APPD

CERT.
ORIGD

GEMSS-M-03
Revision No. 02
Condensate System Including Condensate
Extraction Pumps

DESCRIPTION
DATE

PROPRIETARY INFORMATION
This document contains proprietary information developed by and for exclusive use of
Saudi Electricity Company. Your acceptance of the document is an acknowledgement
that it must be used for the identified purpose/application and during the period indicated.
It cannot be used or copied for any other purposes nor released to others without prior
written authorization of Saudi Electricity Company. Saudi Electricity Company will not be
responsible for misuse and/or misapplication, and any harm resulting therefrom. Saudi
Electricity Company also reserves the right to take any necessary actions to protect its
interest against unauthorized use.

Originated By

Certified By

Approved By

Abdul Rahim Al Harbi

Khaled S. Al Rashed

Tariq M. Al Tahini

Division Manager
Generation Projects
Engineering & Design

Department Manager
Generation Projects
Engineering

Executive Director
Generation Engineering &
Projects

3.

2.

1.

Date:NO.

REVISIONS

VOLUME - 1

Date:-

Date:-

Generation Engineering & Materials

Standard Specifications
GEMSS-M-03 Rev 02
Condensate System Including Condensate Extraction Pumps
Document Responsibility:- Engineering and Design Division

Volume - 1

Next Planned Update : Based on new development & technology with the consent of designated division

Table of Contents
1.0

GENERAL DESCRIPTION---------------------------

2.0

SCOPE--------------------------------------------------

3.0

APPLICABLE CODES & STANDARDS------------

4.0

DESIGN CRITERIA AND SYSTEMS

DETAILS------------------------------------------------

5.0

MATERIALS--------------------------------------------

6.0

GENERAL TECHNICAL REQUIREMENT----------

6.1

Condensate Extraction Pumps---------------------------------------

6.2

Condensate reserve tank----------------------------------------------

7.0

MISCELLANEOUS REQUIREMENTS--------------

7.1

Instrumentation & Control System---------------------------------

7.2

Electrical System------------------------------------------------------

7.3

Field Quality Control-------------------------------------------------

7.3.1

Sequence of Testing & Commissioning----------------------------

8.0

TECHNICAL SCHEDULES/ DATA SHEETS-------

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Document Responsibility:

Engineering and Design Division

Next Planned Update:-

Based on new development & technology

with the consent of designated division

1.0

Volume - 1
GEMSS-M-03 Rev 02
Condensate System Including Condensate
Extraction Pumps

GENERAL DESCRIPTION

The requirements of this section shall apply to condensate system including condensate
extraction pumps unless other sections of the Specification dictate otherwise.
The CONTRACTOR shall ensure that the design engineering, selection and supply of materials,
fabrication, construction, installation, inspection, testing, performance and operation of all the systems
comply with the latest rules, regulations, standards and codes.
The extent of work for the condensate system shall comprise the complete system design and
supply of all related piping, fittings and equipment (including special tools) whether specified in detail or not.
The Tenderer is required to state the corrosion prevention measures he intends to use for all materials in
contact with the cooling water.
The Contractor shall be responsible for the detailed design and engineering of the system used
in the plant.
Selection of sizes, materials, components, methods of construction and erection shall be made
with due consideration to the requirements and capabilities of the equipment served, as well as the reaction
and thermal, chemical, or other effects of the medium being handled by each system or component. The
equipment, materials and services provided by the Contractor shall be consistent with the need to develop a
safe, dependable, and adequate installation. The Contractor shall ensure that no individual element or
system will set a limit on the station capability, when completed.
2.0

SCOPE

The scope of the condensate system shall comprise condensate pumps, gland steam
condensing and control systems and accessories.
This Specification provides for the design, manufacture, construction, supply, testing in works,
packaging for export, shipping, transport, delivery to Site, unloading at Site, complete erection, painting,
commissioning and putting into normal operation, performance and reliability testing on completion and
instruction of the Companys personnel for the Condensate System Including Extraction Pumps, which are
common to all systems, plant and equipment being provided under the Mechanical Equipment and Material
specifications and all obligations during the defects liability period as stipulated in the Conditions of Contract.
All equipment, spare parts and materials used in the construction of the plant shall be new and unused.
3.0

APPLICABLE CODES & STANDARDS

Equipment supplied from Europe shall be designed, manufactured and tested to the
MANUFACTURERs drawings, procedures and processes that are in general compliance with applicable
sections of the European industry codes and standards effective on the date of the proposal.
Where conformance to other supporting codes and standards is required, the latest editions (at
the time of award) of these supporting codes shall apply. Other applicable design codes and standards that
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Document Responsibility:

Engineering and Design Division

Next Planned Update:-

Based on new development & technology

with the consent of designated division

Volume - 1
GEMSS-M-03 Rev 02
Condensate System Including Condensate
Extraction Pumps

are used by the manufacturer, such as International Organization for Standardization (ISO), that govern the
design and manufacture shall be subject to review by the COMPANY/ Engineer.
In the event of conflict between codes, or the technical specifications and codes, the more
stringent requirement shall apply.
The pumps shall operate free of any harmful vibration under any condition of loading. Vibration
levels shall comply with the requirements of ISO 10816 and ISO 7919 as applicable category for new
machines and unrestricted long term operation. For general requirements relating to codes and standards,
please refer to Section 3 of GEMSS-G-01 General Requirements for Equipment / Material and other more
specific codes and standards are listed within the text of this specification.
4.0

DESIGN CRITERIA AND SYSTEMS DETAILS

The design criteria and system details applied to the design of the system and equipment
defined in this specification shall be as specified in the particular system specification .
Only reliable system including pump & equipment requiring minimal maintenance shall be used.
Skid mounted equipment shall be provided where appropriate.
Easy access is necessary from the ground floor or from an installed platform to each valve,
instrument, man way, utility connection, etc. Therefore, all stairways and platforms required shall be
considered as an integral part of the equipment, unless otherwise specified.
The design, manufacture, installation and testing of the system, pump equipment, material and
work shall be in accordance with the requirements and recommendations of all appropriate internationally
recognized and accepted Codes and Standards.
The design and construction shall conform, in all respects, to the highest standards of
engineering design and workmanship. The system shall be designed, constructed and installed such that
every reasonable safeguard and provision for the safety of all personnel concerned with the construction,
commissioning, operation and maintenance of the equipment is incorporated.
The design, construction and installation of the system shall be carried out with due
consideration to maximizing the continuity of supply, availability of service and reliability.
The design criteria and system details shall be provided in accordance with the sub-sections in
section 6.0 General Technical Requirements below.
5.0

MATERIALS

Reliability and simplicity of operation are of utmost importance. First class and new materials
shall be used, best workmanship applied, conservative stress levels employed, sufficient clearances
provided, and the latest proven design philosophy shall be applied.
All pump and components in the system shall be new and designed and manufactured for the
specific purpose for which they shall be used within the plant.
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Document Responsibility:

Engineering and Design Division

Next Planned Update:-

Based on new development & technology

with the consent of designated division

Volume - 1
GEMSS-M-03 Rev 02
Condensate System Including Condensate
Extraction Pumps

The design, construction and installation of the system shall be such as to minimize the risk of
the outbreak of fire and to minimize the potential and consequential injury to personnel and damage to
equipment.
Care shall be taken in the selection of materials for the condenser extraction pumps to prevent
erosion and corrosion of any part. However, all parts of the pump in contact with feed-water shall be of
stainless steel construction. Parts subject to wear shall be fitted with renewable liners and sleeves.
6.0

GENERAL TECHNICAL REQUIREMENT

The Tenderer shall provide with his proposal a description of the condensate system, together
with details regarding the design and proposed arrangement of the condensate system which meet the
design/operating requirements specified for this plant, and details of previous experience on pumps of
similar size.
6.1

Condensate Extraction Pumps

The pumps shall be designed to fulfill the primary duty of extracting condensate from the
condenser and pumping it to the deaerator under all conditions, including extended bypass operation.
The pumps shall have sufficient capacity and the discharge head shall be sufficient to meet the
condensate system resistance under all conditions of operation. The layout of pumps and pipework shall
ensure that adequate NPSH is available at the pump suction at all plant conditions.
The pumps shall be arranged so that one of the pumps automatically starts on trip/failure of
another pump. The isolating valves on each pump shall be open whenever the pumps are started except
when initially priming the system.
The pumps shall be capable of operating in parallel, and shall be provided with minimum flow
protection and the means to prevent cavitation, bearing in mind that the forward flow will vary from zero up to
that corresponding to the most onerous operating condition.
Suction strainers with dual redundant differential pressure indicating transmitters shall be
provided to each pump. The strainer elements shall be of stainless steel (316 L grade) of appropriate mesh
size . Adequate lifting arrangement for the strainers shall be provided (incase wet cooled condenser ).
Temporary strainers shall be installed for commissioning purposes. Sufficient spares for strainer
maintenance shall also be provided.
A complete condition monitoring and diagnostic package shall be supplied and installed with
vibration measuring devices installed at each thrust bearing of the pump and driver. These shall consist of
seismic probes and proximity probes in the X and Y plane for each thrust bearing location as defined in
Instrumentation and Control Section.
The rated flow shall be the maximum continuous flow plus a margin for control purposes and to
cover for pressure changes during transient operating conditions plus a five (5) per cent margin to cover for
pump wear between overhauls.
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Document Responsibility:

Engineering and Design Division

Next Planned Update:-

Based on new development & technology

with the consent of designated division

Volume - 1
GEMSS-M-03 Rev 02
Condensate System Including Condensate
Extraction Pumps

The rated total head shall include a twenty (20) per cent margin on the frictional resistance part
of the total head at a flow corresponding to the normal maximum flow plus the margin for control purposes.
The motor rating shall include a margin of at least five (5) per cent over the maximum power demand. The
pump shall be sized to operate at its best efficiency point at a flow that corresponds to the mean economic
weighted electrical load of the power plant over the plant lifetime and capable of operating at worst condition.
The power required by a single pump starting with a flooded atmospheric hot well of water at
20C shall be taken into account in determining the motor requirements. Details of the maximum power
demand and the condition under which it occurs shall be defined by the Tenderer.
The 'Pump Can' housing, discharge head, baseplate and column pipe shall be carbon steel.
Bowl and suction bell shall be either cast iron or ductile steel. Line shaft bearing in contact with condensate
shall be bronze. All remaining parts of the pump in contact with feed water shall be of stainless steel
construction.
The pumps shall be provided with mechanical shaft seals (if required) seal water coolers as per
API mechanical seals piping plan.
For design purposes, the condensate system and feed-water system shall be treated as a single
system and shall be designed to ensure freedom from hydraulic shock. The hydraulic design of the systems
shall be such that after the system is primed on commissioning, or after a long shut-down, it shall be possible
at any time to restart the condensate extraction pumps without creating hydraulic shock in any part of the
system. This condition also applies to temporary cessation of pumping without re-priming and to a shut
down of up to two ( 2) days duration.
Details of the method of flow control and control valves shall be given in the tender together with
their characteristics.
6.2

Condensate reserve tank

The Contractor shall provide each unit with a condensate reserve tank which shall be installed
close to the turbine hall. The tank shall be used to provide make-up water to and receive surplus
condensate from the condensate system. Tenderers should refer to drawing GESDRW-M-03.
A full description of the tank and associated equipment (pumps, valves, etc.) shall be provided in
the Tender with the operating philosophy in association with the steam/water cycle.
7.0

MISCELLANEOUS REQUIREMENTS

7.1

Instrumentation & Control System

Instrumentation and Control shall be provided in accordance with specification GEMSS-I&C-07 Unit Auxiliary Control Systems and specification GEMSS-I&C-31 - General Requirements for Control and
Instrumentation.

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Document Responsibility:

Engineering and Design Division

Next Planned Update:-

Based on new development & technology

with the consent of designated division

7.2

Volume - 1
GEMSS-M-03 Rev 02
Condensate System Including Condensate
Extraction Pumps

Electrical System

Electrical equipment shall comply with specification GEMSS-E-42 General Electrical

Provisions. Electrical drives shall comply with specification GEMSS-E-22 Low Voltage Motors, GEMSS-E23 Medium Voltage Motors & all other applicable sections.
7.3

Field Quality Control

The CONTRACTOR shall submit for approval a comprehensive quality control plan covering the
erection, flushing, hydro testing, testing, cleaning, blowing and commissioning activities . This document
shall identify the degree of inspection and testing to be carried out by the CONTRACTORs personnel.
The CONTRACTOR shall permit access to the equipment to verify that the manufacturers
recommended clearances are set. Drawings clearly identifying such dimensions shall be available to the
COMPANY and/or the ENGINEER.
7.3.1

Sequence of Testing & Commissioning

Testing, Commissioning & Start up activities shall be undertaken by the CONTRACTOR in

coordination and with the participation of the COMPANY/ENGINEER.
All necessary tests including functional tests shall be conducted by the CONTRACTOR in
coordination and with the participation of the COMPANY/ENGINEER in accordance with the agreed Test
protocol.
Performance Tests of the system shall be carried out to establish the system performance at site
conditions as stipulated in the agreed Test protocol and the Contract.
Field Quality Control shall be managed in accordance with specification GEMSS-G-03 Factory
Inspection and Testing, GEMSS-G-04 Startup, testing & commissioning and specification GEMSS-G-05 Quality Control and Quality Assurance.
8.0

TECHNICAL SCHEDULES/ DATA SHEETS

Technical Schedules and data sheets shall be completed and submitted along with the proposal
for COMPANY / Engineer review. (Please refer to Volume 2 )

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