each
and
shall
and handshall
also
bimetallic
type
with
used
on
LP
saturated
steam
minimum
working
or
working
differen-
compressed
All gate valves shall be of the fullway gate type and when in full
position. the bore of the valve shall not be obstructed by any part of the
The internal diameter of all valves at the end adjacent to the pipe work
be the same as the internal diameter of the connecting pipe.
air
open
gate.
shall
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
spindles
shall
have
back-scaling
seats
to
allow
glands with the valve open under pressure conditions.
all cases
renewing
where applicable,
of
the
spindle
and
valves
water shall be
for the remain-
shall
be
delivered
system, such
the discharge
c)
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:
= heat insulation
CI
= cold insulation
C
WI
= chilled-water insulation
PPI
service temperature up to
density
water adsorption
6000 C
120 kg/m3
0.5% weight
compressive strength
0.84 kJ/kg UK
50
100
150
200
250
300
Conductivity allowance is limited to + 5 %.
20 kPa
Blanket (W/m K)
0.034
0.040
0.048
0.058
0.070
0.083
0.100
and
the
material
properties
shall
be
labeled
on
each
The insulating mats shall be stitched to galvanized wire mesh using galvanized steel
wire. The mesh size shall be approximately 19 mm.
For special purposes such as for turbines, boilers, etc. spray type insulation or
insulation brickwork (for example calcium silicate) may also be applied. The special
insulation materials shall be stated by the Contractor and their design shall match the
overall design and guarantee the requirements stated in the specifications.
Outer
insulation
to 150 mm
Outer
insulation
to 450 mm
Tanks and other
ment
diameter
up
diameter
up
large
equip-
Sheet
thickness
0.7 mm
Sheet
thickness
0.9 mm
Sheet
thickness
1.2mm
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,
sockets, etc. shall be sealed with funnel-shaped recesses or sheet metal rims.
The seams and penetrations of any sheet metal insulating jacket installed
thermometer
outdoors as well as
spray etc., shall be
silicon based sealant.
aluminum jacket
of the insulating
shall
mats
house in
of water
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
support ring shall be
edges.
against contact
fitted with heat
corrosion, the
insulation tape
shall
be
applied
in
and
one
layer,
stitched
above
to
one
with
shall
way
but
this is
spacers
as
by
pipes,
using
except
strong
essential for
to
process
Where necessary, drain lines and valves shall be provided with a contact guard of
minimum 30 mm thickness against accidental contact, and this shall be installed in
the same way as the other insulation.
Where insulation is provided for heat conservation it shall reduce the heat loss to
an economic minimum. The maximum heat loss shall be 200 W/m2 at an ambient
temperature acceptable at 30C and a wind speed of 2 m/s.
For personnel protection all surfaces with a temperature above 50C and which
are within the reach of personnel shall be provided with protection insulation. The
maximum insulation surface temperature shall be 60C.
Cold insulation
Pre-fabricated
equal quality).
block
and
sleeves
insulating
pieces
made
from
polyurethane
(or
Pipes and flanges shall be cleaned and given an external protection; coat of paint
to 0.35mm (or equivalent).
Prefabricated pieces shall be fitted tightly to the pipes. A self-adhesive
shall be wrapped tightly around the hard foam shells to serve as a steam seal.
plastic
foil
The material and thickness of insulation for the various temperature groups of cold
piping shall be as given in the following table:
Temperature
of pipe
28ucto 5C
if required for
condensation
Piping sizes
mm
100 and smaller
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.
Chilled-water insulation
Material: Polyurethane foam or equal 40 to 50 kg/m 3 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.
covers
vessels,
of
provisions
nominal
weight
must
be
more
than
made
20
for
kg
fixing
shall
and
be
supporting
provided
with
the
hinged
All tank internals must be replaceable through the manhole. Prefabricated vessels
must as a minimum have a coat of primer applied before transport. They shall be
cleaned and internally dry. All openings must be secured closed before transport.
Tanks
Unless otherwise specified, tanks used for the storage of liquid fuels, lubricating
oil, raw water, makeup water, condensate, chemicals, etc. and tanks used for
mixing and agitation shall be of welded construction, manufactured from mild steel
plates of accepted quality and thickness in accordance with the approved relevant
standards.
All welds shall be continuous, including welds
supports (see also Article "Welding" of this Section V).
around
internal
slays,
All large tanks shall have at least two manholes each of 600
complete with covers of the bolted type, fitted with a davit for easy handling.
mm
stiffeners
inner
and
diameter
All tank nozzles shall be provided with flanges, if not otherwise specified.
Nozzles shall be
controllers and piping.
provided
where
necessary
Internal
and
external
protection
painting
according to the requirements of this Contract.
for
of
the
the
fitting
tanks
of
instruments,
shall
be
level
performed
Arrangements shall be made for the blanking off or removal of all valves or pipe
connections during sand- blasting and painting to prevent the ingress of sand or
other matter. The protective process shall be applied also to any ferrous or nonferrous parts mounted inside the tanks.
Heat exchanger
Heat exchangers are to be designed,
with the recognized international standards.
manufactured
and
erected
in
accordance
Only proven products shall be delivered. No cast iron components are permitted.
It must be possible to install and remove the heat exchangers without
difficulty. Lifting lugs and eyes and other special tackle shall be provided to
easy handling. '.
Tubular heat exchangers or
Where necessary the tubes
number of visual inspection
condition monitoring.
undue
permit
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
exchangers.
importance
will
be
attached
to
the
ease
of
cleaning
the
heat
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.
IEC 34
IEC 56
IEC 72
IEC 76
IEC 79
IEC 86
IEC 123
IEC 129
IEC 137
IEC 141
IEC 144
IEC 157
12
2
IEC 162
IEC 214
lEC 269
IEC 287
lEC 292
IEC 298
standards
at
least
The Contractor shall provide the Owner/Owner's representative with four sets
(official, complete, unabridged and in the English language) of all relevant standard
specifications according to which the equipment is manufactured.
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.
12
3
shall
be
applied
for
all
electrical
and
instrumentation
Color code for indications, push buttons on control cubicles, panels, desks, etc.
shall be worked out by the Contractor according to the relevant IEC/VDE
regulations to be approved by the Owner/Owner's Representative.
Where the On/ Off function of a push button cannot easily be identified by the
location, this will be indicated by a sign "ON"/ "OFF" or "0"/ "1" or by color code as
se4scribed above.
Mimic diagrams to be arranged on switchgear cubicles, control panels/desks etc.,
shall be color coded as follows:
green
blue
silver
similar to
similar to
similar to
400/231 V
220/110 V DC
yellow
violet
similar to
similar to
24/48 V DC
pink
similar to
earth
black
similar to
80
15
60
02
50
15
90
06
10
21
30
17
01 0 CD
O
33 kV
11 kV
6.6 kV
R
A
R
A
R
A
R
A
R
A
R
A
R
A
R
A
R
A
o
o
similar to
similar to
brown
red
o
o
230 kV
132 kV
12
4
The additional measures shall consist of sunshades, protection covers againstsplashing 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
12
5
are
to
to
be
the
values.
observed
in
IEC 79 and 364 including VDE 0100 and 0190 for installations up to 1000 V
given
in
carrying
VDE
out
0141
protective
the
purpose
of
6.6/0.42
kV
Connection to neutral
The LV network shall be of the TN
auxiliary transformers are earthed directly.
type,
i.e.
the
LV neutrals
of
the
12
6
parts
vicinity
(e.g.
of
consumer
the
particular
enclosures,
local
frames
is
of
as
as
the phase
a
neutral
in general areas:
in electrical rooms:
The
above-mentioned
measures
for
protection
against
contact
are
also
to
be
applied to 'dead' parts of the plant where, in the case of a fault, a dangerous
contact potential might arise, however, where the parts must not be connected to
the protective earthing system for operational reasons.
12
7
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 Requirements for local cubicles and local housings for e.g.
switchgear, control, measurement and signaling equipment
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.
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
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:
signal collecting and distribution points for firc alarm, telephone, loudspeaker
and clock system
central distribution points for local signals.
Terminal boxes and cabinets must at least have class of protection IP 54 and
must be equipped with the necessary terminal strips, cable glands and fittings
components for the connection of the cables ..
The necessary earthing terminals are to be provided for the earthing of the
boxes and cabinets.
In any area subject to the danger of explosion, the necessary explosion
protected technical boxes and cabinets are to be provided in accordance with
IEC 79 and VDE 0165/0170/0171.
and
(2) where the breakdown or faulty operation of process equipment could
release explosive concentrations of fuel and cause a simultaneous failure
of electrical equipment.
(1)
.
which
may
occasionally
be
reached
by
Oil Immersion:
The parts capable of igniting inflammable or explosive mixtures shall be
immersed in oil to such an extent as to prevent- ignition of explosive
mixtures above the surface of oil by means of sparks or hot gases produced
under oil.
Increased Safety:
To obtain an increased degree of safety on electrical equipment special
measures should be taken to prevent unpennissible high temperatures,
sparks or arcs' inside and outside of the equipment on which they do not
occur under normal working operations.
Intrinsic Safety:
An electrical circuit or part of such a circuit shall be considered as intrinsically safe if neither during normal working operation nor under fault
conditions explosive mixtures are ignited by me~ arcs, sparks or any heat
generation.
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.
Service factor
Up to 1 kW
More than 1 kW up to 10 kW
More than 10 kW up to 50 kW
More than 50 kW
1.3
1.2
1.15
1.1
Electric features
The following electric features shall apply:
a)
b)
c)
d)
e)
f)
g)
h)
Protective features
The following protective\'e features shall apply:
i)
High
voltage
motors
must
be
fitted
determination of slot and bearing temperatures.
with
measuring
points
for
the
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
connections
to
the
thermometer
as
well
cutouts shall be brought into separate terminal boxes.
free, to
as
the
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
box cover. If motors are suitable for only
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
sleeves and end caps.
must
be
longitudinally
divided
to
facilitate
filling
of
cable
opened
terminal
box
an
boxes
earthing
must
clamp
have
for
provision
connection
for
local
of
the
earthing
Bearings
Motors smaller than 2000 kW shall preferably be provided
gravity-fed type oil lubrication system with reservoir and oil breather.
motors
cable
to
with
be
are
to
shield
must
carried
constant
be
out.
level
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
dismantling
the
bearings.
The
bearings
shall
further
be
protected
and
against dust penetration and oil leakage.
without
sealed
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.
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.
Technical requirements
The design of the converter (maximum continuous
maximum shaft output required by the equipment assembly.
rating)
is
to
be
based
on
the
connections
to
rated.
speed
of
three-phase
be fully equipped for
asynchronous
motors
to
be
remote control and monitoring
to
be
provided
the
converter
should
that
the
the
must
are
such
from
The
converter
allows
adjusted steplessly. It
in the control room.
contactor
be
possible
and
power
are
be
input
and
sides
always
An on-load disconnector
input of the converter.
output
must
at
the
converter
be
parallel
power
shall
designed
be
in
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
85% of the motor rated current.
be
designed
for
braking
current
which
is
at
least
If the voltage reduction or the power failure lasts for a long time, the drive mustremain switched off; in
this
case,
it
must
subsequently
only
be
possible
to
switch it on again either manually or by means of the higher order control.
The converters arc to be designed for 10% more than the maximum power
output required by the system. The purpose of regulating the converter is to
ensure that the indirect current and voltage remain within the permissible limits
during all control processes. This should apply both when the motor is started
up and when the speed is adjusted during operation.
All thyristors and diodes arc to be protected by
The fuses are to be arranged upstream of the semiconductors.
The reactors in the DC link
rise in the event of a malfunction.
should
Forced
ventilated
double fans).
are
converters
smooth
to
the
be
means
DC
current
equipped
of
with
to
semiconductor
and
limit
redundant"
monitor
the
fuses.
the
current
fans
fans.
(two
Positive
Converter transformers
The
converter
designed and
76.
transformers
the auxiliary
for
supplying
equipment to
the
be
frequency
converters
are
to
be
provided in accordance with IEC
The
transformer
output
frequency converters.
shall
correspond
to
the
power
requirement
of
the
are
to
be
All
accessories
especially
sensors
arranged so that they are readily accessible.
protection
provided
and
for
arc
be
provided
maintenance
purposes
terminal
to
connections
The
windings
must
be
flame-retardant
and
self-extinguishing.
mixture
must
not
contain
any
flame-inhibiting
additives
which
vapors or gases either under the influence of secondary fires or
arc.
to
the
(earthing
must
be
The
cast-resin
develop
toxic
in the electric
A moisture-proof design will be provided. It will not be necessary to dry the.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
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).
temperature
monitoring
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
applied to a transfer terminal strip as individual signal lines.
monitoring
systems
are
to
be
a)
b)
c)
d)
f)
a)
b)
c)
d)
e)
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
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
and
writings
shall
,be
diagrams or
door of the
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:
Labels for conduits, etc.
The material shall be non-corrodible and the inscription be done with 4 mm
high letters/ciphers.
Labels for cables
Each cable when completely erected shall have permanently attached to it at
each end and at intermediate positions as may be considered necessary by the
Owner/Engineer, non-corrodible labels detailing identification number of the
bar for pressures of steam, water, oil, compressed air and high pressure gas
mbar
for combustion air, flue gas and low
pressure gas
C
for temperatures
mm or m
for levels
^S cm
for conductivity
rpm
%
Nm3/h
t/h
% Vol.
^m or mm/sec
mm
cps
for frequency
A,kA
for currents
V,kV
for voltage
MW, kW
MVAr, kVAr
Wh, kWh
V Arh, kVArh
96 x 48 mm or
96 x 96 mm
48 x48 mm
Indicators
on
control
control room
72 x 72 mm or 144 x 72 mm or
- Recorders:
144 x 72 mm or
72 x 72 mm
panels
144
x
144
recorders)
288 x 288 mm (foI' 12-point
recorders)
mm
in
144 x 144 mm or
96 x 48 mm
mimic diagrams)
(for
line
(when
incorporated
and
6-point
in
Active interlocks shall automatically disconnect units or parts of the powerplant 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.
All secondary shut off valves equalization valves and drain blow-off valves
shall be of the non-corrosive type.
All metallic instrument piping must be protected with corrosion protecting
painting.
All I&C equipment exposed to sun must be protected against direct sun
radiation. This may be done by sun roofs. protection casings. etc.
All multicore I&C cables (with more than 7 cores) outside the buildings shall
be covered completely by means of closed cable trays flexible conduits. etc.
The individual cables from the
terminal
preferably 160 mm diameter
boxes to the instruments shall be
protected as far as practicable.
The
cable
direct
at
the
instruments
connection
must
only
be
protected, if
exposed to direct sun radiation
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
minimi7.c
line
restrictions.
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
permanent pressure losses.
be
considered
when
operating
economy
requires
measuring
low
devices
air
flow
pressure
measurements
at
measuring
points
should
be
provided
with
automatic
with
variable
correction
of
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
the transmitters.
of
flow
measurements
shall
be
effected
electrically
within
special
circumstances
within
some
shall
generally be
carried
out
with
protective
to the
outside
700C
NiCr-Ni
for temperatures up to
950C
Pt Rh-Pt
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:
the attachment of the well in the wall of the exhaust gas channel or air duct
must be gas-proof.
For the measurement of temperature of other media the following requirements
shall be observed:
For all pipe work a minimum immersion depth of 55 mm in the internal pipeline
cross-section and a minimum distance of 15 mm from the opposite pipe wall
must be provided. If the diameter of the pipeline does not allow the
thermometer to be inserted perpendicular to the pipe axis while still maintaining
the above mentioned measurements another solution must be found in
cooperation with the Engineer.
When determining the lengths of the insertion
insulation thickness is 10 be taken into consideration.
and
connecting
tubes
the
potentiometers
will
not
be
accepted
for
use
as
on racks or
tapping point
The
design
and
arrangement
of
tapping
points,
according to VDI/VDE rules 3512 Bl 3 or equivalent standards.
piping
valves
shall
be
the
pressure
and
blow-off
sensor
shall
be
arranged
impossible
condensate
craps
sensor
valves
shall
shall
be
be
arranged
mounted
above
and
the
blow
below
the
if
this
is
be
provided,
with
the
measurements
(half-hour
mean
Power failure and system failures of analyzers shall be monitored in the DCS
by a group alarm.
Adequate measures shall be taken to eliminate dirt from the sampled gas
before it reaches the analyzer. Besides; effective measures shall be taken to
avoid-sulfuric corrosion within the samplers/or analyzers.- .
The analyzers shall be a type which does not continuously consume reference gases (like hydrogen).
The analyzers shall fulfill the following requirements:
maximum
All other meters for acceptance testing shall be not less than class 1.0.
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
voltage circuit
frequency.
input
nor
exceed
0.5%
shall
due
not
to
exceed
10%
5%
of
change
the
in
the
maximum
input
signal
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
full rated input shall not exceed 2 VA and 12 VA respectively.
and
voltage
transformers
at
full
the
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
0 mA representing an input range of 0 to 240% of rated input voltage.
The burden imposed
shall not exceed 5 VA.
on
the
primary
circuit
voltage
linear
transformer
output
at
of
nominal
10
to
input
Current transducers
Current transducers shall have a DC output
current. The transducer output shall be 0 to
input current.
The nominal input current rating shall be 1 amp. The effective range of the
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 adjustablefrom
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:
erosive service
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:
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 correctfailure
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).
0.6.18.6.12.2 Electrical actuation
Two classes of actuators are identified; firstly the motorized actuator which shall
cover the isolating actuator type and including actuator type required: for open
loop (binary) control; secondly the modulating actuator which shall cover the
switched types and continuous control type required for closed loop control.
10 min. to IEC
open/close cycles.
34-1,
and
maintenance
free
interval
better
than
10,000
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 switclll1 nit and actuator shall be
supplied by the same manufacturer as a complete system.
The following features shall be provided for each actuator:
and
be
All
switch
units
and
actuators
shall
be
incorporated
in
enclosures
with
n
protection class of at least IP 54. Better type enclosures shall be provided
where
specified
for
special
applications.
Contractors
if
not
integral
with
the
actuator
shall
be
incorporated
in
the
actuator
boards,
in
in9ividual
compartments
logically
arranged
according
to
their
function.
These
cubicles
shall
be
accommodated in a switchgear room.
(b) Electrical actuators for modulating duties
Modulating
and
regulating
(inching)
actuators
to duty cycle type S4 20% 1200 cycles/h to
interval better than 50,000 hours in normal operation.
These
actuators
shall
be
principal types are recognized:
provided
for
shall
have
a
rating
appropriate
IEC 34-1 and a maintenance free
closed
loop
control
functions.
Two
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 10 7
operations shall be guaranteed by the Contractor. They shall not be used
when full travel times of less than 20 seconds are required.
the
rate
well
AC
of
as
the drive unit shall accept an analogue (4 - 20 mA) actuator position demand
signal or pulsed raise and lower signals if an external position loop is provided
stroking
the
actuator
in
either
direction
for
binary
(v) monitoring of common fault conditions such as thyristor drive fault, motor
temperature high, AC power supply failure, circuit continuity fault, high torque etc.
(vi) all necessary protection devices to protect the actuator and drive unit against
abnormal operating conditions.
Generally the actuator drive units shall either be integrated in the actuator or be
grouped and mounted within cubicles of appropriate enclosure standard. Unless
otherwise specified the later cubicles shall be located in an electrical switchgear
room to obtain protection from the normal plant environment.
The Engineer's approval shall be required where different types of actuators are
offered to those specified above or where the drive unit and actuator are
selected from different range of manufacture (preferably from two different
manufacturers). Additionally these shall he subject to a type test, approved by
the Engineer, to prove their satisfactory performance under equivalent operation
conditions.
0.6.18.6.12.3 Pneumatic actuators
All pneumatic actuators shall be provided with a positioner using a standard 0.2
to 1.0 bar signal.
Pneumatic actuators and drive units shall automatically return to the rest position
upon signal and/or air supply failure unless "process control" or the specification
requirements dictate for "stay put" response.
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.
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.
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
central collecting points for individual analog and binary signals and local
transmitters
Table of Contents
Workshop
manufacturing and
pre-assembly
Works inspections
Testing during
manufacturing
Material tests
Tests at site
General remarks
Hydraulic tests
Test runs and functional
tests
0.7.2.2.4 Visual
inspectio
n,
checking
of
dimensio
ns, test
i
n
s
t
r
u
m
e
n
t
s
0
.
7
.
2
.
3
M
a
n
u
f
a
c
t
u
r
i
n
g
t
e
s
t
s
0
.
7
.
2
.
3
.
1
W
e
l
d
i
n
g
0
.
7
.
2
.
3
.
2
P
r
e
s
s
u
r
e
t
e
s
t
i
n
g
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
Control
and
monitoring
equipment
0.7.3
Testing at
site during installation
0.7.3.1
Erection
Tests
0.7.3.2
Pre-
commissioning tests
0.7.3.3
Tests
completion
0.7.4
0
on
xxx
0.0
xxx
0.1
xxx
0.2
xxx
0.3
xxx
0.4
xxx
0.5
xxx
0.6 xxx
0.7 Inspection and Testing
0.7.1
General
0.7.1.1
0.7.1.2
0.7.2
0.7.2.1
0.7.2.2
0.7.2.2.1
0.7.2.2.2
0.7.2.2.3
0.7.5
Reliabil
ity Test
run
Perfor
mance
tests
0.8 Abbreviations
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:
test program
test standards
manpower and deployment schedule of' the Contractor for performing the tests
forms of test records and report .
description of instrumentation to be used, including accuracy, and calibration
test results
method of data recording
method and equations/correction curves used for adjustment of recorded data to
the design conditions.
The results of all tests shall be
independent agency as appropriate.
certified
by
the
manufacturer, Contractor
or
Document files containing material certificates, welding procedures, test report etc.
shall be compiled for each item of plant and shall be suitably identified (including
equipment classification reference) and bound.
Where the Contractor provides for test in the factory of the Contractor except
where otherwise specified shall provide free of charge such assistance, labour,
materials, electricity, fuel, stores, apparatus, machines and instruments as may
be required and as may be reasonably demanded and approved by the
safety conditions
consideration of the applied standards and regulations
execution of workmanship
conformity with the present state of modern technology.
The following procedure has to be adhered to with respect to test certificates:
Whenever inspections or tests are carried out in the manufacturers' workshop, all
material certificates as well as all other intermediate test certificates, in accordance
with the agreed upon test schedule, shall be made available to the
Owner/Owner/Owner's Representative for inspection. Besides the latest issue of
the related drawings, indicating also the state of approval by the Owner/Owner's
Representative, shall be made available.
The same applies to the final works' inspections or workshop tests when all test
certificates have to be submitted to the Owner/Owner's Representative.
Further, for each kind of test, a "Test and Inspection Manual" has to be prepared
showing all steps of the test procedure as well as the relating standards and
codes.
All these test manuals have to be sent to the Owner/Owner's Representative.
in
be
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
and should include, but not be limited to:
a)
b)
c)
d)
e)
f)
state
the
quality
and
inspection
requirements
other
components
the
Rotor forgings
The profile of forgings at the stage of final ultrasonic
to minimize the regions where complete coverage is not possible.
Ultrasonic indications
AVG (DGS) method.
should
be
measured
by
the
Inspection
equivalent
flat
should be such
bottomed
hole
as
or
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.
18
4
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 fracturemechanics calculations.
Bores,
when
provided,
shall
intrascope used for examination.
be
magnetic
particle
inspected
and
suitable
shall
clearly
state
the
quality
and
inspection
requirements
a)
b)
c)
d)
e)
or
cast-on
reference
numbers
Non-destructive testing
Minimum requirements are as follows:
b) Ultrasonic
inspection
of
temperature or high pressure.
all
surfaces
of
to
future
Standard Level of ASTM E446 or E186 as appropriate):
e) Radiographic
examination shall
indicated by ultrasonic inspection.
also
be
used
castings
to
operate
butt
weld
regions
to
assist
in
testing
all
surfaces
shall
be
satisfactorily
high
(Acceptance
defining
at
defects
cast items,
heat treated
prepared
Repair welding
18
5
and
Unacceptable
defects
observed
by
visual
examination
or
indicated
by
nondestructive testing shall be excavated by chipping or thermal gauging and grindingand their complete
removal proved by crack detection.
In the case of excavations which penetrate more than 25 mm or 50% of the wall
thickness
or
cover
more
than
10,000
mm 2
area
the
Owner/Owner's
Representative's Representative written approval of the proposed repair must be
obtained.
Only welders
used.
qualified
by
performance
tests
on
similar
cast
materials
shall
be
to
the
applicable
on
all
raw
materials
to
ensure
that
they
comply
with
the
and
reactivity.
Long term hoop strength (type test for pressure pipes only)
In accordance with ASTM D2992 Procedure D with the exception that the test
results shall be extrapolated to determine the stress which the pipe can withstand
for a period of 60 years without failure. The lower 95% confidence limit at 60 years
shall also be calculated.
Hydraulic test
18
6
100% of the pipes shall be subjected to an internal hydraulic pressure test at the
manufacturer's works prior to delivery. The test shall be applied to a pressure
equal to 1.5 times the maximum working pressure stated for each classification
of pipe. The test pressure shall be applied for a minimum period of 5 minuteswithout signs of
leakage.
In addition to the above the first pipe and every thirtieth thereafter of each class
and diameter shall be maintained at test pressure for a minimum of 4 hours
without signs of leakage.
Each pipe and fitting shall be subjected to an internal low pressure air test at the
manufacturer's
works
prior
to
delivery.
The
test
pressure
shall
be
an
overpressure of 0.1 bar and this shall be applied for a minimum period of 5
minutes without signs of leakage or distress. Fittings which are of mitred
construction shall be manufactured from pipes which have successfully passed
the tests defined above.
Dimensions
The dimensions and
with ASTM-D 2122
tolerances
of
all
pipes
shall
be
determined
in
accordance
Stiffness
A minimum of one pipe for every 30 pipes manufactured shall be tested for
stiffness in accordance with ASTM-D 2412 "Method of Test for External Loading
Properties of Plastic Pipe- by Parallel Plate Loading". A minimum of one pipe of
each class and diameter of pipe shall be tested.
Cure
Curing, to be tested by the Barcol Hardness test determined in accordance with
ASTM-D 2583 standard: 100 % of the produced pieces. Minimum acceptable
hardness is 90% of the value recommended by the resin manufacturer of the
particular
resin
used,
when
non-reinforced.
The
sample
pipe
shall
also
withstand a commercial acetone test on the internal portion of the laminate.
Loss on ignition
A minimum of one pipe for every 30
accordance with ASTM-D 2584 "Standard
Cured Reinforced Resins".
Joint tests
A minimum of two pipes in every] 00 pipes manufactured shall
tested in accordance with the requirements of section 7.2 of ASTM-D 3262.
in
of
be
jointed
and
Visual inspection
Each pipe and fitting shall be subjected
shipment in accordance with ASTM-D 2563.
to
complete
visual
inspection
18
7
before
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.
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 individ ual 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
conversion factors shall be applied.
be
simulated
if
possible
otherwise
appropriate
specified
by
the
applicable
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.
which shall be
Representative's
> 0.85
Wall
thickness
(mm)
Inside
diam
(10m)
Remarks
nozzle
Fillet
<10
all
<
all
10%R
>40
all
10%M
10%M
<40
< 100
100% R
10%R
> 100
100% R
IO%M
10%M
>40
all
100% R
100% M
100%M
<30
all
10%M
10%M
10%R
> 30
all
100%R
100%M
100%M
all
all
100% R
100%U
100%M
100% R
100% M
100% R-
100%M
100% U
100%U
all
<100
> 100
100%M
100% M
19
1
T ype 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.
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
2.
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
3.
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
4.
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
19
2
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
19
3
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
blisters or
shall
prove
compliance
with
the
rubber
manufacturers
19
5
the running or
shall necessitate
Steam turbines
The turbines shall be completely assembled with their control, stop and
governing valves on a suitable erection rig at the manufacturer's works and
shall be carefully inspected and measured for manufacture and assembly
tolerances. Functional tests shall be performed on the safety equipment
(running with steam is not requested).
Important items of turbine control equipment which cannot be adequately
tested during the main tests shall be separately bench tested.
Furthermore testing shall comprise:
19
7
open circuit saturation, short circuit and loss curves for the generator
a performance chart of the generator (being a diagram of constant
stator and rotor current curves plotted on rectangular axis of MV Ar
and MW load) The recommended loading, stator core end heating
and stability limits shall be shown on the chart.
calculations of full load temperature rise for the stator, rotor and exciter. Any correction factors used to allow for different voltage current
and cooling conditions shall be justified by reference to published literature or to previous type tests.
calculations of the efficiency of the complete generator at 100%, 75%
find 50% load. Any correction factors for losses that could not be
measured at routine tests shall be justified by reference to published
literature or to previous type tests.
calculations of machine parameters such as transient reactance and
time constant, sub-transient reactance and time constant, short circuit
ratio,
synchronous
reactance,
negative
phase
sequence
reactance,
zero sequence reactance capacitance and also the harmonic analysis
of the neutral current.
circulation of full load excitation of the machine at rated power factor
lag1i.ing and at unity power factor, excitation V curves .
Generator rotor
ultrasonic examination
efficiency calculation
19
8
unbalanced load test for negative-phase sequence and zero se-quence reactance
measurement of vibration
polarization index
noise measurement
moment of inertia
and
of
VR
generator,
cubicle
exciter
resistance of windings
insulation resistance
short-circuit characteristic
no-load characteristic
MV Motors
IEC 34, ISO R 1680, VDl 2056
Type tests (each motor type) as far as type test certificates are not
available
efficiency measurement
noise measurement
19
9
at
no
and
dielectric test
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
IEC 262
lEC 400
fluorescent
Telecommunication installations
IEC 215 Safety requirements for radio transmitting equipment
Aerials
IEC 597-2
IEC 169
IEC 492
Protection equipment
Equipment for modular numeric protection systems (e.g. generator, distance, bus
synchronizing units
flow evaluators
On request the correct operation of equipment with specified temperature
and humidity limits shall be demonstrated .by tests conducted within the
limits.
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.
Electrical measuring instruments
All electrical measuring instruments shall be tested in accordance with the
following rules and regulations. Alternatively, equivalent standards approved
by the Owner/Owner's Representative's Representative may be used.
VDI 0410
IEC 51
IEC 258
IEC 414
reactive
power
and
VDE 0418
IEC 338
similar
Calibration tests
The Contractor shall conduct calibration tests of the following
instruments and equipment:
remote
indication
all binary transmitters over the full range including initial setting
and
control
nozzles
e.g.
have
to
printing
system
shall
be
tested
using
DCS system
The system shall be thoroughly tested at the manufacturers' workshops
before dispatch to site. Test programs shall be devised and these shall
subsequently
be
made
available
to
the
Owner/Owner's
Representative's
Representative. Tests shall be made to ensure that the system operates
correctly within the ambient conditions as specified by the manufacturer
and that if these conditions are exceeded, Le. in the case of failure of the
airconditioning system, that the system will automatically fail safe and that
completion
Mechanical
Completion
Certifi-
The activities necessary for mechanical completion shall included but not
be limited to following testing:
safety audit
checking of coating
fire-proof partitioning
rotating-field measurement
voltage checks'
fuses, over current trips, short-circuit trips, time settings, relay settings
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
fire protection
boiler protection
generator
protection
transformer
protection
auxiliaries
LV supplies
start-up tests
normal automatic start to preset load
staged automatic including start to synchronous speed, manual
synchronizing (including synchro-check), automatic synchronizing,
manual and automatic loading
between
variations
30%
by
and
100%
increasing
or
operate
reactive
start-up
including
facilities-
systems
standby
tests
of
checking
the
of
Plant
equipment,
facilities
automatic
change-over
and
of
quality
monitoring
0.7.4
The reliability test run shall be carried out for the power unit including
related equipment and systems and shall last for a period of six (6)
weeks each.
During the specified period, plant unit and related equipment and systems
shall be operated continuously and in accordance with the prevailing
power requirements of the transmission system or as required by the
Owner/Owner's Representative. If possible with reference to the grid, Unit
shall run at MCR.
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
standards:
tests
shall
be
conducted
in
accordance
with
following
the boiler
generator
steam turbine
transformer
The
curves
required
for
the
correction
of
the
power
output
specific
heat
rate
to
the
site
specified
ambient
conditions
shall
listed
in
the
technical
schedules
of
the
Plant
performance
and
turbine performance.
All
margins
required
for
instrument
inaccuracies
reasons shall be deemed to be included in the guarantee figures.
and
for
all
and
be
gas
other
calibrated
shall be
for
as
0.8 Abbreviations
In general when
with KKS numbers .
using
abbreviations
care
shall
be
taken
to
prevent
ASC
AC
AVR
COD
DC
DCS
EHV
EMC
ESP
GRP
H.R.C
BV
I&C
IR
KKS
LHV
MNCL
MCR
MCS
MHS
System)
lower heating value
minimum continuous load
maximum continuous rating
mean cold season (winter) site condition
mean hot season (summer) site condition
O&M
OHL
PC
PPCS
SCAD
A
SWG
SWY
pulverized coal
Power Plant Coding System (~ KKS)
TOV
Technischer Oberwachungsverein
(Technical Surveillance Association)
Deutsche Industrie Norm
DIN
VDE
confusion
Table of Contents
B1.
1.1 General
1.2 Scope of Supply and Services
1.2.1
1.2.2
1.2.3
1.2.5
1.2.7
1.2.9
Boiler accessories
1.2.10
1.2.11
General
1.3.1.1
1.3.1.2
Design
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
1.3.2.2.1
Steam generator
Furnace and connection pass for dry slag/ash extraction
1.3.2.2.2
Pressure parts
1.3.2.2.7
Headers
1.3.2.2.8
Coal bunker
1.3.3.2
Coal feeders
1.3.3.3
Coal mills/pulverizers
1.3.3.4
1.3.3.5
1.3.3.6
1.3.3.7
1.3.3.8
1.3.3.9
1.3.3.10
1.3.3.11
Filters
1.3.3.12
1.3.3.13
1.3.4
1.3.5
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
local instrumentation
1.2.2
1(one)
continuous
blow-down
flash
tank
blow-off pipe, control valve and necessary equipment
(atmospheric
tank) incl. Cooling system,
1 (one) boiler drain flash tank with flanges, vent drain and
1.2.3
connecting pipes.
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
two PC sampling studs with air scaling connections for each PC pipe
1.2.4
coal handling plants, including bunker isolating arrangement, feed chutes, mill
downshafts and coal feeders with all electrical drives, fuel bed depth regulators, coal
sampling points, remote sensors for electronic fuel bed depth and rotary speed
checkback signals
flow meters for oil supply and return line and each burner
oil trays
1.2.5
Comprising essentially:
furnace wall steam soot blowers
semi-stroke rotary steam soot
electrical drive
blowers
with
retractable
lance
and
electrical cubicles with incoming feeder circuit breakers, motor protection and indicators for power consumption, pressure, temperature, advance and retract operation
1.2.6
1 (one) boiler wall inspection lifting equipment (for steam
generator)
Comprising essentially:
lifting capacity
one lifting winch
type
3,000 kg
external winch
construction
The
working
The whole working platform is fitted with a guard plate on top. In addition the working platform has to be fitted with:
platform
2 safety catches
plastic rollers to keep off the working platform from the boiler walls
plastic wheels for transporting the working platform outside the boner
plant
2 hand lamps, 42 V, 60 W
accessories
special tools
Comprising essentially
moulded refractory lining and shaped fire bricks in the area of the
burners, access doors and peepholes, etc.
furnace moulded refractory
1.2.8
Comprising essentially:
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.
1.2.9
Boiler accessories
Comprising essentially:
boiler inspection cradles for fast inspection and repair of combustion
chamber and stock
utility station for air, steam and water from connection branch of main
distribution supply up to the consumer, including hoses, hose couplings
and stop valves
fire fighting equipment for steam generator, complete with all integral
pipes, valves, nozzles, hoses
equipment and provisions for stand-still conservation of the steam
generator.
1.2.10
(one) auxiliary steam boiler fired with diesel fuel oil, complete as
package with all systems and accessories including at least (to allow
start-up and critical operation without any external supply of steam):
economizer furnace and super heater
one forced draft fan
complete duct work from FD fan to the oil burners
oil burners
complete
instrumentation,
control
and
monitoring
equipment
burner
management
associated piping
feed Water system including feed water pumps
flue gas ducts from boiler outlet to the stack
steel stack.
under
the
Section
refer
to
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,
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
from the coal bunkers and supplied by coal feeders to the inlet chutes of
four coal mills (one standby). In these, the coal is pulverized, dried
classified. The coal is supplied to the burners via pulverized coal (PC)
with distributors. The classifier temperature is regulated by mixing with
air.
The main design criteria of pulverizer design has to be:
MCR has to be generated by 3 pulverizers
coal, without supporting oil
in
service,
burning
rate
the
and
lines
cold
design
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.
Start-up at any time of the warm or hot steam generator with hot turbine.
start-up of the warm steam generator with cold turbine, if after a short
steam generator operating time during which the turbine did not roll, the
unit has to be started up new
1.3.1.3
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.
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.
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
1.3.2.2
Steam generator
The steam generator to be installed shall be of natural circulation water
tube type and designed for dual coal and diesel oil firing. The unit shall be
208
of balanced furnace design with two regenerative air heaters, two FD fans
and two ID fans.
1.3.2.2.1 Furnace and connection pass for dry slag/ash extraction
The furnace shall be of the fully water-cooled welded membrane wall type.
The volume and dimensions of the combustion chamber shall prevent flame
impingement or excessive heat transfer upon any portion of the watercooled walls or other parts of the furnace enclosure at all operating
conditions.
The furnace size shall provide sufficient space for flame development and
shall allow complete and efficient combustion of the fuels specified before
leaving the furnace. Central or division walls are not accepted.
The configuration of the furnace shall be so that the air/flue gas flow will
reach all its parts and there will be not dead zones in which the formation of
an explosive gas/air mixture can occur.
The furnace outlet temperature (at first bundle heating surface inlet) shall
be selected under consideration of the initial deformation temperature of the
fuel with the worst ash specified.
The design will consider that no fouling in space superheaters for these
coals which can affect the reliability of the unit will occur. The supplier
should present detailed design of furnace- and gas outlet temperature
profiles to the purchaser during the design stage of the project for the whole
band width of all fuels specified.
The furnace and burners shall be such that when burning the types of fuel
specified and under all conditions of load up to the maximum output, there
shall be no flame impingement on any surface of the furnace walls and no
accumulation of slag on the walls, tubes or hoppers or other part of the
boiler units that will interfere with the continuous operation of the units.
Furnace design shall be designed primarily taking into consideration the
operation of the boilers on Barapukuria coaL
No additives are to be used to improve combustion, fouling problems,
corrosion problems or other reasons.
The furnace and convection pass shall be equipped with all necessary
access and inspection doors, access doors being located at both side walls.
A sufficient number of observation windows shall be provided in the
appropriate positions to allow for visual observation of the flames, the
combustion process and the roots and the tip of the flame of each burner.
Numbers of TV cameras and suitable position of openings shall be so that it
will be possible to observe the root and the tip of each flame, as well as the
number of burners in operation.
The combustion chamber shall be welded flue gas tight whenever possible,
22
4
wall
of
the
furnace
shall
be
duly
protected
against
All loads of the furnace with framing and insulation as well as burners and
ductwork shall be led by the evaporating tubes and anchors to the supporting steel structure at the boiler top casing without causing bending stress in
pressure parts.
Slag/ash removal from the boiler shall be by means of a submerged
slag/ash scraper extractor. Ash falling into the hopper of the flue gas blank
pass and regenerative air preheater shall be directed to the wet ash scraper
extractor. The water in the slag extractor shall flow in a circuit via a cooler,
and shall be cooled and conditioned so that continuous or discontinuous
blow down is not necessary.
Provision shall be made at the steam generator for the attachment of
furnace inspection equipment. Inspection and repairs from inside of all walls
above the furnace bottom shall be possible.
The following are required to ensure a good combustion at all loads:
attention
is
to
be
paid
to
the
following
characteristics
in
the
even flue gas distribution for intense heating of the furnace area
good reswirling of the flue gas to the burner section to stabilize the
ignition of the pulverized coal;
special deflection and removal of the flue gas flows for optimal fly ash
retention;
no or low CO content in the flue gases.
An optimal solution for the furnace design and shape is to be found by
means of special flow tests-'1' model experiments), Further it is to be
ensured that the ash carried in with the coal extract heat from the flue gas
considering possible change of flue gas profile which can lead to a
decrease in the end temperature of the furnace.
22
5
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.
1.3.2.2.5
of
the
gas-tight
for the
efficient
uniform distriseparation of
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:
removable baffle plates located close to drum internal face, in front of
riser pipes.
centrifugal or cyclic type separators or similar distributed on both sides
of the drum and adequately supported .
steam
scrubbers
made
of
perforated
plate
and
located
below
the
saturated steam exhaust pipes .
feed piping, perforated on its whole length, with adequate supports,
extended inside the drum to both sides .
in case of chemicals injection into the drum for uniform distribution of
injected
chemicals,
adequately
supported
and
securely
attached
to
structural member.
continuous blow-down tube extended along the whole length of the
drum and perforated along its whole length.
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.
1.3.2.2.8 Safety valves, fittings and mountings
All fittings and
regulations listed
mountings
shall
comply
with
applicable
standards
and
The boiler shall be valved so that start-up and shut-down can be done
remotely from the control room. Subsequently, all valves, except the
isolating ones which will be shut-off only in case of repair, shall be electro
actuated.
It must be possible to operate the motorized valves by hand also.
The valves and actuators installed in the steam generator's steam/water
system shall be of an identical pattern and manufacture with those applied
for similar piping systems of the power station, which are subject of this
Contract.
Double valves on vents and drains and on tapings for instruments and
sampling points shall be installed on high pressure and intermediate pressure (reheat) pipes.
For the steam generator, the drain configurations shall be as follows:
superheater and reheater drains shall consist of one shut-off valve and
one throttling valve
vents shall consist of two shut-off valves
evaporator and economizer drains shall consist of two shut-off valves.
These valves shall be arranged so that the upstream valve when closed,
has. a spindle and gland which is load-relived and the operation shall be
performed with the downstream valve.
blow-down
devices
are
installed,
shall
line.
be
fitted
to
number
the
boiler
of
safety
drums
and
valves
of
superheaters
where
approved
and
shut-off
another
on
applicable
design
the
hot
and
reheat
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:
provided to
temperature
which may
temperature
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.
1.3.2.2.10 Water level indicators
Two local drum level gauges, showing the full scale complete with
lighting fitting shall be included. The electrical energy for these fittings
will be taken from the DC supply of the power station.
One gauge shall be fixed so that the water level can be easily seen
direct at the boiler drum level. The second bicoloured gauge shall be
fitted to enable the water level to be seen from the location of the
feedwater control valve.
The gauges shall be fitted with drains, and valves for shutting off and
blowing through. Double isolating valves shall be provided.
Two sets of nozzles and isolating valves for water level transmitters
shall be provided under the Section B9 (Instrumentation and Control
Works). All water level devices shall be provided with independent drum
nozzles.
The gauge glass fittings shall be of forged steel and shall be designed
so that they can be removed as a complete assembly without shut-down
of the boiler.
The water level transmitters shall be connected to a separate pair of
branches on the drum for a water level indicator on the main control
panel and for the three-element feedwater closed loop control:
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.
detrimental
drain
lines
to
be
of
heat
resistant
material
(80C
sootblower
Sootblowers
shall
be
operated
by
electrical
drives
with
local
pushbuttons
as
well
as
a
common
panel
for
the
whole
sootblower
system. The preheating of the piping system as well as its drainage and
the operation of all sootblowers in a suitable sequence shall be actuated
by a master pushbutton from this panel. Failure in the operation shall be
indicated by alarm lights of the panel and a common alarm signal will be
conducted to the unit control room.
Two cooling and sealing
for flue gas corrosion.
air
fans
(on
stand-by)
shall
avoid
the,
tendency
All
retractable
type
sootblowers
shall
be
adequately supported and
be
provided with lateral protection against accidentally knocking as well as
to
provide
correct
guidance
during
insertion
procedures.
All
sootblowers
shall be suitably guarded to prevent personnel coming into contact with
moving parts or hot surfaces.
Accommodation
for
test
pressure
gauges
shall
be
provided
in
the
medium supply pipes and/or at the blower lance to check the blowing
steam pressure. The pressure shall be adjusted as necessary to obtain
the optimum cleaning conditions.
The
numbers
of
sootblowing
cycles
shall
be
three
per
day
maximum.
Sootblowing
shall
be
possible
at
any
load
of
the
generator.
as
a
steam
shall
give
no
process
shall
be
for
washing
chosen
with
of
the
regard
steam
to
a
fixed
suited to
installed
washing
system
wash one of the air
23
7
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 Firing and grinding system
The steam generator shall be equipped with a complete coal grinding
and firing system and an ignition and back-up firing system based on
diesel fuel, comprising the following main items:
coal bunkers
coal feeders
coal mills
PC burner pipes
The PC firing as the principal firing for the boiler shall be designed for
direct firing. It shall be capable to cover the specified boiler turn-down
range. The MCR load point and partial loads of 30% MCR and greater
shall be achievable without the aid of the ignition and backup firing, but
taking into account the specified fuel range. Depending on the coal
quality, in the minimum load range it shall be permissible to operate the
ignition, back-up and support firing system.
The number, type and arrangement of the PC burners shall be decided
by the Contractor. It shall be guaranteed that the prescribed design data
and operational requirements are met completely.
Of particular importance is that the statutory emission standards for
nitrogen oxides will be met.
Also the isolation arrangements shall be of low wear design and require
versionly no maintenance.
The burners shall be so assigned to the mills that if one or more of the
mills is switched off or fails, asymmetric fireside temperatures wiIl be
avoided.
Shut-down of one or more complete burner levels shall also serve the
purpose of achieving the required minimum load. Cooling measures for
the burners which are not in operation have to be foreseen for avoiding
the
bunkers
shall
be
as
The bunkers shall be properly integrated with the boiler steel structure,
presenting
an
overall
neat
appearance.
For
this
reason,
they
should
preferably be of rectangular or square form in plain view with pyramidal
hoppers.
The following recommendations should be followed for the section of the
shape of bunkers:
steep sides of hoppers, with a minimum inclination of 75 to the horizontal
opposite
sides
having,
if
possible,
a
different
angle
of
inclination,
bunker
discharge
zones
with
large
outlet
openings,
minimum
dimension of 1.0 m
no
additional
constructions
between
outlet
openings
and
feeders
(maximum length of 2.00 m)
round off with a minimum r = 600 mm at bunker edge.
The geometry of bunkers shall be satisfy the mass flow requirements,
taking into account the following:
effects
of
funneling,
Carbon
steel
of
sufficient
abrasive
resistance
and
good
welding
properties shall be used for bunkers plates. Stiffeners and all supporting
steel shall he conform to the standard specification.
The
bunkers
shall
be
designed
with
unlined
considering no plugging and smooth coal discharge operation. '
inside
surface
by
of
as
erection tolerance.
Bunker emptying facilities are to be provided. These shall consist of:
A
permanent
mild
steel
chute
extending
form
underneath
each
feeder, through the operating floor to a position just above the mill
cranage runway beams. The cute shall be positioned so that coal in
the feeder will reach it before reaching the discharge opening in the
mill.
One
motor
bunker outlet.
A
temporary
chute,
for
attachment
to
the
permanent
chute
and
extending from the permanent chute to a position in the mill aisle
convenient for direct discharge onto a lorry. The chute shall be made
from mild steel except for the least 2 m of the chute which shall be of
a reinforced rubber to facilitate even distribution on the lorry.
operated
slide
gate
valve
shall
be
be
provided
emptied
at
at
time
each
and
automatically a
handling control
to operate a
and
operate
pneumatic
remote
adjustment
are
to
be
provided
as
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.
shall
be
suitable
equipped
with
for
pressurized
adjustable
operation
classifier
in
system
by
an
electric
failure,
they
other
starting-up
can easily
repairs can
It shall be possible to isolate the mills from the hot air/gas ducts and
from the dust ducts in such a way that the boiler operation will not ~e
disturbed when isolating one mill, and that maintenance work such as
rearmouring has not to be done under hard conditions. Doors of the
pulverizers
shall
be
provided
with
hinges
and
quick
acting
opening
dosing facilities.
Pulverizer
maintenance
and
operation in a quick and safe manner.
repair
shall
during
be
failure
possible
during
plant
of
one
pulverizer
without
fuel
oil
and
conditions
Particular guarantees
wear
and
erosion
quantities).
shall
(the
shall
be
possible
firing
in
All parts subject to wear and tear shall be so designed that an exchange
of worn-out parts shall be possible (easy access), even while boiler is in
operation.
After
the
guarantee
period
of
pulverizer
parts,
subject
to
wear
erosion,
the
pulverizer
capacity
throughout
may
decrease
by
maximum of 10%.
Suitable
measures
shall
be
taken
to
prevent,
under
conditions, each part of the mill being endangered by over temperature.
all
and
a
operating
provided on
the bearings
1.3.3.4
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.
and
discharge-side
silencers
with
The provision of the plant with an inerting system will be mandatory. The
offer shall consider an inerting system based on nitrogen, CO2,
inertisation with steam or flue gas (according to the manufacturer's
standard and for experience).
1.3.3.8 Start-up and backup firing system operating on diesel fuel oil
The diesel oil system will be used for boiler start-up and backup firing up
to 35% MCR boiler load.
The diesel oil system to be in accordance with TRD 411 or other similar
standards shall be completely up to the burners comprising following
main items:
diesel oil burners with burner stations in groups, integrated in the
centre of the PC burners with oil return system .
flow measurement devices for supply and return pipes motor driven
main shut-off valve arranged at the end of the oil supply ~ pipes
(before distribution to the burner stations.
Type, number, arrangement and size of combined coal - diesel oil burners
shall be selected in such a way as to cope with the above requirements.
Each combined coal diesel oil burner has to be equipped with ignition and
cooling air supply, high energy spark plug ignitor and all necessary valves,
dampers and flame detectors.
Openings for burner lance, flame detectors, ignition Iance and inspection
peep holes are to be provided.
Each burner has to be equipped with an adjustable airswirl vane assembly
for optimizing the flame shape.
Burner shall not be subject to any deterioration by radiant heat when out of
operation. Therefore oil guns and ignition equipment shall be pneumatically
retracted in cooling position. A separate cooling air system has to be
arranged for cooling the burners, which are out of operation.
Flame detection system (IR/UV receiver) shall be of the self-checking
design. Start-up and shutdown shall be realized by a sequence programme.
232
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 m 3);
Diesel oil unloading station [Two (02) diesel oil unloading pumps including
valves, pipings, filters and others as per requirement];
Interconnection with the existing diesel oil system.
reliably
stiffened.
The specific gravity of all tank contents shall be considered with 1,000 kg/m 3.
Corrosion allowances shall not be provided for the tanks.
The tank bottom
slope of at least 1 %.
shall
be
pitched
downwards
conically
to
the
outside
with
Around the inside tank perimeter two drainage sumps shall be provided. Each
sump shall be equipped with a 50 mm diameter drain pipe connected to the
shell double flange nozzle. A shut-off valve with a blind flange shall be provided
outside the tank.
All flanges at the tank shall meet the requirements of the piping
in
Section
B06
General
Technical
Requirements,
Mechanical
flanges shall be of the welding-neck type.
All connection and spare
outside of the tank. All
outside the tank.
nozzles shall
spare nozzles
The fill nozzle is to be designed as a roof unit. A bend pointing on to the- tank
wall is to be flanged on to the inside of the tank so that incoming oil ' flows
tangentially to the tank wall. Care must be taken to ensue that the bend is
located with about half its effective section above the highest liquid level. A
baffle plate is to be provided at the tank wall.
All other nozzles - with the exception of ventilation and sounding hatch and the
return nozzle of the heavy fuel oil tank - are to be arrange din the lower shell
course.
Shell
manholes
are
to
be
equipped
with
hinges
(davits). A safety device
prevention unintentional closure of the cover is also to be provided. The clear
diameter of all manholes (shell and roof) shall be 600 mm at least.
A shell spiral staircase shall be furnished from grade
intermediate platform is to be arranged at half the tank height.
to
the
top
of
the
tank. An
Two roof vents shall be provided and each shall be designed for 100% capacity
to pass air so that at the maximum possible flow rate of the oil, either entering
or leaving the tank, excessive positive or negative pressure will not be
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,
sockets, manholes, measuring instruments, etc., allowance shall be
an insulation layer with a thickness of approximately 100 mm. The
shall meet the requirements set out in Section B06 (General
Requirements).
such as
made for
insulation
Technical
device
which
allows
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
initial pressure drop as low as possible
maximization
of
useful
screen
area
to
keep
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
resistant and heat resistant materials.
pourers
shall
be
made
of
process
water
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 equivalentmaterials shall be
used.
The
nominal
pressure
of
the
foam
system
should
with adequate reliability be above the maximum possible operating pressure.
1.3.3.13 Electrical, control and monitoring equipment
The diesel oil pumps sl1all be controllable from the auxiliary panel in the
central control room. Indication of operating conditions, must, however,
also be available at the local control board.
Oil levels of tanks as well as all hazard, fault and monitoring information
from tanks, filters, pumps, etc., must be clearly arranged and recognizable
in the central control room.
The foam system shall work automatically by means of push button
control in the central control room.
1.3.4 Auxiliary steam boiler (if required)
Existing 2 x 125 MW units have 1 (one) 10 ton/ hr capacity auxiliary steam boiler.
If these capacity is not enough for the proposed 250 + 10% MW unit, then 1
(one) auxiliary steam boiler is required.
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
auxiliary steam boiler shall be decided by the Contractor.
and
arrangement
of
the
and
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 pipingand 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 Inside cleaning of boiler pressure parts
After erection of each boiler the manufacturer shall perform boiling out and
blowing out as a protection measure. If necessary, the boilers shall be
passivated after this procedure. No acid cleaning measure is required but the
coal fired boilers themselves must be designed and fabricated in such a way
that an acid cleaning process can be carried out if required by the Purchaser.
If it will be found out after boiler erection that the inside tube and header
surfaces "are rusty and dirty, acid cleaning of boiler and all other equipment will
be carried out by the supplier without any costs for the Purchaser.
The criteria for above decision are as follows:
1. Thermodynamic Data
Minimum requirements
Unit
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
It RH inlet
kg/s
bar
0
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 (latest edition)
Chemical mode of Operatiion 1 alkaline as per VGB Directive
8.0 - 8.5
pH-Value
Flue Gas
flue gas temperature It regenerative preheater outlet
max. allowable flue gas temperature at ESP inlet for 10
min.
150
350
B1/FB1
Minimum requirements
Unit
Data
2. Performance in Service
n/a
8500
10
30
100
20
(referred
(referred
to
to
MCR)
MCR)
CD
+1 +1
From
50
From 30 Start-up times
% MCR/ min
% MCR/ min
and 70 bar
Cold start
from OC/bar 50/1.0
up to OC/bar 450/70
min
min
min
Minimum requirements
Unit
Data
m3/ h
400
mm
380 x 425
m/s
12
1.8
1.2
plain tubes
in-line
100
80
10
on both sides
Directly
down
stream of
mm
mm
%
evaporator
mm
800
mm
60
m
m
pieces
2
inline
100/200
mm
mm
B1/FB3
1.2
2 pass 3
stages
crosswis
e
1.8
55
on both
sides
10
75
Minimum requirements
Unit
Data
Reheater (RH)
Max. height of heating surface tube banks
Minimum clearance between two tube banks where an
access possibility is provided and! Dr where sootblowers are
installed
Design of reheater
Arrangement of connection pipelines between the RH stages
Number of necessary attemperators between reheater
stages I and II
Tube arrangement
Transverse
pitch
RH
I
not
less
than
Longitudinal
pitch
RH
I
not
less
than
Transverse
pitch
RH
ll
not
less
than
Longitudinal
pitch
RH
II
not
less
than
Add-on
reserve
heating
surface
Arrangement of access doors
m
m
1.8
1.8
2-pass
crosswise
2
pieces
mm
mm
mm
mm
%
in
100
70
400
70
10
line
on both sides .
The attemperator spray water quality corresponds to that of
the feedwater
PC direct firing
gas-side vacuum
high volatile
bituminous coal
Annex
Note:
1. The boiler shall attain its MCR when firingng the coal
within the band with specified at any of the local ambient
conditions.
2. Optimizing of boiler design Shall be based on the guarantee coal.
Annex
MJ/kg
%
0- 35
42
Minimum requirements
Unit
Data
20
steel structure
Minimum requirements
operation
hours
Unit
or 1 single
fan: minimum
Range
of control,
Resistant up to pressure of
capacity
Coal
preparation
and burning equipment
Other
data:
%MCR
0
Minimum
Type control
number of pulverizes In operation at minimum
load of the boiler of 30%.
Pulverizers
Ingestion temperature at design point
Type of drive
Minimum interval between two scheduled Overhauls of the
mills
-1
Maximum speed
Design
margins
of each pulverize:
Sealing
air fans
addition
of
wearMinimum number to-tear
min 1
Data
bar
110
Minimum
admissible velocity at pulverized coal/air mixture
capacity
m/s121
Type
Pulverized coal burners
T ype of control
The capacity of an burners shall be such that the boiler
MCR
can be
malntainedat
with
one burner
Ingestion
temperature
design
point out of operation
(n-1)
Type of drive
Primary air fan
capacity
Firing capacity of ignition burners
B1/FB5
18
-1
min 1
%MCR
%MCR
1:5
delivery head
110
capacity
121
Safety margins
B1/FB6
radial
60
1:5
3.5
design temperature +
n-1
5O 0K
radial
Maximum
speed
Safety
margins
for design
and back-up
firing system operating
2 Start-up
fans operating
in parallel:
on diesel fuel oil
deliveryof
head
Capacity
diesel oil pumps
24 at MCR
Minimum requirements
Unit
Data
60% MCR
MSL
%MCR
0
0
C
C
60% MCR
Superheater spray water flow at
kg/s
100% MCR
60% MCR
Reheater spray water flow at
kg/s
kg/s
100% MCR
60% MCR
Coal consumption for
100% MCR
Boiler efficiency based on HHV for
100% MCR
60% MCR
Air temperature at pulverizer inlet at
kg/s
t/h
%
%
0
60% MCR
Flue gas temperature (uncorrected) at stake inlet at
60% MCR
C
C
100% MCR
oo
oo
100% MCR
Excess air in furnace at
100% MCR
60%MeR
MSL
B1/FD1
%
%
%
Bidder/Contractor
Unit
Data
Bidder/Contractor
-
Unit
Unit
Data
- 0C
- 0C
Attemperator 3 outlet
Summarized
data
Number of pulverizers
in operationperformance
for
Reheater 2 outlet
100% MCR
pc.s
60% MCR
pc.s
pc.s
MSL
MWC
kg/h
MW
0
C
kg/s
0
C
100% MCR
Note:
Bidder/Contractor
After reheater 1
60% MCR
All data refer to MCR
andsuperheater
guarantee conditions
After
1
kg 0/s
MSL
kg/s
Feedwater
After
regenerative
air preheater
Live steam
pressure (constant
over the whole load range)
kg/s
barC
Live steam
At stack inlet
kg/S
kg/s
(drum temperature equal with ambient temperature)
kg/s
attemperator 2 MSL
Time of preparatory measures (including time for heating
Reheater spray attemperator
kg/s
Range
constant
temperature
up
theofboiler
vialive
thesteam
deaerator)
up to first ignition
attemperator
bar
bar
bar
0
Cold
temperature at
Drumreheat
temperature
Drum/evaporator
min
%MCR
Warm
60%MCR
start
B1/FD2
Superheater
C burner
1 outletTime of preparatory measures up to Ignition of first
0
burner to MCR
Attemperator 1 outlet
Atlemperator 2 outlet
min
0
0
min
kg/s
kg/s
min
kg/s
Superheater
C
C
0
bar
min
min
0
bar
min
min
Superheater 3 outlet
B1/FD3
C
C
100%, MCR
Economizer outlet Time from ignition of first burner up to MCR
Drum
temperature (after preheating)
Hot reheat steam flow at
Water/steam temperature
at (after 48 hours shut-down)
Cold start
B1/FD4
Data
Minimum requirements
Bidder/Contractor
Unit
Data
Unit
Manufacturer
min
Cylindrical length
Type of internals
Safety valves
bar
0C
0C
Drum level
mm
%
Excess air
Number
%/ min
bar
0C
Capacity
Set pressure
Data
0C
% MCR
Drum level
mm
%
bar
Excess air
Max.
heat release per unit related to:
Hot reheat line safety
valves
projected heating surface
Number
volume of combustion chamber
Capacity
"
m2
% MCR
m3
bar
MW/m2
-
MW/m3
% MCR
Set pressure
mm
Blow-down rate
kg/h
m
mmxmm
mm
mm
B1/FD7
B1/FD5
mxmxm
m3
m3
kg/h
Bidder/Contractor
Unit
Data
Manufacturer
Platforms
kW
W/m2
Denomination (type)
Manufacturer
Bricksetting material
Denomination (type)
Manufacturer
Form of delivery
Refractories
Sootblowers
--
soot towers of SH
Numbers of sootblowers
pcs
Type
Soot blowers for economizer
Numbers of soot blowers
Type
Soot towers of RH
Numbers, of sootblowers
Type
pcs
-
pcs
-
Bidder/Contractor
Unit
Data
pcs
-
pcs
-
mm
t
mm
Chute material
Coal feeders
Manufacturer
Number
Type of construction
pcs
-
Capacity
Design coal density
kg/h
kg/m3
-
Operation range
Conveying width
Max. bed coal height
For withstanding an inside explosion pressure of
mm
mm
bar
Rated power
kW
-
Design
Coal
Coal mills
Number of mills
Manufacturer
pcs
-
Type / Model
Capacity per mill. max. after 3.000 operation hours
kg/s
kg/s
kg/s
B1/FD9
kg/s
Worst
Coal
Bidder/Contractor
Unit
Data
Design
Coal
mbar
kg/s
0
C
kW
Type of gear
BPDB,
Barapukuria
Plant
Weight
per mill
incl. gearPower
and motor
Section
B1:
Steam
Generator
Cooling water mass
Technical Data by the Bidder
Mill Inerting
drivingsystem
motor for coal mills and coal pipes and ducts
Manufacturer
Medium used for inertisation
TypeQuantity of medium required
Rating
PC burners
Rated voltage
Manufacturer
Speed
Type/model
t
kg/s
Primary
Number
air fans
of burners per boiler
Manufacturer
Pressure loss in the burner (air side)
of primary/secondary/tertiary air
TypeProportions
of construction
Bidder/Contractor
Unit
kg/h
kW
kV
min1
-/pcs
mbar
pcs
m3/h
kg/s
TotalNumber
head of flame detectors
Weight per burner
Air temperature
mbar
0
C
pcs
t
kW
rpm
pcs
-
-/-
MW
kg/S
bar
pcs
m3/h
mbar
0
C
pcs
pcs
m3
kW
m
m
rpm
B1/FD10
Worst
Coal
pcs
t/ h
bar
-
kW
kV
.1
min'
bar
Data
Bidder/Contractor
Unit
mm
mmxmm
m3
Type
Number of pumps
Flow rate per pump
pcs
Kg/s
B1/FD12
Kg/s
pcs
Data
electro and hydraulically operated control valves at the inlet part of the
HP section of the turbine
check valves and motorized isolation valves for LP bleed to the deaerator/feedwater tank
jacking oil pumps one with AC, one with DC motor drive (if applicable)
control oil pumps with AC motor drive (if separately necessary)
oil vapour extraction fans with AC motor drive with oil separation in the piping
oil coolers
double oil filter for the complete lubricating oil flow
double oil filter for the complete control oil flow
all connecting piping, fittings, non return valves. safety devices. fastenings., supports of
the oil system. Sheet metal ducts for oil piping and other oil spray protection equipment.
connections for mobile purification plant
'.
1 (one) common mobile oil purification plant for all turbine oil systems
Waste oil disposal system
Drains for oil tanks, oil coolers, etc. to liquid waste basin including all required piping,
filters, valves, instrumentation etc.
Downtime Ventilation Plant
1 (one) transposable downtime ventilation
complete with air drying plant, etc.
plant
to
avoid
down
time
corrosion,
Condenser
2 (two) condensers, complete. with spring sponsor expansion compensators on the
on the steam duct, with hotwell, condensate level control etc., each including at
least:
vacuum breaking device
all connecting piping, safety devices, fastenings, etc.
1 (one) steam/air ejector for start up complete.
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.
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
1 (one)
follows:
synchronous
synchronization,
associated
etc.
CO 2
equipment
AC
generator
including
with
fire
complete
cooling
measuring,
protection,
metering
pipework,
system
as
and
control
2.2.4
Piping, insulation
Piping, valves and accessories
All required piping as far as not included in the other sections (as e.g. steam
generator plant, water treatment systems, auxiliary systems) including all
accessories such as drains, vents, valves, safety devices, steam traps,
condensate drainers, strainers, actuators, pipe supports, anchor points,
expansion joints, nozzles for instrumentation and control fixtures, flanges,
gaskets, connection elements, calibrated pipe pieces for expansion measurements, silencers for blow-off lines, lines and bypasses for start-up lines
etc.
Insulation
2.2.5
Heat conservation
Personnel protection
Vessels
Cold condensate tank
2
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.
2.3.2
Steam
turbine
Casing
The steam turbine is to be designed to ensure a very good and rapid adaption of the turbine to alterations in load and alterations in the steam conditions.
In order to be able to check the condition of the turbine blading without
opening the casing, borescope openings are to be provided at suitable
points on the casing.
In order to allow for rapid assembly and dismantling, the turbine casing is to
be split horizontally and supplied with guides to permit safe lifting of the
casing.
The casing and their built-in features is to be supported centrically as far as
possible. The design and surface preparation of the supports are to be such
that thermal expansion is not prevented. Packing plates shall be provided to
enable good alignment to be achieved.
Blading, nozzle segments
Rotor and stator blades, nozzle segments and control parts are to be produced in erosion and corrosion resistant material (stainless steel).
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
outside the range from 85% to 120% of the
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
ings. The thrust bearings must be capable of taking load
and be self-aligning. They must be axially adjustable.
split plain
from both
bearsides
bearing
shells
without
removing
the
Gland steam
Gland steam must not be discharged into the turbine hall. The labyrinths
be provided should have spring elements if possible. It must be possible
inspect the outer labyrinth through a removable cover without having
open the turbine.
to
to
to
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.
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.
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
arrangement and different colouring.
be
made
easily
distinguishable
by
clear
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.
2.3.5
Turbine cladding
The turbine cladding is to be designed as a sheet metal cladding with noise
insulation and provided with sufficient corrosion protection. It shall cover the
complete turbine area including the turbine outer bearings. Heat build-up
within the turbine cladding is to be avoided by suitable ventilation.
2.3.6
Downtime ventilation
The maximum relative humidity in the turbines during standstill downtime
periods shall not exceed 40% under all possible ambient conditions and
suitable airdrying plant and connections shall be provided for the ventilation.
The air guidance within the unit to be protected is to be arranged so that all
parts experience a sufficient flow. The ventilation equipment is to be
designed for at least two air changes per hour referred to the volume to be
ventilated.
2.3.7
2.3.8
Condenser
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
functioning of the condenser cleaning practice by chemicals is ensured.
that
satisfactory
must
be
suitable
for
accepting
all
drains
occurring
accepted.
All connections in the vacuum area must be welded.
2.3.9
2.3.10
2.3.11
Evacuation units
Either steam ejectors or waterring pumps may be employed for
maintaining the vacuum in the condenser. They shall be designed
sufficiently large to maintain the vacuum in the condenser even with small
leaks. The start-up vacuum shall be provided by means of a start up
evacuation unit.
2.3.12
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.
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
ready means of checking oil flow, filling and draining.
visual
oil
level
indicators
and
with a dial
warning of
testing
the
excitation
equipment
without
the
be supplied
control and
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
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
incorporating an air-to-water heat exchanger. and shaft mounted fans.
circuit
cooling.
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
ments of the generator in addition to the protection of the diodes.
field
forcing
require-
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
bridge if necessary to afford overall protection of the rectifier
excessive over voltages
rectifier
against
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 eliminated.
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 therectifier assembly.
The
Bidder/Contractor
should
describe
the
method
used
to detect and report such failures and the resultant action of the excitation
system.
Rectifiers for SE system
The thyristor converter shall incorporate a number of three phase full wave ,
bridges, and has to be arranged so that a minimum of20% reserve capacity
is incorporated. The converter should be of modular construction so that a
minimum
of
one
bridge
may
be
removed
for
maintenance
(shut-down
required), which still allow full load excitation and unit operation without any
restrictions.
In the event that the converter derives its AC power requirements from the
main
generator
terminals,
the
excitation
supply
transformer
should
be
capable supplying full field forcing voltage at 80% of rated generator output
voltage. In addition a permanent DC control supply for electronic circuits will
be provided with such a method of converter supply.
The thyristors are to be protected by line or arm H.R.C. fuse as appropriate.
and may operate in connection with suitable crow-bar circuits. Indication of
thyristor failure has to be provided. Provision shall be made in the design of
the converter for the protection of the thyristors against gross over voltages.
The repetitive peak reverse voltage rating of the
the three phase bridges of the converter has
maximum reverse voltage appearing across an
factor of at least 2.0.
included
for
the
detection
and
across
the
annunciation
input
of
of
excess
The system shall include suitable limit control features, fault detection and
protection
features
and
where
appropriate
generator
transformer
overfluxing protection. In the event that dual channel operation is offered,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.
The thyristor output stage of the excitation control equipment
continuously rated for the excitation demand of the generator at
field forcing under fault conditions and a contingency of 75%.
must be
full load,
the
Contractor
for
voltage
Overvoltage protection
Overcurrent protection
will
trip
must be provided
purposes. Control
Means for both local and remote (from central control room) operation or
the manual control shall be provided with
locally
to
non-inductive
and
rated
and
suppress
medium
grinder
circuit
initiating a
temperature
The generator cooling system must be complete and include all necessarycoolers, 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
cooler) as preferred solution, cooling classification
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
expansion and vibration. Any necessary apparatus
withdraw
the
air coolers or permit repair has to be provided. Water
detectors
must
be provided for all coolers, which will initiate an alarm in
a
leak
occurring.
CO2 equipment
leak
1 position
1 position
the event of
18 positions
1 position
position
positions
each
2 positions.
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 cubicles
Along the indoor run of the GMC's, all
voltage transformers, overvoltage capacitors,
be housed in steel sheet cubicles.
as
to
(VT)
are
to
be
partitions are to be
and the transformer
stress,
three
protective
capacitors
the
generator
main
connection
must
near
he
the
in
in
aforementioned
protection
equipment
V switchgear and with the protection
Synchronizing
The general synchronizing point will be the 230kV
type electronic parallel-switching apparatus must be provided.
circuit
breaker.
plugin
possible
when
switching-
to
the
general
requirements
on
control
and
monitoring
in
Speed control
self-monitoring.
Protection equipment
The protection interlock chain "Turbine protection" is to .be executed in
particularly safe and high quality technology and is to he introduced into the
control ns interlock criterion so that the turbine is protected from overload
and damage throughout the complete operating range. The following
Turbine speed greater than maximum [at least two (2) independent speed
checks for 110/112% with the possibility of testing during continuous
operation]
by
All the mechanical-hydraulic and electrical protective circuits 011 the turbine
must be so constructed (for example using 2-channel, 2 from 3 selection,
self-monitored principles) that faults in one protective interlock cause no
erroneous release, on the one hand. but do not prevent the initiation or
rapid shut down in actual cases of danger, on the other. The protective
circuits must be supervised by checking the equipment initiated from the
central control room and it must be possible at any time to inspect the
functional correctness of the protection without causing a trip of the turbine.
The protection signals must operate on all turbine emergency stop valves
and, where applicable, on the bleed emergency shut-off valves.
33
7
to
accommodate
displacement
of
the
pump
The shaft seals shall be of the soft-packed stuffing box type in the case of
booster pump and mechanical seals for main feedwater pumps. The stuffing
box and corresponding gland cover shall be cooled; the seal chamber nt
mechanical seals shall be cooled as well.
Removable wearing
the running joints.
rings
shall
be
installed
on
the
casing
and
impeller
at
Each impeller
impossible to
33
8
33
9
2.3.17
accessories
Pipe and valve specification
The pipe systems must conform to the requirements
"(General Technical Requirements", as a minimum requirement.
declined
in
B0
Interconnection work
Piping systems > DN 80 and > 120 0C must be stress analyzed from anchor
point to anchor point, regardless of battery limits or individual contracts.
2.3.18
Feedwater heaters
Installation and removal of the various items of plant must be possible
without difficulty. Special provisions must be made for the withdrawal of the
heater tube bundles.
The wall thickness for shells and ends shall be at least 8 mm. The heat
exchanger tubes shall be scam less with an inside diameter of at least 15
mm.
An adequate number of inspection holes must be provided at particularly
susceptible areas, such as the steam inlet, above the water level regulator,
etc. to allow visual inspection of the internal condition of the 'heat
exchangers.
The stub pipes shal1 he welded wherever possible, both internally and
externally. Stiffeners with inspection holes for stub pipes should be welded
in place where necessary.
LP feed water heaters
Adequate provision shall be made to protect the turbines against the
backflow of water from the LP feedheaters. In the event of increased level
the condensate of LP feedheaters I shall drain to the turbine condenser. If
the water level rises above a certain set point, a level monitor shall close
the shut-off valves in the bleed steam lines to the LP feedheaters.
Similarly, the emergency drain of the LP feedheaters and the steam side
safety) valves shall be suitable for discharging the maximum rate of
condensate flow according to the requirements
34
0
U(if
All pipe collections and all connections on the vacuum side shall be welded.
Valves and other fittings exceeding nominal size
continuously or intermittently under vacuum shall
water connections.
Shell and tube bundle
protection at the steam
proper air extraction so
changers.
of
be
25 mm
provided
which are
with seal
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
must be capable
off valves.
The HP feedheaters
ME stamped heaters.
shall
be
designed
according
of the HP feedheaters
of the emergency shut
to ASME
and
shall
be AS
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
34
1
34
2
Minimum Requirements
All parts of the pumps coming in contact with the water arc to be manufactured
in stainless material. Casings and rotors arc to be provided with wear rings in
order to permit easy replacement of the parts subject to wear. Condensate
from the discharge pipe is to be used as scaling water as far as required.
In normal cases one pump will be in operation. The second pumps shall
start automatically if the operating pump trips.
MW
%
%
Hz
Unit
Turbine
Turbine type
Number of turbine casings
Maximum Continuous Rating at generator terminals at
cooling
water inlet temperature of 35C (according to mean cold
water temperature of cooling tower)
heating stages
bar
Condenser
Cooling
water
temperature
increase
Maximum cooling
water velocity in
condenser tubes
with
10% blocked tubes
Design pressure
Max.
cleanliness
factor referred to
design
cooling
surface
Frequency
Permissible frequency deviations at Maximum
Continuous Rating
without limitations
maximum 20 minutes duration but not exceeding 2
#
hours per year
maximum 10 minutes duration but not exceeding 1
#
hour per year
Number of pre-
m/s
m/s
Data
Minimum
cooling
water velocity in
condenser tubes
34
3
According to IEC
recommendations
latest edition
104
-0/+3
50
-3 to +3
-4
-5
minimum 6
max. 10
2.2
full vacuum
110
1.5 or according to
requirement of
sponge ball
cleaning equipment
17
34
4
B2/FB-1
34
5
34
6
Minimum Requirements
Unit
Data
kV
Select between
(11 - 15.75) 5%).
50
Rated frequency
Hz
cos phi
cos
phi .
%
0.80
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
0.92
17
0.5M5
5P20
110/ V3,110/3
0.5/0.2
Rated voltage
kV
12 - 17.5
kV(peak)
75.-95
kV
Earthing switch
00
CO
00
CM
B2/FB-2
34
7
Minimum Requirements
Unit
Data
C' Max.
turbine low load
temperature
Design pressure
Design temperature
LP feedheaters
Design pressure of LP
feedheaters (steam
side)
Design temperature of
LP feedheater (steam
side)
Variable
pressure with
fixed minimum
pressure
120% of
respective
maximum
turbine bleed
pressure and
full
vacuum
HP feedheaters
Design pressure of
HP feedhealers
(sleam side)
Design temperature
120%
of
respe
ctive
maxi
mum
turbin
e
bleed
press
ure
and
full
vacuu
m
Maxi
mum
turbin
e noload
tempe
rature
plus
20 K,
but at
least
200
C
of HP
feed
heater
s
(steam
side)
348
feedwat
er
pumps
at
minimu
m flow
and
cold
conditio
ns
120% of maximum
delivery head of the
Drain condensate pumps
No. of pumps
2 x 100%
B2/FB-3
349
Bidder/Contractor
Section B2: Steam
Turbine Plant
Technical Data by
Bidder
Data
Unit
MW
turbine generators
bar
Maximum Continuous
Rating of turbine
generator
kg Is
kg/s
bar
Steam temperature at
Steam Turbine
Manufacturer
Type
Casings
Number of casings
Casing design HP
Casing design IP
Casing design LP
Rotors
Number of turbine
shafts
Distance between
bearing centres HP/IP
shaft
LP shaft
B2/FD-1
rpm
mm
mm
Bidder/Contractor
Section B2: Steam
Turbine Plant
Technical Data b y
Bidder
Blading
HP regulating stage:
Type
of
wheel
Mean
blading
diamet
er
Pressure in the
regulating wheel
chamber at MeR
HP/IP blading:
Type of H.P./I.P.
blading
(impulse/reaction)
Number of stages
Length of blades last
row
Mean blading
diameter last row
LP blading:
Type of LP blading
(impulse/reaction)
Number of stages
Length of blades last
row
Mean blading diameter
last row
Exhaust area of last row
(axially)
Data
Unit
Materials
HP/IP outer casing
HP/IP inner casing
HP/IP blade carriers
LP outer casing
LP inner casing
mm
LP blade carriers
bar
HP/IP rotor
LP rotor
HPIIP nozzles
HP/IP rotor blades
LP nozzles
LP rotor blades
mm
Casing of emergency
mm
stop valves
(HP-steam; reheatsteam)
Casing of HP-steam
mm
governor valves
mm
m
Casing of reheat
steam governor
valves
Casing of LP-steam
governor valves
B2/FD-2
Bidder/Contractor
Unit
Number of valves
HP-steam
reheat-steam
Turbine speeds
Rated
rpm
Overs peed trip - electrical
- mechanical
rpm
rpm
Data
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
Bidder/Contractor
Unit
BPDB,
Barapukuria 250 MW Power Plant
Width
of foundation
Section
B2: Steam Turbine Plant
Height
of foundation
Unit
Data
Gland part
steam
condenser
Heaviest
to be
handled by crane
Bidder/Contractor
Number of condensers
Weight of heaviest part to be handled by crane
Materials:
Weight of complete turbine generator
Tubes
t
-
Cold
start
from ambient temperature
Gland
exhauster
warming-up
time
Number
of exhausters
min.
min.
warming-up time
Type
starting
Drivetime up to nominal speed
loading time up to full load
Speed
Turning device
Material of pump casing
Method of operation
min.kW
min. m3
min. I/h
min.
bar(g)
min.
-
min.
min.
rpm
rpm
-/%
Type
Rating
Rating
B2/FD-4
kW
kW
Speed
rpm
Type
B2/FD-5
Data
Bidder/Contractor
BPDB, Barapukurla Power Plant
Bidder/Contractor
Unit
Rating
Speed
Material of pump casing
kW
rpm
-
Type
Rating
Speed
Material of pump casing
kW
rpm
-
Type
Rating
kW
Oil cooler
Number of coolers
Erection (horiz.lvert.)
Cooler length
Materials:
mm
Tubes
Shell
Oil separator
Manufacturer
Type
Heat rating
kW
Rating of drive
kW
Data
Unit
Data
Type
Grade of filtration
^m
System pressure
bar(g)
Number of pumps
Type
Rating
kW
Speed
rpm
Type
Grade of filtration
^m
Condenser
Manufacturer
Type
Arrangement
Steam flow
kg/s
m/h
bar
kJ/m2sK
%
m2
Bidder/Contractor
BPDB, Barapukuria 250 MW Power Plant
B2: Steam
Turbine Plant
Section B2:Section
Steam Turbine
Plant
Technical Data by Bidder
Technical Data by Bidder
Type or name of system
Diameter of tubes (bore)
mm
mm
mm
Bidder/Contractor
Unit
Unit
Data
Shell
Vibration Measurement
minutes
-/%
-
m3/h
Motor rating
Closed valve head
Manufacturer
kW
m
Designation of system
Speed
Type of bearings
Type or name of system
rpm
Material of pump
casing/shaft/impeller
Total
number of shaft vibration sensors
Control and monitoring
equipment
Total number
of bearing vibration sensors
Electro-hydr. governor:
Manufacturer Manufacturer
Designation ofMaximum
system air humidity downstream the turbine
Designation of system
B2/FD-8
Data
B2/FD-9
Bidder/Contractor
Unit
-/%
Material of tubes
Synchronous generator
Applicable standards
Manufacturer
Type
Protection class
MVA
cos phi
cos phi
MW
Rated voltage
kV
%
A
Rated frequency
Hz
Rated speed
rpm
kA (peak)
kWs/ KVA
kV
kV
Data
Bidder/Contractor
Unit
mm
m
kw
V
A
Exciter voltage
At rated generator output: Exciter current
Exciter voltage
Exciter machine
V
A
V
Manufacturer
Type
Power Input
Insulation class
Voltage regulator
Manufacturer
KW
-
Type
Generator dimensions
Total length
Total height
Total width
Generator weights
Stator weight
Rotor weight
Transport weight complete generator
t
t
t
-/t
Data
Bidder/Contractor
Unit
Hz
msec
El
-
V
%
Type
Generator main connections
Manufacturer
Type of ducts (short description)
Rated system voltage
kV
Rated frequency
Hz
Rated current
kV(peak)
kV
kA(peak)
kA
Data
Bidder/Contractor
Unit
Data
A
-
protection
Secondary voltage of voltage transformers
Accuracy class: measuring
V
-
metering
protection
voltage regulation
Earthing switch
Manufacturer
Type of earthing switch
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)
Bidder/Contractor
Unit
Data
Capacity of steam
t/h/%
Capacity of steam
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
-/%
-
m3/h
m
-
kW
VOITH,
Germany
m3/h/m*/h
m/m
m
kW
Bidder/Contractor
Unit
Coupling
Type
Data
kw
Type
Materials:
Pump casing
Shaft
Impeller
m3/h
Delivery head .
kw
Type
Maximum allowable transmitted load
kw
Bidder/Contractor
Unit
Dat
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
Bidder/Contract
Unit
Manufacturer
Nominal capacity
m3
m3
Outside diameter
mm
Total length
mm
Materials:
Shell
Internals
Operating weight
kg
kg
bar
bar
Type
Heat rate
kJ/s
kJ/m2sK
Drain side
K
m2
mm
Total length
Tube outside diameter
Tube wall thickness
Materials:
Tubes
Tube plate
Shell
Weight
mm
mm
mm
kg
Data:
Bidder/Contractor
Unit
kJ/s
kJ/m2sK
Drain side
m2
mm
Total length
mm
mm
mm
Materials:
Tubes
Tube plate
Shell
Weight
kg
Manufacturer
Type
Heat rate
Heat transfer coefficient (outside diameter) condensation / drain
kJ/s
kJ/m2sK
Drain side
Total heat exchanging surface (outside diameter)
K
m2
mm
Total length
mm
mm
mm
Materials:
Tubes
Tube plate
Shell
Data
Weight
kg
Bidder/ Contractor
Unit
Type
Heat rate
Heat transfer coefficient (outside diameter) condensation/drain
Terminal temperature difference
Steam side
D rain side
Total heat exchanging surface (outside diameter)
kJ/s
kJ/m2s
K
K
K
m2
mm
Total length
mm
mm
mm
Materials:
Tubes
Tube plate
Shell
Weight
kg
Type
Heat rate
Heat transfer coefficient (outside diameter) condensation /drain
kJ/s
kJ/m2s
K
Drain side
m2
mm
Total length
mm
mm
mm
Materials:
Tubes
Data
Tube plate
Bidder/Contractor
Unit
kg
m3
Installation level
%
kW
Data
41
4
Dryer
Processed coal weighing belt scale etc.
two coal crusher complete with feed hopper, electric drive, necessary
supports, explosion and fire protection measure, dust proof housing,
classifier, inertisation devices, screening system
traversing
and
reversible
distribution
belt
conveyors
for
coal
transportation from the crusher to the new coal storage area (open and
covered storage area)
extension of existing two coal supply belt conveyors 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
passive safety measure to protect the stored crushed coal against selfignition
scaling system
such
suppression
walkways,
as
belt
system
conveyor
drives,
idlers,
including
bridges,
pulley,
water
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
spray
necessary
belt
and
system,
the
belt
conveyors
shall
be
lodged
in
closed
outside
cladding.
Above the conveyor heads or take-up stations respectively trolley beams for
a payload of 3 tons shall be provided.
3.3.3
3.3.4
3.3.5
of
instantaneous
conveyance,
totalizing
and
tripping
shall
be
Reclaiming system
The raw coal shall be handled by conveyor to the crusher/screen house.
The crushed coal shall be conveyed directly to the boiler coal bunkers. In
the case coal is not needed in the boiler coal bunkers the crushed coal shall
be sent to coal storage areas. The transfer of the crushed coal to the coal
storage area and the distribution shall be done by traversing and reversible
belt conveyors. Crushed coal storage area shall have a capacity of 8 days
plant - MCR requirement considering the worst coal involved. The coal
storage area will be operated only in emergency when coal is not received
from mines.
Suitable traveling type of stacker shall be provided to stack the crushed coal
to a height relevant to the availability of space. Necessary platform with
drainage facility shall be considered. Soil improvement to improve bearing
strength and other requirement shall be considered as required. Reclaim
from both coal storage areas (covered and open storage area) shall bedone 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.
3.3.6
3.3.7
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.
3.3.8
3.3.9
quality
in
which
respirable
3.3.10
the interlocks provided shall permit one stream operation retaining the
flexibility in operation.
Control room
The inplant coal handling system starting from the crusher up to boiler
bunker feeding trippers operation shall be controlled from inplant coal
handling control room located in the Plant near to crusher house. Other
equipment/components shall be operated from local stations (see also
Chapter 9).
Minimum Requirements
Unit
Data
kg/m3
0.65
kg/m3
1.0
1.1
1.0
hours
m/s
2.0
1 x 100%
1 x 100%
1 x 100%
coal crusher
2 x 100%
2 x 100%
1 x 100%
belt scale
1 x 100%
2 x 100%
mg/m3
0.5
B3/FB-1
Bidder/Contractor
Unit
Manufacturer
Belt widlh
mm
Height of borders
mm
Handling capacity
Belt velocity
kg/h
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
Data
Bidder/Contractor
Unit
Data
Weighing scale
Type
Manufacturer
Capacity
Accuracy
location
_
kg
%
-
Tripper conveyor
Manufacturer
Type of construction
Number
length
_
-
pcs
m
Capacity
kg/h
Width
mm
Belt velocity
Coal bulk density
m/s
kg/m3
B3/FD-2
Table of Contents
B4. Air and Flue Gas System
General
4.1
4.2
1
2
3
1
2
34.3
4
5
6
7
General
Air and flue gas ducts and dampers
FD fans and ID fans
Steam air preheaters
Regenerative air preheater (AH)
Flue Gas recirculation fans (if required)
Electrostatic Precipitators (ESP)
4.2.2
the FD fan and mill primary air ducts between the air fans and the
regenerative air preheaters
all measures necessary for damping out vibration and for noise
attenuation including silencer.
B4.
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 preheaterinlet
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
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
damping
out
vibrations
and
for
noise
rapping
equipment
shall be
lor
the
operation with two (2) regenerative air heaters but one (I) FD fan
respectively one (1) ID fan
the
be
dampers shall be of
wherever possible/shall
maximum differential
fitted
with
locking
the
be
multi-leaf
arranged
type
with
Dampers in flue gas ducts shall be designed and located so that the buildup of ash behind the damper blade is reduced to a minimum and their
opened and closed position has to be used for the FD fan and boiler
interlocking.
The damper spindles shall be of steel which is sufficient resistant and
special attention shall be given to the design of the dampers. spindles and
hearings to protect them against the ingress of dust/ash and distortion or
deterioration due to high temperature. The bearings of the dampers shall
be located outside and shall he or the self-lubricating type.
Special attention shall be given to the sealing arrangements
dampers to ensure gas and air tightness when in the shut position.
Each damper shall be equipped
unmistakable notch on both shaft ends.
with
local
indicator
and
or
isolating
an
easy
Tapping holes
suitably and correctly located for its
purpose
shall be
provided
for
permanent
instruments
and
for
checking
and
testing
purposes for pressure readings and flue gas sampling. All ducts shall be
designed to minimize resistance to air and gas !low and to give good
distribution of air flow particularly to boiler sides and the burner air
registers or to the burner wind box.
The air or flue gas leakage of the dampers when closed shall not exceed 1
% of the maximum flow.
All flue gas dampers which are installed
operation of the unit shall be provided
shall be supplied between the dampers.
Both
regenerative
air
preheaters
shall
be
provided
with
one
common
bypass on flue gas side so that during cold start-up operation without anyregenerative 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
fed separately.
burners
shall
be
designed
so
for
burners
and
that
the
at
least
each
membrane
row
wall
will
be
shall
be
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.
of
drawing
the
combustion
air
in
for
the
shaft
shall
be
thermally
fans also at a
the rated horse
stabilized
prior
to
final
The shaft forged and machined from mild steel or high tensile steel
shall be designed to have its first critical speed not less than 125% of
rated
speed.
The
impeller
shall
be
statically
and
dynamically
balanced before shipment commissioning.
If as a result of electrical black-out there is a total failure of the
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.
coolers
and
all
other
operation of the Plant. .
equipment
required
for
the
safe
and
sheets
efficient
of
not
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
cleaning of the AH heating surfaces.
The
AH
shall
be
equipped
fire
alarm
equipment
display
arranged
for
water
washing
shall be supplied.
to
be
designed
for
the
most
effective
with
fire
extinguishing
devices
including
panel.
The
AH
elements
shallbe
and
all
necessary
washing
equipment
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
sufficient length, electrically operated, shall be provided.
the
elements
or
accordance
with
the
before
the
Electrical part:
The
spraying
and
collecting
electrodes
shall
be
designed
replacement. , Sectionalized collecting electrodes would be preferred.
for
easy
Dust/ash
loading
shall
be
considered
when
designing
dueling.
To
prevent
the
formation
of
condensed
water
protection
against
freezing.
the
ESP
shall
be
equipped
electrically
operated
heating
system
for
the
complete
hoppers.
raw
and
with
fly
gas
as
an
ash
The
insulator
devices
at
the
HV
electrically and designed for easy replacement.
inlet
passages
shall
be
healed
The gas-tight casings. access doors and peep holes in the casings of
electrical
and
mechanical
connections
shall
be
designed
to
minimize
air leakage into the ESP. Internal pockets or ledges where ash might
accumulate
shall
be
avoided
wherever
possible.
The
rapping
gear
for
the
collecting
electrodes shall
as
far
as
possible be
arranged
inside
the ESP. The intensity and frequency of the rapping shall be variable
and the gear shall operate without undue noise.
Expansion
joint
against erosion.
shall
be
provided
from
steel
with
inside
protection
The Contractor shall take all necessary steps to ensure free ash flow
out of the hoppers. A rapping mechanism which raps intermittently at
the
hopper shall
be
provided
to avoid
bridging of
fly ash
in the
hopper.
The
hopper
shall
be
effectively
dried
out
during
commissioning
and
shall
be
insulated
as
specified
to
prevent
condensation
which
impedes removal of the dust. The dust hoppers shall be provided with
ash bridge -breaking devices of the approved type which shall be a
permanent
fixture
arranged
near
the
outlet
from
each
hopper
and
operable
from
a
platform
underneath
the
hopper
when
the
precipitator is in service.
The hoppers shall be furnished with double rotary locks for isolation.
Special attention shall
across the precipitator.
be
given
to
ensure
uniform
flue
gas
distribution
The
local
control
panel
for
the
precipitator
shall
be
provided
placed
near
the
ESP
and
shall
cont61in
all
equipment
instrumentation
for
both
automatic
and
manual
controls.
There
be remote indication for from this cubicle to the mimic diagram of
central
control
panel
to
indicate
precipitator
operation
status
(e.g.
and OFF). All precipitator and rapping gear fault alarms for the
shall be brought up by a common signal at the control room to
alarm panels.
and
and
shall
the
ON
ESP
all
each
shall
be
insulator
monitored
separate
arranged
will not
an
alarm
compartment,
to
each
into
and
access
any
Bidder/Contractor
BPDB, Barapukuria Power Plant
Section B4: Air and Flue Gas System
Section B4: Air and Flue Gas System
Technical Data by BIdder/Contractor
Technical Data by BIdder/Contractor
Air flows
Bidder/Contractor
Unit
Data
Unit
Data
mbar
m3/s
m3/s
mbar
mbar
mbar
Air
0
Barapukuria
Power Plant
wet/dry (m3 at 0 BPDB,
C, temperatures
1013
mbar)
Ambient B4: Air and Flue Gas System
Regenerative airSection
preheater secondary side:
Primary steam
air heater outlet
3
Technical
Dataheated
by BIdder/Contractor
wet/dry (m at OC, 1013 mbar)
Secondary part
Number
Pulverizer
inlet
0
of bearing
wet/dry (m3 at 0 Type
C, 1013
mbar)
Air pressure
FD fan outlet
m3/s
m3/s
C
m /s
m3/s
Unit C
m3/s
m3/s
- C
m3/s
m3/s
Fan
speed
Forced
draft fans
Inlet temperature
Manufacturer
Bidder/Contractor
C
rpm
mbar
Tubematerial
Combustion chamber
Power
Forms of tubes (oval or round)
Before superheater Related voltage
Fin material
Before economizer
Speed
Pitching of fins
Before air preheater Cooling water consumption
Thickness of fins
Before ESP
B4/FD-2
Weight
B4/FD-1
mbar
mbar
mbar
mbar
pcs
pcs 2
mm/s
kg/s
mbar
bar
0
C
pcs
kg/s
0
%
kW
bar
- kW
kV
rpm
mm
kg/s
mm
mbar
Number
pcs
-
Type
Heat exchanged
MW
m2
B4/FD-3
Data
Bidder/Contractor
Unit
Data
mm
mm
kg/s
kg/s
kg/s
kg/s
"c
"c
"c
Rotational speed
-1
mm
Manufacturer
Type
Rating
kW
Rated voltage
kW
Speed
min-1
Manufacturer
min
min
kg
kg
B4/FD-4
Bidder/Contractor
Unit
Data
Washing medium
wash water flow
kg/s
Type
Number
pcs
kg/s
Flow rate
pcs
-
mbar
kg/m3
kg/s
%
kW
Type of controller
Gearbox manufacturer
Type
Range of control
Weight per fan and motor
Motor:
Manufacturer
Type
kW
Rating
kV
Rated voltage
Speed
Cooling water consumption
B4/FD-5
-1
min
kg/s
Bidder/Contractor
Unit
Manufacturer
Type of construction
Number of fans
Capacity of each (m3 at O0 C. 1013 mbar)
pcs
m3/s
m3/s
Capacity of each
Bidder/Contractor
Static head
mbar
Unit
Manufacturer
Type
Thickness
mm
Power
Material
Rated voltage
Number per treatment zone
Data
Data
kW
kV
Speed
rpm
kg/s
Electrostatic
(ESP)
Effective
lengthprecipitator
between
plates
Manufacturer
mm
pitch
mm
mm
Number of ESP
Number of treatment zones in series per ESP
Specific of
absorption
surface
Number
HT sets per
zone
pcs
pcs
m2/m3/s
Collecting
electrodes
Number of HT
sets per unit
-
T ype of rectifier
Type
Thickness
Type
of rapping gear
Collecting
Material electrodes
mm
-
Discharge
electrodes
Number per
treatment zone
Frequency
or rapping
Total number
per unit
Steel casings
Effective height
Projected area per zone
Thickness
mm
m
m2
Total projected
area per unit
Casing
design temperatures
m2
Effective
area static
per unit
Casing
design
gas pressure
mbar
m2
mm
Pitch
B4/FD-6
Method of insulation attachment
Type of external finish
Hoppers
Number of dust hoppers per precipitator
Capacity of each dust hopper
kg/m3
mm
B4/FD-7
mm
Unit
Type of rapping
g/m3
Gas temperature
m3/s
wet
m3/s
%
g/m3
g/m3
ESP inlet
g/m3
mg/m3
P/o
mls
Treatment time
Draught loss
Temperature drop in ESP
Rated capacity of each HT set
Ash discharge capacity In case of silo loading
B4/FD-8
s
mbar
C
kW
t/h
Data
General features
B ottom ash removal sy stem
Crusher
Bottom ash bunker
Ash hoppers. gates and dust isolating valves
Belt conveyors for ash handling
Fly ash removal system
Jet conveyors
Intermediate fly ash bunker (if necessary)
Pressure vessel ash conveyors
Air slides
Rotary seal and traversing chutes
Heating system
Flat isolating valves
Exhaust air filters. exhaust fans. air supply system
Fly ash silo
Compressed air system
Slurry pumps. waste water pumps
5.3.4
1(one) drag link scraper ash/slag extractor complete with driving unit for
variable speed air tight casing tensioning device for drag link all electric drives
base frames. steel structure, etc designed for operation with process water
ash/slag chute for feeding the scraper conveyor
complete process water cooling system
connecting pipes separating valves. controls to the process water circulating
system
complete ash, slag crusher including gear, motor coupling base plates and
anchoring holts
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.
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
water recirculation system from ash pond to ash/water mixing vessel including
recirculation water pumps
facilities for drainage and cleaning of the slurry pipelines
pipeline scraper.
The bottom ash slag removal system has to be designed for worst coal
operation. The submerged scraper conveyor is to be constructed in such away 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-regulatingtension
devices to be used.
Corner towers if necessary) shall consist of steel frame work and outside
cladding. Intermediate stairs and steps shall be provided with grid floorings.
Above the conveyor heads or take-up stations respectively trolley beams for a
payload of 3 tons shall be provided. The bottom ash supply into bottom ash
bunker shall be done by means of a horizontal tripper conveyor. For drives,
brakes, etc. the general provisions stated in other specifications for cranes and
hoists will apply.
5.3.2.2
5.3.2.3
Exhaust air from intermediate bunker and fly ash silo shall be removed via
adequate filters. At the fly ash silos exit, the ash shall be wetted by a
humidifyingworm 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)
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
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).
5.3.3.2
5.3.3.3
5.3.3.4
Air slides
Air slides are to be provided with inspection glass and hand hole covers at
intervals of at least 3 m.
The insulation must be split designed and be provided with quick action service
locks.
5.3.3.5
5.3.3.6
Heating system
All the hopper gates in the ESP, collecting bunker coal chutes rotary locks cellular
wheel sluices and air conveyor chutes are to be equipped with steam trace heating
including the necessary isolating valves and condensate separators. If steam is
not available they arc to he equipped as electrical trace heating (at least 400
Watt/m2).
A list showing which plant parts are to be provided with heaters must accompany
the offer.
5.3.3.7
5.3.3.8
5.3.3.9
5.3.3.10
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.
Minimum Requirements
Unit
Data
as per Annex
MCR of boiler
1.1
1.0
25
%
%
15
90
days
Net storage capacity of fly ash bunker corresponding to the ash production
at MCR
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%
Bidder/Contractor
Unit
Operating data
Data shall be filled in for guarantee coal at MCR
Ash resulting from:
furnace
nd
kg/h
kg/h
kg/h
ESP
kg/h
kg/h
kg/h
kg/
m3
kg/
m3
kg/
m3
kg/
m3
kg/
m3
kg/
m3
kW
m3/h
kg/h
Data
kg/h
kW
m3/h
kg/h
kW
kg/h
Bidder/Contractor
Unit
Design Data
Bottom ash handling system
Submerged link scraper slag extractor
Number
Type
pcs
-
Conveying capacity
kg/s
-
Turndown range
Gradient of the inclined section
Type of chain
m/s
m
m3
Motors:
manufacturer
type
rating / rated voltage
kW/ kV
speed
Required water quality
rpm
-
kg/s
-
kg/h
Weight of conveyor
mg/l
%
-
Data
Number
Capacity
pcs
t/h
Power demand
Bulk density
kW
kg/m3
Screen dimension
mm
mm
Bidder/Contractor
Unit
Motors
manufacturer
Data
-
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
Belt velocity
kg/s
m/s
kW
Type
m3
Net volume
Overall dimensions (length/width/height)
Inclination of bottom
Number of bagging and truck loading connections
m/m/m
0
Material
shell
bottom lining
Type of bottom ash silo extractor shell
Capacity of bottom ash silo extractor
B5/FD-3
---kg/h
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
Number of jet conveyors
Conveying capacity
pcs
kg/h
Conveying distance
pcs
-
Size of gates
Number of jet conveyors
Conveying capacity
Conveying distance
Jet conveyor air fans (if any)
Number of fans
pcs
kg/h
m
pcs
Type of fans
Manufacturer
Air flow rate
Discharge pressure
Motor speed
Rating
Air inlet temperature at MCR
m /s
mbar
rpm
kW
0
Bidder/Contractor
Unit
Number
Heat rate
Heating surface
MW
m2
Type
Net volume
m3
m/m/m
bottom (lining)
Air pressure vessel conveyors
Type
Manufacturer
Number
Handling capacity of each
kg/h
Conveying distance
3
m3/s
Air pressure
Rating
bar
kW
Speed
rpm
Data
Bidder/Contractor
Unit
pcs
m3/h
bar
Rating
kW
m3
m/m/m
bottom (lining)
m3/h
c
kW
kW
kW
pcs
m3/s
Discharge pressure
mbar
Data
Bidder/Contractor
Unit
Data
Motor speed
rpm
Motor rating
kW
Number
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
Slurry pumps
Number
pcs
Manufacturer
Type/arrangement
kg/h
min-1
Rating
kW
Material:
impeller
casing
pcs
Manufacturer
Type/arrangement
kg/h
Bidder/Contractor
Unit
. -i
min
Speed
Rating
Medium handled
Material:
impeller
casing
B5/FD-8
kW
Data
6.2.7
6.2.8
6.2.9
6.2.10
6.2.11
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
and
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
treatment
system
of
this
section
includes
the
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
clarifiers.
system
must
be
incorporated
with
all
tanks/
reservoirs
and
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 m 3/ 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.
6.2.3
6.2.4
6.2.5
6.2.6
Dosing system for condensate. boiler feed water and cooling water
conditioning
equipment
The condensate
chemical feed
equipment
ammonia and hydrazine feed to the auxiliary boiler.
arranged
shall
be
shall
to
be
provide
shall
be
equipment
arranged
shall
to
he
provide
The
system
will
provide
temperature,
pressure
and
now
control
for
continuous
automatic
analysis
and
recording.
The
equipment
will
consist
of freestanding sampling panels, sink, conductivity cells, pH cells, oxygen
analyzers,
silica
analyzers,
sodium
analyzers,
hydrazine
analyzer,
recorders,
components
for
either
returning
samples
to
the
condensate
system
or
dumping
them
to
waste
tubing
piping
valves
instrumentation
and controls.
Grab samples will
be
located in the service building.
carried
back
to
the
central
sampling
laboratory
1.
2.
3.
4.
5.
6.
7.
1.
2.
3.
4.
1.
2.
3.
4.
Boiler blowdown
Condensate polisher outlet
Economizer inlet
Main steam
Sodium analysis and recording shall be provided for:
1. Condensate pump discharge
2.
3.
4.
5.
6.
Condenser hotwell
Condensate polisher outlet
Economizer inlet
Main steam
Boiler blowdown
Hydrazine analysis and recording shall be provided for the economizer
inlet and auxiliary boiler feedwater.
Chemical feed - Cooling water
The scope of this equipment includes the cooling water conditioning feed
system which will consist of a feed tank with mixer and dosing pumps all
mounted on a skid along with piping, valves, fittings, welding
instrumentation and controls, hungers and supports.
Adequate space and means for maintaining the equipment
provided. as well as for controlling containing and treating of spills.
shall
be
6.2.7
6.2.8
6.2.9
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.
6.2.11 Laboratory
The laboratory
control of
installations
and
equipment
shall
be
installed
for
routine
service water
water-steam-condensate water
waste water and
coal and ash
oil
in a coal fired power plant.
The
scope
of
supply,
installation,
necessary supplies and services even
these.
The instruments
The
laboratory
stipulations.
and
shall
testing,
commissioning
comprises
if no special reference is made
all
to
Analysis
The scope of supply,
necessary equipment to
power plant.
Laboratory instruments
The
laboratory
equipment
shall
comprise
all
instruments
and
apparatus
necessary
for
the
analytical
investigations
including
all
necessary
accessories.
All
programmable
instrumental
computers
must
be
maintained
English
version
software.
Minimum
requirements
for
instruments and apparatus are as follows:___________________________________
Sl.
No
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
Sl
.
N
1
0
1
1
1
2
1
3
1
4
1
5
1
6
1
7
1
8
1
9
2
02
12
22
32
42
52
6
2
27
82
93
0
3
31
23
3
Name of instruments
Quantity
Remarks
02 (two) pcs
02 (two) pcs
02 (two) pcs
02 (two) pcs
Pour pointer
02 (two) pcs
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
01(one) pc
01(one) pc
02 (two) pcs
02 (two) pcs
01(one) pc
01(one) pc
02 (two) pcs
01(one) pc
02 (two) pcs
02 (two) pcs
02 (two) pcs
02 (two) pcs
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
vials for later dilution (type; Merek Titricol or equivalent).
in
the
form
of
prefabricated
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.
S
l.
Quantity
Remarks
2
3
Eye-protectors
Rubber thick hand gloves
(Acid/caustic proof)
50 (fifty) sets
50 (fifty) sets
Good quality
Good quality
4
5
15 (fifteen) sets
25 (twenty five)
sets
Good quality
Good quality
20 (twenty) pcs
1
0
11
1
2
10 (ten) pcs + 10
(ten) pcs +10 (ten)
pcs +10 (ten) pcs
+10 (ten) pcs
05 (five) pcs.
1
3
1
4
Glass transparent
good quality
1
5
20 (twenty) pcs
different size
20 (twenty) pcs
1
6
20 (twenty) pcs
Good quality,
twenty pcs.
1
7
20 (twenty) pcs
Good quality,
twenty pcs.
1
8
20 (twenty) pcs
Good quality,
twenty pcs.
1
9
20 (twenty) pcs
Good quality,
twenty pcs.
Good quality,
twenty pcs.
Good quality,
twenty pcs.
Laboratory furniture
The following laboratory
supplies as a minimum:
equipment
shall
be
included
in
the
scope
of
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
potable water
cleaning.
The
automatic system
fully automatically
Starting
Stopping
Selection of a particular step and
Repeat of each step of the program
The individual steps of the program e.g. backwashing, introduction of acid,
rinsing acid etc. must be indicated on the local control panel by means of
process graphic displays and specially designed control displays.
The program sequence shall stop at
operator
may
check,
for
example,
separated or mixed correctly.
The program must stop when regeneration has finished. The line, which
has been regenerated is to be brought back into operation by a control
action from the water treatment local control room.
The correct position and actual position of the various valves for each
stage of the program must be monitored automatically. In the event of a
fault, the program must stop and the fault indicated on the local control
panel. An alarm must also be given. if the operating programme is not
completed within a given time. Suitable precautions must be taken to
ensure that no switching errors can occur and no critical situation may
arise in the case of voltage or compressed air failures.
The
operation
or
the
demineralisation
plant
shall
be
controlled
by
continuously
measured
indicated
and
recorded
conductivity
readings
downstream of the anion and mixed bed exchangers.
Regeneration (end or the service cycle) of the mixed
be initiated based on first occurrence of anyone of the following:
bed
exchanger
shall
provided
at
all
requisite
points
upstream
and
(regeneration)
water
lines
are
to
be
equipped
with
flow
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
station shall ensure no ammonia gas leakage.
of
the
ammonia
conditioning
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
Bidder/Contractor
Unit
m3 / hr
no.
m3
no.
m3
no.
m3
no.
m3
No. of clarifiers
no.
m3 / hr
-
no.
m3 / hr
no.
m3 / hr
No.
m3
Material
No.
m3/h
kW
Material: Housing/impeller
Data
Bidder/Contractor
Unit
Data
No.
Net capacity
m3
Material
No.
Bidder/Contractor
m3/h
RateB6:
of delivery
Water Storage and Treatment Systems
Unit
kW
Material: Housing/impeller
Number of filters
No.
Throughput:
Minimum/Maximum
Number
of pumps
3
mNo.
/h
Material
Rate
of delivery
Diameter
Power consumption at coupling
Cyl. jacket length
m3/h
mm
kW
mm
Total height
Material:
Housing/impeller
mm
Number
of airstorage
blowers
Clear
water
Number
of
tanks
Rate of delivery
No.
N No.
m3 /h
Each
tank Net capacity
Degasifier
3
m
/h
No.
Material
Number of unils Throughput:
m3 /h
Number of pumps
No.
Demoralisation
water plant
Flow rale of pumps / Delivery head
m /h / bar
Number
Diameterofoflines
degasirier lower
Net continuous flow rate each line
Height
Net treated water volume per cycle each line
Material tower
Cycle length
Number of air blowers
No.
m3/h
mm
m3
mm
h
Regeneration
time
Rate of delivery
h
No.
No.
kg/cycle
m3/h
Exchanger
NaOH
100%capacity:
each lineCation
Total
waste water discharged
Anion
eq
kg/cycle
m3/cycle
eq
Anion
eq/IE
eq/IE
|jS/cm
mg/I
I
I
m/h
m/h
Design pressure
Diameter
bar
mm
Cyl. jacket
mm
length Total
height
mm
mm
B6/FD-3
Data
Bidder/Contractor
Unit
Number of units
Volume tank
No.
Material:
No.
No.
Bidder/Contractor
Type
of pump
B6: Water
Storage and Treatment Systems
Rate of delivery
Data
I/h
Unit
Regenerationofstation
caustic
soda
Concentration
dilutedfor
acid
for regeneration
Volume of dosing tank
Number of regeneration stations
Data
%
I
No.
B6/FD-4
Number of pumps
No.
Type of pump
Rate of delivery
Material
I/h
-
No.
Rate of delivery
m3/h
kW
Material: Housing/impeller
Air blower
Number of blowers
No.
Nm3/h
Rate of delivery
Delivery head
Bar
kW
No.
Rate of delivery
m3/h
kW
Material: Housing/impeller
No.
m3
Diameter
mm
Cylindrical height
mm
Material:
B6/FD-5
Bidder/Contractor
Unit
Data
Chemical handling
No.
Capacity
mJ
Diameter/cy!. height
mm
Material
No.
Capacity
mJ
Diameter/cy!. height
mm
Material
Sump pumps
No.
Pumping rate
m3/h
Material
Capacity
Material
mm
Discharge pump
Number of pumps
No.
Pumping rate
m3/h
kW
Malerial
Neutralisation tank
Number of tanks
No.
Capacity
mJ
Diameter/cy!. height
Material
Power consumption agitator
mm
-
kW
Bidder/Contractor
Unit
Discharge pump
Number of pumps
No.
Pumping rate
m3/h
kW
Data
Material
Settling tank
Number of tanks
No.
Capacity
m'
Surface area
m2
Material
Sludge dewatering
Type of sludge dewatering
Conditioning station
Medium: Ammonia solution
Number of dosing stations
No.
m'
Material: Tank
Agitator
Pipes, Valves
Pumping head
No.
bar
I/h
Medium: Hydrazin
Number of dosing stations
No.
No.
m'
Material: Tank
Number of dosing pumps
Pumping rate variable from - to
Material: Head/Piston
B6/FD-7
Pipes, Valves
No.
l/h
Bidder/Contractor
Unit
Medium: Trisodiumphosphate
Data
No.
No.
m3
Material: Tank
Agitator
Number of transfer pumps
No
m3 /h
Rate of delivery
Material:
Number of lifting and tipping devices
Capacity of dosing lank
No.
m'
Material:' Tank
Number of dosing pumps
Pipes. Valves
No.
I /h
Material: Head/Piston
Diaphragm
No.
No.
m3
Material: Tank
Agitator
Number of transfer pumps
Rate of delivery
No.
m3/h
Material:
Number of lifting and tipping devices
No.
m3
Material: Tank
Pipes, Valves
No.
I/h
Bidder/Contractor
Unit
Data
Net treated water volume per cycle of each ion exchanger line
m3
Chemical consumption:
Regeneration time
h
h
Regeneration mode
Chemical consumption:
HCI 100% each line
NaOH 100% each line
kg/cycle
kg/cycle
m3/cycle
|jS/cm
Cartridge filter
Number of filters
No.
Throughput:
m3/h
Material
Type and material of cartridge
Cation exchanger
Number of exchangers
No.
Throughput: Minimum/Maximum
m3/h
Exchanger capacity:
Exchanger material quantity
eq
l
eq/lE
m/h
m/h
Design pressure
bar
Diameter
mm
mm
Total height
mm
Anion exchanger
Number of exchangers
No.
Throughput: Minimum/Maximum
m3/h
Exchanger capacity
Exchanger material quantity
eq
Bidder/Contractor
Unit
Anion exchanger
Data
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
I/h
Material
No.
No.
Type of pump
Rate of delivery
I/h
Material
Concentration of diluted acid for regeneration
Volume of dosing tank
No.
Rate of delivery
m'/h
kW
-
393
4
0
0
v
l
m
a
e
o
w
l
b
e
w
t
B
a
k
l
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6
6
0
0
v
ol
ts
m
ai
n
s
R
e
d
la
b
el
wi
th
W
hi
te
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er
C
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at
te
ry
s
u
p
pli
e
s
-
W
hi
te
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el
wi
th
Bl
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s