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Power Plant Facility for the ALPA Project

Technical Proposal (Mechanical Part)

OwnerVALE of Brazil EPC ContractorHangzhou Boiler Group Co., Ltd., PR.C Zhejiang Xizi United Engineering Co., Ltd., P.R.C. Oct., 2009

Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

Catalog 1. Project overview........................................................................1 2. Initial conditions for design.............................................15 3 The selection of combustion system and its auxiliary facilities....................................................................................17 With noise level held to meet national standards, the noise 1m away from fan cover should be confined below 85 dB..................................................18 .........................................................18 Air-sucking hole filter and silencer shall be set at inlet of fan ....................19 ..................................................................................................................19 4. Selection of thermo-systems and auxiliary facilities........................................................................................................19 5. ..........................................................................................26 6. ..............................................................................................26 7............................................................................................................27

Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

1. Project overview
1.1 Design consideration The reference standards, documents and drawings listed under this item, are integral part of this technical requisition. All the basic and detailed design studies must fully comply with Vales Engineering Standardization System (SPE). Some of these documents and templates are shown in item 3.4 as a reference. All of the equipment is to be designed, manufactured and tested in accordance with Standards as listed under item 1.1.1 here below. Standards cited under item 1.1.1 are mandatory 1.1.1 CODES AND STANDARDS a) ABMA American Boiler Manufacturing Association b) ABNT Brazilian Association for Technical Standards c) ACI American Concrete Institute d) AD Association for Pressure Vessels e) AFBMA Anti-Friction Bearing Manufacturers Association f) AGMA American Gear Manufacturers Association g) AISC American Institute of Steel Construction h) AISE Association of Iron and Steel Engineers i) AISI American Iron and Steel Institute j) AMCA Air Moving and Conditioning Association k) ANSI American National Standards Institute l) API American Petroleum Institute m) ASHRAE American Society of Heating Refrigerating and Air Conditioning Engineers n) ASME American Society of Mechanical Engineers o) ASNT American Society for Nondestructive Testing p) ASTM American Society for Testing and Materials q) AWS American Welding Society r) AWWA American Water Works Association s) CTI Cooling Tower Institute t) CMAA Crane Manufacturers Association of America u) CEMA Conveying Equipment Manufacturers Association v) DIN German Institute for Standardization w) DDA German Committee on Pressure Vessel x) DGZfp German Society for Nondestructive Testing y) DruckbehV Regulation for Pressure Vessel, Vessels for Pressure Gas and Filling Plants z) DVGW German Society for Gas and Water Works aa) DVM German Association for Material Research and Testing bb) EIA Electronic Industries Alliance cc) EJMA Expansion Joint Manufacturers Association dd) EPA Environment Protection Agency

Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

FCI Fluid Control Institute German Pressure Vessel and Piping Manufacturer Association HEI Heat Exchanger Institute HI Hydraulics Institute Hoists Manufacturers Institute International Association for Hydraulic Research IBAMA Federal Environmental Agency International Electrotechnical Commission IEEE Institute of Electrical and Electronic Engineers ISA Instrument Society of America ISO International Organization for Standardization ISO14000 Environmental Management and Certification JEC Standard of the Japanese Electrotechnical Committee rr) JEM The Standard of the Japan Electrical Manufacturers Association ss) JIS Japanese Industrial Standards tt) MBMA Metal Building Manufacturers Association uu) NBFU National Board of Fire Underwriters vv) NEC National Electrical Code ww) NESC National Electrical Safety Code xx) NEMA National Electrical Manufacturers Association yy) NFMA National Fan Manufacturers Association zz) NFPA National Fire Protection Association aaa) PFI Pipe Fabrication Institute bbb) SSPC Steel Structures Painting Council ccc) TEMA Tubular Exchanger Manufacturers Association ddd) TIA Telecommunications Industry Association eee) TIMA Thermal Insulation Manufacturers Association fff) TRD Technical Rules for Steam Vessels ggg) VGB Technical Association of German Power Utilities hhh) VDE Association of German Electrical Engineers iii) ZVEI German Electronics and Electrical Manufacturers Organization 1.1.2 SYSTEM OF UNITS The International System of Units (SI) will be the system of measurements adopted by the Project. The only exceptions are for those renowned cases like the use of the US Customary Units for diameters and length of screws, pipes, connections and electro-ducts. 1.1.3 VALES REFERENCE DOCUMENTS The following documents, templates, drawings, etc must be considered as references for the development of the basic and detailed design phases. These documents are part of Vales SPE.
NUMBER Vales Procedures PR-E-002 PR-E-004 PR-E-013 PR-E-028 6 9 10 9 Vale Project Coding Definition of Work Breakdown Structure Identification and Issuing of Engineering Documents Identification of Assets, Equipment and Instruments REV. TITLE

ee) ff) FDBR gg) hh) ii) HMI jj) IAHR kk) ll) IEC mm) nn) oo) pp) qq)

Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

PR-E-029 PR-E-019 PR-E-020 PR-E-022 PE-A-500 PE-G-601 PE-G-602 PE-G-603 PE-G-604 PE-G-605 PE-G-606 PE-G-607 Vales Design Criteria CP-A-501 CP-B-501 CP-C-501 CP-E-501 CP-J-501 CP-J-506 CP-K-501 CP-L-501 CP-M-501 CP-S-501 CP-T-501 EG-B-401 EG-C-401 EG-C-402 EG-C-403 EG-C-406 EG-E-401 EG-E-436 EG-L-401 EG-M-401 EG-M-402 EG-S-401 EG-T-401

2 2 1 4 0 3 3 3 3 3 6 3 1 0 2 8 2 2 2 2 3 3 4 1 0 1 1 1 5 1 1 6 5 0 3

Lines, Isometrics and Piping Spools Numbering Issuing of Word Documents Issuing of Excel Documents Issuing of AutoCad Drawings Vales Main Gate Standard A0 Drawing Template A1 Drawing Template A3 Drawings Book Template A4 Drawing Template A4 Drawings Cover Template Word Document Template Excel Document Template Design Criteria for Architecture Design Criteria for Civil Works Infrastructure Design Criteria for Civil Works Concrete Design Criteria for Electrics Design Criteria for Industrial Automation Design Criteria for Instrumentation Design Criteria for Telecommunication Design Criteria for Mechanical Arrangement Design Criteria for Mechanical Equipment Design Criteria for Steel Structures Design Criteria for Piping General Specification for Rain Water drainage General Specification for Concrete General Specification for Foudations General Specification for Anchor Bolts General Specification for Industrial Floors General Specification for Electrics General Specification for Electrical Material General Specification for Plate Work General Specification for Mechanical Equipment Supply General Specification for Industrial Painting General Specification for Steel Structures General Specification for Piping

Vales Templates and Standards

Vales General Specification

1.1.4 ALPAS REFERENCE DOCUMENTS

Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

The following documents are specific for the ALPA Project and must be considered as references for the development of the basic and detailed design phases.
NUMBER CL-7000AP-G-001 RA-7000AP-G-001 RL-7000AP-G-001 7000AP-L-001 EG-7000AP-G-001 EG-7050AP-J-001 EG-7050AP-J-002 EG-7050AP-J-003 EG-7045AP-J-001 REV. 0 1 0 0 0 0 0 0 0 Local Conditions Areas and sub-areas Take Over Points (TOP) General Layout General Specification for Utilities General Specification for Automation General Specification for Instrumentation General Specification for Fire Fighting General Specification for IT and Telecommunication System TITLE ALPAs Reference Drawings and Documents

1.2 Design scope VALE Par Marab ALPAAos Laminados do Par As the power plant associated with the ALPAAos Laminados do Parsteelmaking factory built in Marab, Par State in northern Brazil by VALE (Companhia Vale de Rio Doce), this project will utilize gas, the by-product from coking plant and blast furnace, and gas recovered from steelmaking process which could fuel boilers, to generate high-pressure steam to supply electricity while offering process steam for the whole steelmaking factory. The construction of power plant will move forward simultaneously with that of steelmaking plant. VALEALPA BFG LDG COG 2240t/h +257.5MW2x65MW ALPA In the spirit of conserving energy and preserving environment, through joint research and verification by Zhejiang Xizi United Engineering Co., Ltd. (UEC) and ALPA of VALE, by harnessing blast furnace gas (BFG) linz donawitz Gas (LDG, recovered from linz donawitz or

Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

converter) and coke oven gas (COG) which could be used for ignition thanks to its relative stability to fuel boiler, this design intends to incorporate 2240t/h single pressure gas boilers+257.5MW 2x65MW high temperature and high pressure extractioncondensation machine sets in the format of one machine set per one boiler. Besides utilizing steam from boiler to generate electricity, its also expected to provide process steam for steelmaking plant and its subsidiary air separation plant(s), dock(s) and all factories which are located on the field of ALPA and serve electric plant, with redundant team from steelmaking process to be recovered as heat source to boiler. Its detailed as follows: 1) 1) The contractor takes charge for boilers themselves and their accessory facilities including boiler furnaces, steam drums, combustors, air preheaters, ignition devices, steel structure, platform, staircase and so on; 2) 2) The contractor takes charge for boilers gas system from boilers outlets to chimneys inlets, involving induced draft fans (IDF), gas heaters, gas ducts, compensators, chimneys, damper; 3) 3The contractor takes charge for boilers air supply system, the boilers combustion air system including air-sucking holes, silencers, fans, air duct, damper, compensator and so on; 4) BFG LDGCOG 4) The contractor takes charge for boilers gas system, with boundary between the two parties and fuel conjunction located around hydroseal, namely BFG, LDG, COG. Contractor is also responsible for design of electric butterfly valves, blind valve, hydraulic quickly-breaking valve along the gas duct, as well as gas ducts, valves,

Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

compensators behind, while proprietors are responsible for diffusion and combustion of redundant gas; 5) 5) The contractor takes charge for turbo-generators, including turbines, generators, static magnetic excitation facilities, condenser, air-cooler, lubricant systems, velocity regulators, high and low pressure heaters, water jet air ejector; 6) 100% 6) The contractor takes charge for steam-water system, all equipment and plumbing, including main steam system, main water-feeding system, water condensate system, heat recovery system, boilers blowdown system, water drainage system, closed industrial water system, sampling and dosing system, 100% bypass system, involving water-feeding pump, condensation water pump, deaerator plus water tank, cooling waters heat exchanger, temperature and pressure lowering devices, valves, supports and hangers, compensators, etc.; Other work not mentioned above is considered out of contractors responsibility scope. 1.3 Models, parameters and primary technical specifications of main machines Through design calculation based on gas volume, the primary technical parameters of the machine groups are fixed as follows: 1.3.1 1.3.1 gas boiler Model: Form: Quantity: 2 NG-240/9.8-Q2 NG-240/9.8-Q2 Single-pressure gas boiler 2 sets 220 t/h

Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

Rated evaporation volume 220 Cold air temperature 1.3.2 1.3.2 20 20 180 Turbine C65-8.83/1.2 C65-8.83/1.2 <3 540 9.8 11.28 215 %

t/h MPa(G) MPa(G) MPa(G) MPa(G) <3 %

Temperature at outlet of overheated steam 540 Pressure at outlet of overheated steam 9.8 Working pressure of boiler drum 11.28 Temperature of water fed 215 Boilers continuous blowdown rate

Temperature of gas entering furnace Model Form: Quantity: Rotary velocity: Rotary direction: 2

180

High temperature and high pressure extraction and condensation system 2 sets 3000r/min 3000r/min Clockwise, if viewed along the direction from prow 1 2JG+CY+2JD 2JG+CY+2JD

Regulatory steam-extracting stage count: 1 Water-feeding and heat recovery stage count: 80 The maximum allowable operative temperature inside low-pressure steam-exhausting casing: 80

Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

~6h The duration for turbine to be cold-started from null-load to full-load: ~6h 40t/h Minimum steam exhausting flowage: 40t/h 1CII+1C+15P Stage count of turbines flow passage component: 1CII+1C+15P Structure of end-stage blade: twisted impellor reinforced by tie bar 6.5m The minimum distance from overhead cranes hook to platform: 6.5m if loaded with crossarm - Type of regulatory system: digital electro-hydraulic regulation Type of regulatory valve: group of valves and lifting board Type of emergency protector: flyball structure electric Vacuum-breaking devices: safety diaphragm plate 6-10t/h Low-load water-spraying flowage: 6-10t/h 8m Elevation of operative floor: 8m (1) (1) (1) Single-extraction working conditions Power: 57.5 MW MW At turbines rated working condition: 57.5 6.12 7248 Kg/KWh Kg/KWh KJ/KWh KJ/KWh Rated steam consumption: 6.12 Rated heat consumption: 7248

Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

65

MW MW

At turbines max working condition: 65 Parameters on injection of main steam 8.83 +0..5 0 5 8.83 +0..5 0 5 MPaG MPaG

Steam pressure:

5 535 +10

+5 Steam temperature: 535 10

Steam extraction parameter: 1.2 +0..3 0 289 MPaA MPaA t/h t/h

+0.3 Steam pressure: 1.2 0.289

(2) (2)

~304 25

Steam temperature: ~304

Steam extraction volume: 25 (2) Working condition of pure condensation Steam consumption: Heat consumption: Power: 1 (1) Generator WX18Z-054LLT 65 65 20-35 215 3.95 3.95 1014 1014 MW Kg/KWh Kg/KWh KJ/KWh KJ/KWh MW Temperature of circulated water: 20-35 Temperature of water fed: 215

1.3.3 Turbo-generator

Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

Model: Rated power:

WX18Z-054LLT 65MW 65MW 3000rpm 3000rpm Clockwise if viewed along the direction from turbine to 0.85 0.85lag 10.5KV 10.5KV 3881.3A 3881.3A 50Hz 50Hz 3 3 2 2 Y Y 98.42% 98.42% 0.62

Rated rotary velocity: Rotors rotary direction: generator Rated power factor: Rated voltage: Rated current: Frequency: Phase count: Stage count: Stators wiring type:

Efficiency (guarantee value): I2/In Stable I2/In I2/In2t TemporaryI2/In2t Peak voltage 10% 10% 8s

Short-circuit ratio (guarantee value): 0.62

8s 2 2 times the rated excitation voltage 2 /s

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Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

95% 0.1s 0.15s Voltage response ratio 2 times rated excitation voltage/s; As for high initial response excitation system, when increase in voltage reaches 95% of difference between peak voltage and rated excitation voltage, the corresponding response times ascendance value and descent value should be confined respectively below 0.1s and 0.15s. 1 Cooling type 50s 50s less than 90 dB 90 by air 6 6 25 25 Temperature in design 33 33 Maximum temperature Temperature of cooled air 2 (2) Excitation system Type Brushless Parameters of AC excitor Rated power Rated voltage 239KW 239KW 215V 215V 40 40 Allowed duration for strong excitation Noise (1m away from outer cover)

Count of terminal outgoing lines from generator Cooling water temperature

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Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

Rated current Cooling type Insulation grade Peak voltage 2

1110A 1110A by air F F 180% 180% 120% 120%

Hyper-speed test (2 min) Rotary rectifier (ballast) / Max/rated voltage / Max/rated current / Voltage/current margin Diodes rated current Diodes rated voltage AVR

487/312V 487/312V 2340/1500A 2340/1500A 156% 156% 156% 156% 1 1 5 (6 arms) 5 6 300A 300A 1400V 1400V

Count of diodes in series per circuit Count of diodes in parallel per arm

AVR voltage regulatory characteristics Voltage regulatory range 70%~110% 70%~110% 20%~110% 0.5%

Manual manipulation range 20%~110%

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Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

Precision

0.5%

1.4 Main design principles 1 (1) Introducing advanced technology and software to design project, adopting mature, reliable, pragmatic and stable high-temperature and high-pressure electricity generation technology by gas and equipment, we shall make our technology and equipment meet internationally advanced level; (2) (2) For equipment whose manufacture has been appointed by proprietors, well select model according to proprietors requirements; With regard to other equipment, under the precondition of guaranteeing product quality, in principle, we prefer to purchase equipment made in China; 3 (3) In the spirit of economizing investment, ensuring a compact reliable system convenient for repair and maintenance, we shall fully utilize conditions on site in order to do layout reasonably; 4 (4) For BFG boiler, we shall adopt parameters suitable for high temperature and high pressure; 5 (5) For all boilers main steam and main water-feeding headers, well adopt an alternation mode to ensure that electric plant still can operate safely by using boiler and turbine alternately in case of shutdown, overhaul or malfunction of boilers and turbines compatible with each other; 6 3 (6) Each boiler shall be equipped with 3 water-feeding pumps;

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Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

7 (7) After being connected with high pressure steam header, the boilers main steam header will have 2 steam pipes stretched from it to supply steam for corresponding turbine;_ 8 (8) Each turbine will have a pipe stretched from it to supply process steam for steelmaking plants, with another part of steam source gained from high-pressure steam header; 9 (9) The dosing and sampling systems, water drainage and blowdown systems shall be installed wherever necessary; 10 120m, 4.4m (10) Each boiler shall be equipped with 2 forced draft fans (FDF) and 2 induced draft fans (IDF) of which ones respectively will adopt high-voltage frequency variation technology; Chimney will be made of concrete, as high as 120m, with its capacity designed for 2 boilers and outlet inner diameter at 4.4m; 11 180 125 (11) Boilers shall be equipped with gas heaters, with boilers outlet gas temperature and gas temperature behind gas heater respectively at 180 and 125; 12 DCS (12) Power plant shall be controlled automatically through DCS; 13 (13) Machine and boiler control room shall have comfortability air conditioner. 1.5 This projects operative mode and usage hourage per year 97.5% 365 8541

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Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

6000 30% 110% 30%50%-110% 540+5-10 2550 With annual usage rate of 97.5%, calculated on the basis of 365 days per year, the power plant is expected to operate for 8541 hours annually. With their hourage of continuous operation above 6000, the boilers which could be burdened with basic load are also available for peak modulation via load variation with peak modulation range between 30%110%; if above 30% load, BFG will be burned only to guarantee boilers safe and stable operation; if between 50%-110%, the overheated steam temperature shall be confined between 540 +5-10. When with surrounding temperature around 25, the outer surface temperature of boiler wall shall be confined 50. Under normal start-up conditions, the duration since ignition til full load of boilers should meet following requirements;
a)

72h 34h

a) Cold start-up (after over 72h of shutdown): 34h b) 1072h 23h b) Warm start-up (after 1072h of shutdown): 23h c) 10h 11.5h c) Hot start-up (after less than 10h of shutdown): 11.5h. 24 3 According to proprietors requirements and steelmaking plants operative realities, the power plant shall run around the clock by the manner of 3 shifts per day. Considering this projects nature as a support for steelmaking plant instead of an independent power plant, the operative type of this project shall be completely in compliance with production and craftsmanship requirements.

2. Initial conditions for design


2.1 Gas balance Preliminary gas balance is indicated below. UTE shall be fired with surplus gas, except stabilizer gas that must be at stable flow at minimum.

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Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

Pcal/year Gas balance Lime plant Coke facility Pellet plant Blast furnace Steel making Continuous casting Power Plant Hot strip mill loss Total consumption 2.2 Gas Makeup 2.2.1 Blast furnace gas - BFG: COG 183 294 525 319 48 119 519 161 44 2,212 172 3,379 1,886 688 633 BFG

. LDG

468 = 2,876Pcal/year maximum 25 493

Most available gas in the steelworks, and low heat value ranging from 750 to 850kcal/Nm3, average LHV 840kcal/Nm3 (3,516kJ/Nm3) and PCI rate @ 165kg/t hot metal in a range till 180kg/t hot metal. 2.2.2 Converter gas - LDG: Heat value ranging from 1,700 to 2,100kcal/Nm3, 1,958kcal/Nm3 averaged (8,200kJ/Nm3) and unit recovery rate 95Nm3/t hot steel in a range of 90 to 105Nm3/t hot steel. 2.2.3 Coke Oven Gas - COG: Low heat value: average 4,276kcal/Nm3 (17.900kJ/Nm3). This gas will be the most import fuel in the steelworks and its availability to UTE is strongly controlled. In ALPA, it is intended for applications like fuel gas for coke facility, pellet plant, hot stoves and Steckel Mill, as well as for cutting slabs in the continuous casting machines, heating of ladles and main runners. 2.3 Gas composition
BFG vol % CO 20.8~23.4 CO2 22~23.5 Hydrocarbon 0.2~0.5 H2 1.5~3 O2 0.1~0.45 N2 50~60

LDG vol %

CO 47.4~69.5

CO2 12~18

Hydrocarbon ~2.5

H2 ~7.6

O2 ~0.2

N2 16.4~26.5

COG

H2

CH4

CO

CO2

Hydrocarbon

O2

N2

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Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

vol %

59.4

22.4

7.7

2.1 hydrogen cyanide 1.0

2.3 Organic sulfur 0.2

0.1

COG Traces MG/Nm3

tar 0.02

NH3 0.04

H2S 0.2

BTX 26.0

Naphtalene 0.2

3 The selection of combustion system and its auxiliary facilities


3.1 The combustion system BFG COG LDG BFG LDG 1 COG 1 4 BFGCOGLDG BFG, COG and LDG pipelines from factorys main gas network will be connected with boiler, with each header pipe equipped with electric hard obturation butterfly valve, gas eyeglasses valves and gas quickly breaking valve, followed by nitrogen blowing pipelines. After being heated by gas preheater, each pipeline shall be diverged into 2 branches which are to be connected respectively with the front and back of boiler. The gas pipelines led to the front and back of boilers will be diverged further into 2 branches each, each of which will go through an electric hard obturation butterfly valve and a gas quickly breaking valve to be reorganized into 3 groups into boilers combustor. Each group of BFG and LDG pipelines is to be equipped with 1 group of electric regulatory valve, manual butterfly valve, with each group of COG pipelines equipped with 1 group of electric regulatory valve and manual globe valve. Boilers front and back respectively have 2 combustor groups, each consisting of 3 combustors. Totally 4 combustor groups are there at the front and back of boiler. Within each combustor, the combustion of BFG, COG and LDG mixed

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Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

together shall take place. 410KPa 120 With gas pressure in front of combustor confined between 410KPa, the smoke fostered from gas after complete combustion will release heat along its path through high-temperature separator, high-temperature super-heater, low-temperature super-heater, economizer, air preheater, gas heater (optional) till it is expelled out of boiler and diffuse through the 120m high chimney. COG will be used to ignite and start boiler. 2 2 Each boiler combustion system is equipped with 2 FDFs and 2 IDFs, with upper limit prescribed in standard taken into consideration for selection of fan delivery model. 3.2 Parameters on main auxiliary machines of combustion system Based on date on combustion systems aforementioned, we select the following models: (1) FDF Model G4-73-11D type Motor power: Technical requirements: 1 85 With noise level held to meet national standards, the noise 1m away from fan cover should be confined below 85 dB. 200 200 KW KW 4 sets G4-73-11D 4

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Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

Air-sucking hole filter and silencer shall be set at inlet of fan (2) IDF Model Y4-73-11 F type Rotary velocity: Motor power: 450 KW 960 r/min 960 r/min 450 KW 4 sets Y4-73-11 F 4

Motor voltage: (3) Chimney Height Inner diameter at outlet 120 1

10.5 kV 10.5 kV 1 set 120 m 4.4 4.4 m m m

CEMS The online gas monitoring system CEMS shall be set up (4) Gas heater 2 2 sets

3.3 Draft calculation at main smoke ducts

4. Selection of thermo-systems and auxiliary facilities


4.1 Thermo-balance calculation 4.1.1 Thermo-load 220C @12kgf/cm2 2201.2 Mpa 5409.8Mpa 50t/h Upon proprietors requirements, this project is to provide 220C @12kgf/cm2 process steam for steelmaking plant, which could be obtained from turbines steam extractor

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Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

2201.2 Mpa and boilers high-pressure steam 5409.8Mpathat must have its temperature and pressure lowered before use, with total steam amounting to 50t/h. 4.1.2 Steam-water balance and main technical and economic indicators 4.2 Thermo-system 2240t/h 257.5MW265MW This project is equipped with 2240t/h high-temperature and high-pressure boilers which have water fed by manner of bridging header pipes, 257.5MW 265MW hightemperature and high-pressure extraction and condensation turbine groups which have steam fed by manner of bridging header pipes and adopt unit system under normal working conditions; When one boiler ceases for repair and maintenance with its parterner turbine at normal conditions and another boiler is working normally, though with its parterner turbine in malfunction, we can realize scissors movement between boiler and turbine by manner of bridging header pipes. A source of steam from high-pressure steam header pipes could be led through temperature and pressure reducers to low-pressure steam header which will function as a source for steelmaking plants process steam, the same way as a source of steam extracted from turbines is dealt with. 4.2.1 Main steam system 1#,2# , 1# 2# 355.6402240t/h 9.8Mpa540 The overheated steam led from steam header of boilers No.1 and No.2 will separately enter high-pressure steam header pipe which will be diverged into 4 lines into turbines steam pipelines, 2 of which go to turbine No.1 and another 2 of which go to turbine No.2. The main steam pipe at boilers outlet has its diameter at355.640; the flowage is to be

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Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

2240t/h based on boilers rated value, provided steam pressure and temperature respectively at 9.8Mpa and 540. Process steam used in steelmaking plant could be sourced from high-pressure steam header pipe and turbines steam extraction system. Wherever its conjunction between header pipes and main steam pipes from outlet of boiler and from turbine inlet and inlet pipelines of temperature and pressure reducers, block valves shall be set to facilitate maintenance of main steam pipelines. All new steam pipelines to turbines must be equipped with block valve to facilitate warm-up and start-up of turbines and steam entrance pipelines, etc. 4.2.2 Dearation & waterfeeding system 2280t/h, 215 3 360%2 1 2 2 () 2 The flowage of water at 215 fed to boiler is 2280t/h. Within this system, each machine group is equipped with 3 waterfeeding pumps 360%, 2-stage low-pressure heater, 2-stage high-pressure heater and a highpressure spinning film deaerator. The high-pressure heaters are armed with interlinkage devices (large bypasses). Should emergency happen to high-pressure heater, the interlinkage devices would act immediately to guide water directly into boiler by bypassing the 2 high-pressure heaters. This system supplies water to boilers by alternating header pipes. The makeup water and heating steam to deaerator shall be automatically regulated to the nomal water level and pressure inside deaerator. The method of alternating header pipes will be applied to low-pressure waterfeeding header pipes to ensure safety and reliability.

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Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

The waterfeeding recirculation header pipe will be set between water-feeding pump and deaeration water tank to fulfill requirements for start-up and low load operation of waterfeeding pump. 4.2.3 Process steam system 193.720 220C @12kgf/cm2 The steam from high-pressure steam header pipe and from turbines steam-extraction header pipe, the source for process steam will converge together before entering low-pressure steam header pipes.We intend to stretch193.720 branch pipe to temperature and pressure reducer, with temperature-lowering spraying water sourced from the main water-feeding header pipe at the outlet of high-pressure water-feeding pump. The process steam entering low-pressure steam header is 220C @12kgf/cm2 saturated vapour. 4.2.4 Water condensation system 3 350% I II The main condensate water produced when turbine expel steam into condenser shall be sent out separately through 3 condensate water pumps350%, then go through steamejector and air extractor, steam seal heater and I-stage and II-stage low-pressure heaters to deaerating head. Before entering deaerating head, it needs to be connected with heated condensate water header pipe of another turbine, with a shut-off valve isolating them apart. 4.2.5 Blowdown system 1 1 7.5m3 3.5 m3 According to this design, each gas boiler is equipped with 1 continuous flash evaporator, 1 atamospheric intermittent falsh evaporator whose volumes respectively stand at 7.5m3 and 3.5 m3. The continuous blowdown pipes are to be stretched from drum to continuous flash

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Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

evaporator, while intermittent blowdown pipes need to be led from boilers 4 lower headers and concentrated decline pipe, then converged at blowdown header, with sewage drained out through intermittent flash evaporator into blowdown cooling sump. Drums emergency water drainage pipes and boilers other water drainage pipes will also be connected with intermittent flash evaporator via blowdown pipelines. 2100% Each machine groups blowdown system will be equipped with 2 sewage pump (2100%), oil-water separator. The blowdown system shall take charge in transporting clean waste water and contaminated waste water respectively to clean waste water station and contaminated waste water station through oil-water separator. Programmed control system shall be applied to blowdown system to enhance automation level of boilers operation. 4.2.6 Water drainage system 1 Each turbine shall be equipped with 1 independent water drainage expansion tank. Water discharged from turbine and steam seal, main steam valve and regulatory steam valve will all be directed into expansion tank and steam condenser. 4.2.7 Condensers vacuum system 1 For condensers vacuum system, steam-ejector and air extractor shall be adopted for each turbine one-to-one. 4.2.8 Cooling water system 3 This system is the closed cycle cooling water system applicable for turbine and boilers auxiliary machines. There will be 3 vertical cooling water pump set in circulation water pump workshop, with 3 cooling water heat-exchangers for the system. 4.2.9 Industrial water system

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Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

2 water pumps shall be set to transport water to power plants bathroom, eye washer station and washing pond. 4.2.10 Multi-purpose water system 2 water pumps shall be set to transport water from water reservoir to water consumption site. 4.2.11 Fans cooling water system This system is excluded from contractors responsibility scope. 4.2.12 Sampling and dosing system 4.2.13 1 38dBA 4.2.14 4.2.15 , 50t /10t 22.5m 4.3 4.3.1 N-3500 2 3500 m2

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Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

(4) (5) (6) 1100

2 50 2 kW 2 100 2 2 145 2950 2 29 3000 2 36 980

m2 m2 m3/h r/min m3/h r/min m3/h r/min

(7)

(8)

4.4.2 (1) 165 2 0.7 3.5 2 0.1 7.5 6 MPa m3 MPa m (2) (3) (4) DG160-140 2 0.588 Mpa(G)

25

Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

150 1570

m3/h m

5.
5.1 138KV 5.2 5.3 (1) (2) (3) CCTV

6.
6.1 ,,, 3 360% 1#2# 1#2# 6.2 24m 99.2m 92.2m 12.5m 0m 1#2# 23m 1# 2# 8m 4.5m 8m A 10.5m 0.00m

26

Power Plant Facility for the ALPA Project Technical Proposal (Mechanical Part)

1 50/10t 22.5 m

7.
7.1 1) 50 50 2) 3) 4) 27 50 27 25 60( 1m ) 5) 7.2 1) (), , , 2) , 120, 3), , , , , 4) 5) .

27