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MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender

Gas Power Plant Projects 2011

Republic of Iraq
Ministry of Electricity

DIBIS 2xSGT5-PAC 2000E


Dual fuel + Heavy Fuel Oil

CHAPTER 2
PLANT DESIGN CRITERIA

TOTAL PAGES: 11
Including this page

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Table of Contents

2 PLANT DESIGN CRITERIA...................................................................................................................3


2.1 General.............................................................................................................................................3
2.2 Site layout.........................................................................................................................................3
2.3 Plant operating philosophy...............................................................................................................3
2.4 Site conditions..................................................................................................................................4
2.4.1 Site conditions affecting the design of the equipment...............................................................4
2.4.2 Other meteorological data.........................................................................................................4
2.5 Fuel/water supplies...........................................................................................................................5
2.5.1 HFO analysis............................................................................................................................5
2.5.2 LDO analysis............................................................................................................................5
2.5.3 Fuel Gas....................................................................................................................................6
2.5.4 Raw water analysis...................................................................................................................7
2.6 Grid conditions.................................................................................................................................8
2.7 Environmental criteria......................................................................................................................8
2.7.1 Air.............................................................................................................................................8
2.7.2 Noise.........................................................................................................................................9
2.7.3 Emissions during construction................................................................................................10
2.7.4 Aqueous emissions.................................................................................................................10
2.7.5 Visual impact..........................................................................................................................11

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MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011

2 PLANT DESIGN CRITERIA

2.1 General

These Specifications requires a gas turbine power plant design that is modern, well proven, safe, and
economically attractive both in capital cost and running cost and offering a high availability with low forced
outage rate. The plant shall be fully automated and require minimum operator intervention for normal
operation. The Contractor shall comply with the Specifications unless compliance would for any reason put
at risk safety, reliability and economy due to deviation from standard practice of the Contractor. However,
the intent of the Specification shall always be complied with the definitions of all terms are as defined in
General and Special Conditions of these Contract Documents.

Equipment shall be designed and selected to ensure high reliability and availability of the complete plant
with low forced outage rates and minimal maintenance over the lifetime of the power station, which shall be
defined as 25 years.

An appropriate level of redundancy shall be included in each system; the plant shall be designed so that no
single auxiliary plant component failure shall result in the total loss or limitation of the unit generating
capability. In this context, it is required that with agreed exceptions, all unit auxiliaries will be provided with
at least one installed spare (N+1). For the station auxiliaries, no single equipment failure shall result in any
loss of station generating capability.

Prototype equipment will not be acceptable, and equipment that is offered with limited operating experience
must be fully supported by manufacturers warranties and indemnities.

2.2 Site layout

The Contractor shall provide layouts generally in accordance with the conceptual layouts provided with these
specifications, conversant with good operating practice, so that maintenance access is fully available to any
part of the plants.

As indicated in the previous chapter, the Contractor shall take account of the future possibility that the plant
will be extended and converted to combined cycle operation. The Contractor shall therefore lay out the plant
accordingly with space allocation for possible future units and for heat recovery steam generators,
condensing steam turbine and generators and other additional spaces indicated in the annexed layout.

The simple cycle layout is based on GT installation with units installed inside turbine machine hall.
Therefore the site layout, including plant, buildings, roads, gates, laydown areas etc shall take into
consideration the requirement for heavy vehicles and cranes required for installation and future maintenance
of the plant allowing access to carry out the necessary work. The site layout shall be subject to approval of
MoE.

2.3 Plant operating philosophy

The Plant shall be designed for base load and three shifts operation. The intended operating regime for the
immediate future will be base load, operating [8000 to 8150] hours per annum equating to a typical annual
availability of [91 to 93] per cent. In addition, the plant shall also be capable of operating on a two-shifts
operating regime, based on one start per day.
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MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
Plant normal start-up and shutdown will be initiated from the main control room. The gas turbine and other
BOP equipment will be operated primarily from the PCS in the main control room. Each gas turbine unit
shall also have the capability to be monitored and controlled via the control systems local to each unit. The
plant will be automated to reduce the manual intervention required by operations staff.

The plants shall be provided with black start capability.

The main fuel will be heavy fuel oil HFO and the back-up fuels will be Light Distillate Oil (LDO) & fuel
Gas.

2.4 Site conditions


2.4.1 Site conditions affecting the design of the equipment
Equipment shall be designed and installed to enable safe and flexible operation of the plant over the entire
range of operating modes and conditions as defined in these Specifications and shall operate safely and
reliably over the full range of site ambient conditions listed hereinafter.

2.4.1.1 Seismicity
All plant items shall be designed to resist to the following seismic loads:

Seismic Code: UBC97

Seismic importance factor 1

Customer-specified horizontal acceleration. 0.2 g

2.4.1.2 Wind
Minimum wind speed to be considered for all the three plants is 160 km/h, applicable code is UBC 97 and
wind exposure is C.

2.4.1.3 Site temperatures and humidity

The extreme values of temperatures to be considered are:


Minimum ambient temperature -5 C
Maximum ambient temperature +55 C

In Baghdad station in the period from 1937 to 2007 the maximum mean monthly temperature was 46.6 C
on August 1998 and the minimum mean monthly temperature was -2.6 C on January 1964; apart from that
month never the minimum mean monthly temperature lowered below 0 C.

The extreme values of humidity are:


Minimum relative humidity (RH) 10%
Maximum relative humidity (RH) 98%

In Baghdad station in the period from 1961 to 2007 the maximum mean monthly RH was 96% on January
1983 and the minimum mean monthly RH was 20% various times during the month of June.

2.4.1.4 Plants elevations


The elevation of all the plants is lower than 300 m (above sea level)

2.4.2 Other meteorological data


Monthly total rainfall measured in Baghdad station in the period from 1937 to 2007 shows that during June,
July, August and September rainfall is always nearly zero, a maximum of 148,7 mm was measured on March

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MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
1974 and average values ranging from 15 to about 30 mm are present during January, February, March,
April, November and December.

Sometimes dust storms are present in the region. In Baghdad station in the period from 1971 to 2007 a
maximum of 10 days dust storm was recorded during July 1979 but usually the day storm in a month are few
or even zero. On the contrary suspended and rising dust is present in the air many days in a month.

2.5 Fuel/water supplies

The following are the indicative analyses of the fuels and water before treatments:

2.5.1 HFO analysis


Tests Average values

Specific gravity at 15.6 C 0.9546

Sulphur content (% Wt) 4

Viscosity(Cst) @ 50 C 300

Viscosity(Cst) @ 100 C 29

Carbone residue (% Wt) 8.6

Water sediment Vol % 1

Asphalting Wt % 2.8

Pour point C +25

Flash point C > 65 C

Vanadium ppm 64

Nickel ppm 24

Heat value (Kcal/kg) 10310

Calcium ( ppm) 1 to 10

Sodium + potassium( ppm) (30-50)

Ash Content Wt % 0.016

2.5.2 LDO analysis


Tests Average values

Specific gravity at 15.6 C 0.85

Viscosity @ 37.8 C 6.0 Cst

Viscosity @ 50 C 5 Cst

Pour Point -9 C

Flash point (P.M) C (min) 54

Sulphur Content (% Wt) 1%

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MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011

Rams-Bottom C.R. (% Wt) (on 10% Res.) 0.2 %

Distilled at 350 C (%V) 85 %

Diesel Index 55

Cetane No. Minimum 53

Gross Calorific value 10800 kcal/ kg

Ash (% Wt) 0.01

Sodium + Potassium < 1 ppm

2.5.3 Fuel Gas

2.5.4 Pressures
The estimated available pressure at tapping point located at the boundary line in the plants are listed herein
below
Maximum pressure: To be informed later
Minimum pressure: To be informed later
Gas line pressure design: 70 bar (g)
Flow of fuel gas : 90 MMcf (Million cubic feet)

2.5.4.1 Fuel Gas analysis

Composition Result

C1 (Mol %) 85.47

C2 (Mol %) 12.58

C3 (Mol %) 1.69

IC4 (Mol %) 0.09

NC4 (Mol %) 0.14

IC5 (Mol %) 0.02

NC5 (Mol %) 0.01

C6+ ----

TOTAL 100.00

H2S (mg/m3) 7.5 max.

CO2 (mg/m3) 5

M.WT 18.35

thermal value kcal/ Nm3 9663

SP.GR 0.6351

RSH (mg/m3 ) 15

Total Sulphur (mg/m3 ) 21.4 Page 6 of 11


MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011

Raw water analysis


The following is the indicative chemical analyses of the river water. The water coming from the river will be
treated inside the power plant in order to produce different types of water like demi, service & potable
water ...etc.

PH value 7.6

Total dissolved Solids (T.D.S) (as CaCO3) 670 ppm

Total Suspended Solids (T.S.S.) (as CaCO3) 30 ppm

Temperature 25 C

Turbidity 60 NTU

M-alkalinity (as CaCO3) 196 ppm

Silica (as SiO2) 0.546 ppm

Ca** (as CaCO3) 120 ppm

Mg** (as CaCO3) 50 ppm

Na* (as CaCO3) 121 ppm

Cl (as CaCO3) 20 ppm

Sulphate so4 (as CaCO3) 34 ppm

HCO3 130 ppm

Fe 0.069 ppm

Conductivity s/cm 1100

TH 250 ppm

2.6 Grid conditions


The voltage variation on the transmission system will normally remain within the limits stated in Chapter 9.
The frequency of the transmission system will be nominally 50 Hz, and will normally be controlled within
[49.5] Hz to [50.5] Hz. Anyway the plant equipment shall be capable to operate within the following
exceptional conditions:

The units will remain synchronized to the transmission system at transmission system frequencies
within the range [47.5] Hz to [52] Hz for a duration of [60] minutes;

The units will remain synchronized to the transmission system at transmission system frequencies
within the range [47] Hz to [47.5] Hz for a duration of [5] seconds required each time the frequency
is below 47.5 Hz;

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MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
The units remain synchronized to the transmission system during rate of change of transmission
system frequency of values up to and including [0.5] Hz per second;

Sustained operation at the specified minimum stable generation within the range [49.8] Hz to [51]
Hz.

2.7 Environmental criteria


The plant shall conform as a minimum with the current World Bank guidelines, the requirements of the local
environment authorities in Iraq and with all other relevant consents and regulations.

2.7.1 Air
Gas turbine emission control will be performed by demineralized water injection for NOX reduction. The
Iraq national limitation for ambient air pollution is shown in the following table.

N Pollutions name & symbols Period of Limitation type of Limitation Type of analysis method
measure. ambient air type of
Microgram/m3 ambient air
ppm
1 DI-SULPHUR OXIDE 1 hour 0.1 UV FLOURESCENT
SO2 24 hours 0.04
1 year 0.018
2 MONO-CARBON OXIDE 8 hours 10 IR GAS FILTTER
CO 1 hour 35 CORRELATION
3 DI-NETROGEN OXIDE 24 hours 0.05 CHEMILUMINESCENCES
NO2 1 year 0.04
4 OZONE 1 hour 0.06 UV ABSORPTION
O3
5 SUSPENDED PARTICLES 24 hours 150 GRAVIMETRIC
SIZE LESS THAN 10 USING HI-VOL SAMPLER
MICRON (PM10)
6 SUSPENDED PARTICLES 24 hours 65 GRAVIMETRIC
SIZE LESS THAN 2.5 1 hour 15 USING HI-VOL SAMPLER
MICRON (PM2.5)
7 TOTAL SUSPENDED 24 hours 350 GRAVIMETRIC
PARTICLES 1 hour 150 USING HI-VOL SAMPLER
8 DUST FALLING 30 days (10 ton/Km2/Month) STANDARED DUST
FOR RESIDENTAL CONTAINER
AREA
(20 ton/Km2/Month)
FOR INDUSTRIAL
AREA
9 HYDROCARBONATE 3 hours 160 0.24 GAS
HC CHROMATOGRAPHY
AND FLAME IONISATION
DETECTOR
10 LEAD 24 hours 2 GRAVIMETRIC
PB 3 months 1.5 USING HI-VOL SAMPLER
1 year 1
11 GAS0LINE 1 year 0.003 mg/m3 GAS
CHROMATOGRAPHY
12 DIOXANE 1 year 0.6 picog/m3 GAS
CHROMATOGRAPHY

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MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
2.7.2 Noise

General
The facility shall be designed and constructed such that construction workers and operator are exposed to a
minimum level of noise. The Contractor shall take appropriate steps to minimize noise exposure through
equipment attenuation and procurement of inherently quieter equipment.

All noise specified in this document are to be evaluated as L Aeq levels. This is the energy weighted average of
measured noise level as averaged over a specified time period. All sound levels are expressed in terms of
decibels as referenced to a sound pressure of 20 micropascals. The absolute limit of any measured sound
pressure level anywhere in the work area shall not exceed 85 dB (A). In the locations where it is necessary
for operational attendants to make routine examinations closer than 1 m to an accessible part of a running
machine which is between 80 and 85 dB (A), The Owner will wish to adopt hearing protection aids.
Therefore the Contractor is required to draw specific attention to portions of the plant where this situation
may be encountered and fix appropriate warning labels or signs.
Noise within buildings shall comply with the limits specified in Chapter 10 Civil Works.

Construction noise

The maximum noise level caused by construction noise outside the nearest window of the nearest occupied
house shall be:
Daytime 70 dB (A)
Evening 60 dB (A)
Night 40 dB (A)

Noise levels at the time period during public holidays shall not exceed 40 dB (A).
During construction, BS 5228 shall be adopted as the approved Code of Practice in relation to noise and
vibration.

Noise levels shall be limited to 80 dB (A) or lower at a distance of 1 m from all construction equipment and
activities to the fullest extent feasible. If a noise level exceeding 85 dB (A) is likely to occur in any area,
warning signs shall be predominantly displayed in that area, indicating that a noise hazard exists and hearing
protection must be worn. Any area where noise levels could exceed 90 dB (A) shall be controlled access to
prevent unprotected personnel from entering the areas.

Peak or intermittent noise such as those resulting from pile driving shall occur during daytime periods only
and maximum noise levels shall not exceed 70 dB (A) at the nearest inhabited dwelling.

Far field noise during operation

The contractor shall identify the location of the nearest residential, institutional or educational location and
establish the background noise level. The noise level including background and contribution from the plant
during operation shall either (a) raise background noise level by a maximum of not more than 3 dB (A) or
(b) not exceed the following limits:
Maximum allowable Leq (hourly) in dB (A)
Receptor Daytime (0700to 2200)Night time (2200 t0 0700)

Residential, Institutional,
Educational 55 45

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MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011

Industrial, Commercial 65 65

A noise test procedure shall be submitted by the Contractor, outlining the proposed method of noise testing,
to demonstrate compliance with the stated environmental noise limits.

2.7.3 Emissions during construction


The Contractor shall ensure that suitable site practices are employed to ensure that atmospheric dust
contamination generated by the construction works do not exceed levels, which could constitute a health
hazard or nuisance to those persons working on the site or living nearby.

2.7.4 Aqueous emissions


The discharge of any effluents during construction, including site drainage, shall be the responsibility of the
Contractor who shall reach agreement with the regulatory authorities and the local sewerage authorities with
regard to the detailed methods of disposal.

Aqueous emissions from the plant shall be treated and discharged in accordance with the following quality
limits, consistent with the World Bank Guidelines:

Parameter Maximum, mg/l (except pH


and temperature)
pH 6 to 9
total suspended solids 50
oil and grease 10
total residual chlorine 0.2
chromium (total) 0.5
copper 0.5
iron 1.0
zinc 1.0
temperature increase at the edge 3C
of the mixing zone

And accordance with the Iraqi limitation of aqueous emission:

Parameters Maximum mg/l


Chloride 600
Phosphate 3
BOD 40
Sulphate 400
NO3 50
COD 100
Cu 0.2
Cr 0.1
Zn 2
Fe 0.1
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MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011

Aqueous discharges shall be segregated into storm drains, process effluent and domestic sewage streams.
Each shall be provided with an appropriate monitoring and treatment system to ensure that the discharge
limits are not exceeded. The effluent from the water treatment plant shall be bulked, mixed and neutralized
before discharge to the site effluent tank to be provided under this Contract. Filter wash water shall also be
discharged to the site effluent tank. Any areas of the plant that may be subject to oil spillage shall be drained
to an oil water separator. The clean water shall be discharged with the surface water drainage system. A
package sewage treatment facility shall be installed for the operational phase, sized for the number of
operating and maintenance personnel. All fuel oil and lubricating storage tanks shall be sized to contain 110
per cent of the contents of the largest tank. Gas turbine compressor wash effluent shall be segregated and
stored at a suitable location for off-site disposal.

2.7.5 Visual impact


All reasonable measures shall be taken to minimize visual impact of the plant. Structures and buildings shall
meet the standards generally accepted for a facility of this type and shall be in accordance with all applicable
local and national consents relating to appearance. Final architectural arrangements shall be submitted for
approval to the Owners Engineer.

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