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Republic of Iraq
Ministry of Electricity

DIBIS 2xSGT5-PAC 2000E


Dual fuel + Heavy Fuel Oil

CHAPTER 6

Mechanical plant and systems

TOTAL PAGES: 71
Including this page

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Table of Contents

6 Mechanical plant and systems..................................................................................................................3


6.1 Fuel systems......................................................................................................................................3
6.1.1 Fuel gas supply system..............................................................................................................3
6.1.2 Fuel oil supply system.............................................................................................................14
6.2 Water supply and waste water systems..........................................................................................23
6.2.1 General...................................................................................................................................23
6.2.2 Detailed Scope of work...........................................................................................................23
6.2.3 Raw water supply....................................................................................................................25
6.2.4 Demineralized water...............................................................................................................26
6.2.5 Potable water system..............................................................................................................30
6.2.6 Chemicals................................................................................................................................33
6.2.7 Waste water systems..............................................................................................................35
6.3 Fire protection and detection.........................................................................................................37
6.3.1 General requirements.............................................................................................................37
6.3.2 Detailed scope of work...........................................................................................................38
6.3.3 Fire water supply.....................................................................................................................39
6.3.4 Fire fighting systems...............................................................................................................42
6.4 Instrument and service air systems.................................................................................................52
6.4.1 General...................................................................................................................................52
6.4.2 Detailed scope of work...........................................................................................................53
6.5 Painting and protection against corrosion......................................................................................59
6.5.1 Painting...................................................................................................................................59
6.5.2 Galvanising..............................................................................................................................60
6.6 Cathodic protection........................................................................................................................60
6.7 Cranes and lifting equipment..........................................................................................................61
6.7.1 General...................................................................................................................................61
6.7.2 Electrical overhead travelling cranes.......................................................................................61
6.7.3 Runway beams and lifting facilities.........................................................................................62
6.7.4 Testing.....................................................................................................................................62
6.7.5 Use of cranes for initial erection.............................................................................................63

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6.7.6 Chemical Laboratory...............................................................................................................63


6.8 General mechanical requirements..................................................................................................65
6.8.1 General...................................................................................................................................65
6.8.2 Piping systems.........................................................................................................................66
6.8.3 Valves......................................................................................................................................67
6.8.4 Tanks and pressure vessels.....................................................................................................71

6 Mechanical plant and systems


This Chapter of the Specification details the requirements for the
mechanical systems and all associated equipment, and the criteria against
which the equipment will be designed.

6.1 Fuel systems


6.1.1 Fuel gas supply system
6.1.1.1 Gas supply
Fuel gas to the plant will be supplied by the Employer to the plant
boundary fence line.
Preliminary fuel gas supply conditions are provided in Chapter 2 of this
Specification. The Contractor is responsible for obtaining any additional
data regarding the fuel supply conditions, including fuel analyses as
necessary for his design of fuel treatment and handling/storage facilities
to provide the requisite flow and quality of fuel to the gas turbines to
ensure safe, efficient and reliable operation within the environmental
limitations, under all operating modes and climatic conditions as defined
in Chapter 2 of this Specification. Employer will ensure that the Contractor
will have access to gas sampling when required.

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6.1.1.2 Design capacity and operating range


The design flow rate (DFR) for the fuel gas system will be the fuel flow
required for the power plant at conditions of maximum demand. The
minimum flow will be that required to maintain one gas turbine at
minimum part load operation. The fuel gas system will be designed to
operate satisfactorily from minimum flow to DFR over the range of
ambient conditions as defined in Chapter 2 of this Specification.
The gas conditioning ( pressure, temperature and filtering ) equipment
will comply with the redundancy requirements of this specification and
will encompass the design flow requirements for the GTs load range.
6.1.1.3 Detailed Scope of Work
The complete fuel gas handling and treatment system from the gas supply
terminal point to Gas Turbine terminal points will be the responsibility of
the Contractor. The equipment provided will be capable of removing
contaminants from the fuel gas to achieve the required quality, and of
supplying the required quantity, pressure and temperature of gas to each
gas turbine at the required dry and clean conditions.
The fuel gas system will be capable of delivering sufficient fuel gas to
enable the gas turbines to operate, without restriction, at their design
maximum capability over all specified operating and ambient conditions.

Detailed Scope of Work for Project .


6.1.1.3.1
The main equipment will include, but will not be limited to the following:
Emergency shutdown valve station controlled from the central control
room by hardwire
Two (2) x 100 per cent separator type multi-cyclone units
Two (2) x 100 per cent gas filter units (coalescing type) per unit
Two (2) x 100 per cent metering streams for the determination of flow
One gas chromatograph meter with redundant sampling capability to
determine calorific value and density of the gas stream.

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Two (2) x 100 per cent heaters to condition the gas temperature to within
required limits above the dew point.
Two (2) x 100 per cent pressure regulating valve streams, to condition the
gas pressure to within required limits. (One per two GT units)
Gas condensates drains system
Gas venting/nitrogen purge system, and cold vent stack
Gas detection and alarm equipment, including portable gas detection
equipment for gas line purge monitoring.
Notwithstanding the above list, it will be the responsibility of the
Contractor to provide all equipment whether specifically detailed or not,
to effect a fully functional gas supply system.

6.1.1.4 Design requirements


The design, installation and testing of the fuel gas supply system will
comply with the latest issue of applicable Standards and Codes, accepted
International Standards and other local laws and regulations, including
any applicable regulations as reported in Chapter 4 of this Specification.
The gas parameters at GT terminal point will be compliant with SIEMENS
gas fuel quality requirements .
The Contractor will list the standards applied to main items of equipment
and will substantiate selection within the Tender.
The fuel supply systems will comply also with all relevant NFPA or
equivalent standards and special attention will be paid to ensure
increased safety against hazard due to fuel gas handling.
The fluid conditions and characteristics at all interface points with
SIEMENS scope of work will be compliant with prescriptions reported in
SIEMENS documents.

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All equipment will be designed with the primary consideration being


reliability, ease of operation and a minimum of maintenance attention
and will operate satisfactorily under the full range of operating pressures,
gas flow, gas temperatures and ambient temperature.
The Contractor will take into account the composition of the gas in
selection of the material specifications and demonstrate that the relevant
codes have been adhered to.
The venting system will serve as a safe removal system for all possible
hydrocarbon vapors occurring during regular operations or emergencies..
All gas vessel nozzles will be flanged, and equipment will be fitted with
isolation valves to permit removal for maintenance without interrupting
the gas supply.

6.1.1.5Emergency shutdown valve station


An emergency shutdown fire safe flanged ball valve complete with
pneumatic actuator and explosion proof for remote and local operation
and fail safe will be provided.
This valve should be located as close as possible to the supply terminal
point at the site boundary to protect the plant from overpressure in the
gas supply pipeline.

Fuel gas separator/scrubber


6.1.1.6
The initial separation equipment will consist of two 100 per cent
duty/standby cyclone type dry scrubbers.
The scrubber will remove 100 per cent of solid and liquid particles 8
microns and larger at DFR. The scrubbers will be able to maintain the
stated efficiency and remove particles from 25 to 100 per cent DFR, over
the range of gas supply temperature and pressures when handling all
specified types of fuel gases.

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The design will ensure low pressure drop across the scrubber, and
prevent the passing of particulate and moisture droplets to downstream
process equipment.
Corrosion allowance will be determined by the Contractor based on the
gas conditions, with a minimum allowance of 5 mm provided for the
vessel, and a minimum of 2 mm allowance provided for piping connected
to the separator vessel.
The scrubber station will be provided with isolating valves, vents and
drains, and will be designed to allow changeover to the standby unit
whilst on load.
Gas condensate will be drained from the scrubbers to the gas condensate
drains tank via automatic valves initiated by filter level equipment. High
and low level instruments will also be provided to alarm on the
Monitoring and Control System.

Fuel gas coalescing filter /separators


6.1.1.7
The gas filters will be installed downstream of the gas scrubber. There will
be two redundant full flow filter /separators to allow filter cartridge
replacement without interrupting the gas supply.
The filter will include full bore quick closure with safety interlock bleed
and fitted with drains sump.
The filter elements will be replaceable, suitable for the specified gases
and meet the necessary requirements for protection of the gas turbine
units. The type selected will be supported by Contractors experience and
documentary proof.
Final efficiency will be (absolute removal efficiencies): all solid particles
whose size is greater than 3 microns will be filtered with an efficiency of
99.99% and all liquid particles whose size is greater than 3 microns will be
filtered with an efficiency of 99.5%.
Each filter line will be complete with all isolation, vent and drain valves,
to allow changeover on load. The vessel will include temperature and
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pressure gauges and differential pressure gauges, which will alarm the
operator that the filter in service requires cleaning and changeover to the
standby filter is necessary.
6.1.1.8 Gas metering equipment
The Contractor will provide tariff quality metering at the site boundary to
enable the quality and flow rate of gas delivered to the site to be
independently recorded.
The metering system will be of approved type, and will be designed to
provide accurate measurement of the gas flows during all plant
operational conditions, including the frequent starting and stopping of the
plant during two shifting operating regime and at low loads.
The metering station will be complete with all instrumentation, valves,
purge points, vents and drains. A gas chromatograph will be provided to
measure fuel calorific value of the fuel.
Two 100 per cent capacity flow metering streams will be provided with
an accuracy better than 1 per cent over the full flow range of the
metering station. The metering system will include a flow computer to
automatically correct the flow rate for pressure, temperature and
composition (compressibility factor).
The meter will be located such that sufficient straight lengths of piping
are provided both upstream and downstream of the device.

6.1.1.9 Gas heating equipment


Heating of the filtered gas will be provided to ensure that the gas is
maintained at a temperature level above its dew point to prevent the
possibility of freezing of the pressure reduction valves and presence of
moisture and that gas is supplied to terminal point in SIEMENS specified
conditions .
This heating system will be designed as standalone equipment.
Two 100 per cent capacity horizontal indirect/waterbath type heaters for
fuel gas heating service will be provided, complete with integral burners
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and control bypass, burner control panel, inlet and outlet isolating valves,
vent, drain and purge facilities. The heaters will have a minimum
turndown capability of 10 to 1 and will be designed, tested and inspected
in accordance with API 12K.
The system offered by the Contractor will be suitable for the hazardous
area classification for its location. The supply of gas to the heaters will be
tapped upstream of the unit gas flow-meters. The Tenderer will provide
details of the proposed system with the Tender.
6.1.1.10 Pressure control equipment
For a matter of regulation, the acceptable pressure variation is the
following :
Maximum Transient supply pressure excursions are limited to either 1%
per second ramp or 5% step. The 1% per second ramp is applicable over
the range of minimum required pressure to maximum operating pressure.
The 5% step is applicable over the range of minimum required pressure to
95% of maximum
operating pressure and with a maximum of one 5% step change in 5
seconds.
The steady state gas supply pressure regulation at any operating point
within the gas turbine capability will remain within more or less 1 %
pressure at a rate not to exceed more or less 0.25 % / sec over the range
of minimum required pressure to maximum operating pressure.
The pressure regulation system will include a full flow relief valve rated at
70 barg installed upstream SIEMENS filtration skid.
Two streams of pressure reduction/trimming will be provided, each
stream sized for the design flow rate (DFR) of both gas turbine units. One
stream will be operational feeding two gas turbines whilst the second
stream is in standby.
Each stream will consist of two pressure reducing valves in series. The
valves will be of the self acting pilot type, and will act to maintain the
downstream pressure constant at the pressure required by the gas

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turbine making due allowance for pressure drop downstream of this


equipment.
In the event of the upstream pressure falling each pressure reducing valve
should revert to its fully open position.
Each valve will be designed to carry the full pressure reducing duty, one
valve normally being the duty valve and designed to fail open. The second
valve will normally be the standby and be designed to fail closed.
The pressure reducing valves will be controlled automatically to maintain
the gas pressure within the required limits during normal operation and
below the lifting pressure of the relief valves. Control range for each
pressure reducing stream will be from 5 to 110 per cent of the design
flow rate (DFR). Valve opening at DFR will not exceed 80 per cent.
Leakage rates will not exceed 0.1 per cent of maximum CV value.
Actuators will be piston actuated type with air to open and spring to
close. Fail safe position of the valve will be locked in position following
instrument air failure, control signal failure, control power supply failure,
etc.
The pressure reducing control valves will be of an approved type and will
be perfectly stable, quiet and free from vibration in operation when
operating at any flow up to the maximum flow and will be suitable for
continuous use at the operating temperature.
All streams will be provided with upstream and downstream isolation of
the pressure reducing valves. The upstream isolation will comprise an
automatic slam shut type valve together with a manual isolation valve.
A sentinel pressure-relief valve will be provided on the outlet side of each
reducing valve station capable of exhausting to atmosphere at least four
times the maximum station valve leakage without undue build-up of
pressure on the low pressure side. The discharge from the relief valve will
be led to a common vent stack and discharged at a safe location.
Alternatively the pressure relief valves will have their own vent stack.
Pressure gauge and thermometers will be provided upstream and
downstream of the reducing valve.
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All valves will be provided with limit switches in the open and closed
positions for remote indication or alarm purposes as required.
The pressure control station and all its associated equipment will be
designed to give the highest level of availability and security. The
operation of the pressure control station will be automatic over its
complete flow and pressure range. Upon failure of a duty reducing valve
or stream, the standby reducing valve or stream as appropriate, will
automatically commence operation in a pumpless manner

6.1.1.11 Fuel gas condensate system


Gas condensate will be collected from the filter/separators, unit filters
and other relevant system drains into condensate collection tanks. These
tanks will be provided with two 100 per cent drain pumps for emptying
the contents of the tank into road tankers for off-site disposal.
Each condensate tank will be provided with suitable level
controls/alarms, manholes, inlet, vent w/flame arrestor and drains
connections.

6.1.1.12 Gas turbine equipment


In addition to the equipment to be designed and furnished by the
Contractor as specified herein before, SIEMENS will furnish the following
equipments:
Gas Module Skid
Gas turbine unit gas flow metering
GT coalescing filters Skid
Shutoff valves Skid

6.1.1.13 Fuel gas pipework


All gas pipework between gas pipe terminal point at the plant boundary
fence and the gas inlet to each GT gas module will be designed,
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constructed, installed and tested in accordance with ANSI B31.3 or


equivalent internationally recognized standards.
All buried gas pipework will be accommodated in trenches which will be
excavated, prepared and backfilled by the Contractor in accordance with
the requirements of. the latest issue of applicable Standards and Codes,
accepted International Standards and other local laws and regulations,
including any applicable regulations as reported in Chapter 4 of this
Specification.
The Contractor will conduct a flexibility/stress analysis on the gas system
during the detail design stage. The analysis will demonstrate that the
completed pipework system, including line equipment, is not over
stressed or subject to excessive deflections, movements during
installation, including hydrostatic testing, or during operation, including
transient conditions, and the forces and moments on equipment do not
exceed those specified by the manufacturer. Additionally, the effects on
the fatigue life of the installation will be shown to be acceptable.
All welds will be subject to 100 per cent radiography.
The hydrostatic test of the pipework will be carried out by the Contractor
on completion of the installation at site. After completion of this test the
pipework will be dried out using dry compressed air and once dry
inhibited with a slight pressure of nitrogen.
A system of ensuring the line is clean and suitable for use is to be
proposed by the Contractor, (this may be by pigging).
All gas system valves furnished by the Contractor will be in accordance
with API6D and API607 requirements.
The fuel gas piping between the coalescing filter/separator and the gas
turbine connection will be stainless steel.
6.1.1.14 Vents and drains
Adequate provision will be made by the Contractor for safely venting,
purging, and where necessary, draining those sections of pipework and
equipment which have to be isolated during construction, commissioning
and maintenance.
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The venting system will be suitable for the disposal of vented or


emergency relief gases.
All vent gases containing hydrocarbon vapors, e.g. during stream purge on
shut down operation, will be piped to safe locations or to a vent stack.
Block and bleed with integral vent arrangements will be provided, where
necessary, to ensure plant safety, and purge vents will include facility for
connection of gas detection equipment.
Vents and drains only needed for tests will be plugged and seal-welded;
all others will be equipped with blind flanged or blind plugged gate or ball
valves. Vents and drains will have a minimum diameter of 20 mm.
The vent system will be designed to remove the largest amount of vent
gas, which could occur during any reasonably assumed plant condition or
emergency expected throughout the power station. Basic and detailed
design will be subject to Owner/Engineers approval.
6.1.1.15 Corrosion protection
All above ground fuel pipes will be protected against corrosion in
accordance with the Painting and Protection requirements defined in
Paragraph 6.5 of this Chapter.
Buried portions will be protected against corrosion with factory applied
coating and cathodic protection, suitable for the ground conditions.
The selection of coating and method of application will be to the approval
of the Owners Engineer and will be taken to ensure mechanical and
electrical compatibility with the cathodic protection system.
6.1.1.16 Cathodic protection
Cathodic protection will be applied by the impressed current method to
all buried pipe work. The cathodic protection will be brought into
operation immediately upon completion of the pipeline construction with
the protection designed and installed in accordance with the
requirements as defined in the Cathodic Protection, paragraph 6.6 of this
Chapter.. Particular note will be taken of the presence of other buried
services in the area of gas pipeline.

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6.1.1.17 Pressure vessels


All pressure vessels for fuel gas system furnished and designed by the
Contractor will be designed in accordance to ASME Section VIII Div. 1 with
latest amendments, and welding will conform to ASME Section IX for
welding as well as for welders qualifications.
All welds will be examined by appropriate non-destructive technique as
per code, and type of welded seam.
Radiographs will be interpreted using the porosity charts in the above
standard.

6.1.1.18 Inert gas purging


An inert nitrogen gas purging system will be provided for the complete
fuel gas system.
Suitable valved connections will be provided at all necessary points in the
system to allow purging to take place.
The necessary nitrogen bottles will be provided in suitable racks or
batteries. Every battery will have pressure gauge, thermometer, reducing
valve, and a pressure relief valve downstream of the reducing valve. One
hose connection with arrangement for quick connection for each battery
will be supplied. Hose length will be not less than 7 m.
The Contractor will provide a nitrogen storage area and sufficient spare
nitrogen cylinders of the same type and make to enable two complete
system purges.
6.1.2 Fuel oil supply system
6.1.2.1 Fuel oil supply
Fuel oil to the plant will be supplied from the unloading station or via a
direct pipeline source.
Preliminary fuel oil supply conditions are provided in Chapter 2 of this
Specification for information.

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The fuel oil will be supplied as Light Distillate Oil or LDO and Heavy Fuel
Oil or HFO (where disposable).
The Contractor is responsible for obtaining any additional data regarding
the fuel supply conditions, including fuel analysis as necessary for his
design fuel handling/storage facilities to provide the requisite flow and
quality of fuel to the gas turbines to ensure safe, efficient and reliable
operation within the environmental limitations, under all operating
modes and climatic conditions as defined in Chapter 2 of this
Specification.
6.1.2.2 Design capacity and operating range
The design flow rate (DFR) for the fuel oil system will be the fuel flow
required for the power plant at conditions of maximum demand. The
minimum flow will be that required to maintain one gas turbine at
minimum part load operation. The fuel oil system will be designed to
operate satisfactorily from minimum flow to DFR over the range of
ambient conditions as defined in Chapter 2 of this Specification.
For common systems supplying the power plant, 100 per cent duty
equates to the design flow for all turbine units.
6.1.2.3 Detailed Scope of Work
6.1.2.3.1Detailed Scope of Work for Project
The Contractor will provide a complete system to deliver HFO to the gas
turbines and LDO to the gas turbines, black start diesel generator and
diesel fire pump at appropriate supply conditions and quantity.
The scope of supply for the LDO system will include, but not be limited to,
the following:
One complete separated unloading station for LDO designed for the
contemporary discharge of 5 trucks (536000LIT). the unloading station
will include isolating valve and a filter with air release,(2x100% pumps),
mass metering device with all accessories to avoid bubble or gases and
correct metering of flow rate (for each truck) to transfer LDO to storage
tanks.

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Fuel oil supply line; from supply terminal point to the fuel oil tank,
including isolating valves, filtration and flow monitoring/sampling facility.
Fuel oil storage tanks with heating system: tanks with net volume
calculated for 5 days of GT power plant consumption and located in a
bounded area
Fuel oil flow monitoring:
One flow meter for measuring the distillate fuel oil supply to the
black start diesel engine.
One flow meter for measuring distillate fuel oil supply to the
emergency generator.
One flow meter for measuring distillate fuel oil supply to the diesel
fire pump.
All relevant insulation or heating to ensure that waxing does not
occur in cold weather (if applicable).

The scope of supply for the HFO system will include, but not be limited
to, the following:
Fuel oil supply line; from supply terminal point to the fuel oil tank,
including isolating valves, filtration and flow monitoring/sampling facility.
Fuel oil storage tanks with heating system: storage tanks total capacity of
5 days total plant consumption ' Raw, treated tanks and certified tanks
located in a bounded area.
FOTP Fuel oil conditioning/treatment plant
Transfer Pumps complete of duplex self cleaning strainers, 2x100%
pumps skid mounted complete of all instrumentation, safety devices,
vents and drain necessary
One fuel oil heater per unit

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All relevant insulation & heating for tanks, pipe works, pumps,
instruments and others inline devices to maintain adequate viscosity of
fuel oil and to ensure that waxing does not occur in cold weather.
Auxiliary boilers (2x100%) to produce pressurized hot water for heat
tracing.

In addition, the Contractor will provide, all pipework, valves, air


separators, filters, drains, drip pans, vents, fittings, trace heating, and
equipment needed to convey oil from the unloading point to the
consumers, and to convey recirculation oil back to the storage tank. All
instrumentation will be accessible via the monitoring and control system.

6.1.2.4 Design requirements


All equipment will be adequately sized and of material properly selected
for the fuel as specified, and will be designed, manufactured and installed
in accordance with the latest issue of applicable Standards and Codes,
accepted International Standards and other local laws and regulations,
including any applicable regulations as reported in Chapter 4 of this
Specification.
The fuel oil system will designed in accordance with SIEMENS Fuel
specification requirement..
The fuel oil parameters at GT terminal point will be compliant with
SIEMENSs fuel oil quality requirements. .
The fluid conditions and characteristics at all interface points with
SIEMENS scope of work will be compliant with prescriptions reported in
SIEMENS documents. The fuel supply systems will comply also with all
relevant NFPA or equivalent standards and special attention will be paid
to ensure increased safety against hazard due to fuel oil handling.

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All equipment and materials will be easily accessible and suitable for
outdoor installation. The Contractor will provide all necessary access
platforms, stairways and ladders to meet this requirement.
All equipment will be designed with the primary consideration being
reliability, ease of operation and a minimum of maintenance attention
and will operate satisfactorily under the full range of operating pressures,
gas flow, gas temperatures and ambient temperature.
The Contractor will take into account the composition of the fuel oil
reported in Chapter 2 of this Specification in selection of the material
specifications and demonstrate that the relevant codes have been
adhered to.
6.1.2.5 Fuel oil supply line
The Contractor will provide a facility for filling the fuel oil storage tank
from the terminal point on the boundary plant fence line and unloading
truck station.
The tank filling connection will be provided with remotely operated
isolating valves, controlled from local panel and the monitoring and
control system. Automatic closing of the inlet valves will be initiated by
high level switch provided on the fuel oil tank
Flow tariff metering devices will be provided for monitoring
instantaneous as well as integrated fuel oil delivery flow, both locally, and
at the Central Control Room (CCR). The flow monitoring station will have
facility for sampling of the fuel oil.

6.1.2.6 Truck unloading station


A complete truck unloading station will be provided by the Contractor.
The unloading station will be designed for contemporary discharge of
several trucks (number is indicated in detailed scope work).
Discharging pumps will be able to discharge a tanker in 20 minutes and
will be complete of coarse strainers on the suction line, instruments for
local and remote control, suited for local and remote control.
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The transferring pumps will be designed to transfer oil fuel to the storage
tank in order to avoid stop in operation in unloading station.
The transferring pumps will be completed with all necessary devices for
its completion, for instance valves, filter, instrumentation for local and
remote indication via the Monitoring and Control System-

6.1.2.7 Fuel oil storage tanks


The tanks will be vertical cylindrical type, designed, manufactured,
constructed and tested in accordance with the requirements of API 650
and according to SIEMENS Specification.
The tanks will be installed in an impermeable containment bund sized to
contain as a minimum 110 per cent of the entire contents of the largest
tank located within the bund. There will be no bund wall penetration and
all pipe work and cabling will be routed over the bund wall.
Each tank will be complete with stairs, handrails, internal and external
coatings, instrumentation, vents, manholes, drains, filling and extraction
pipework, and any other equipment necessary for the safe operation of
the fuel oil system. As a minimum, the following connections and
equipment will be provided:
Filling connection fitted with screw down non-return valve and motorized
shut-off valve.
For HFO floating suction connection, complete with motorized isolating
valve.
Fuel oil recirculation connection, fitted with screw down non-return valve
and isolation valve.
Water draw-off sump, positioned at the lowest point on the tank.
Clean out door, complete with suitable davit arm support.
Atmospheric vent close to the roof apex, sized for the maximum rate of
filling or emptying with a 10 per cent margin, with domed cover and
flame arrester.
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Four earthing terminals suitable for connection to the existing grounding


system.
Lightning and static protection.
A spray water pipe system erected around the perimeter on top of the
tanks and connected to the fire fighting hydrant main.
Four foam injection points.
One 600 mm diameter roof manhole, with hinged cover and padlocked
grill inside the manhole opening.
One 600 mm diameter shell manhole, with bolted over, located 1 m above
ground level.
Float type tank level measuring instrumentation for local and remote
indication via the Monitoring and Control System (level indication and
high level alarm)
High level switches and an alarm system with display local to the tanker
unloading point and at the Monitoring and Control System and low level
switches .
Lockable dip hatch (minimum diameter 200 mm) located adjacent to the
stairway access, complete with two off graduated steel dip tapes
Access stairways from the bunded area to the top of the fuel oil tank
Trace heating system for tank and outlet nozzle for HFO
The tank filling connection will be arranged in such a way as to avoid
stirring up any material that may have settled on the tank bottoms, and
will include a velocity diffuser to minimize the jet effect of the incoming
fuel. The floating suction connection will be have the travel restricted
such that the inlet is never less than 500 mm from the tank bottom. A
check chain will be provided to limit the height of suction travel with a
cable supplied to permit the operation of the floating suction arm to be
checked.

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6.1.2.8Fuel Oil Treatment Plant (FOTP)


The Contractor will provide a complete fuel oil treatment plant (FOTP)
designed to treat and purify the raw Heavy Fuel Oil provided to the power
plant by pipeline at the relevant tapping point or by truck at unloading
station and stored in the raw HFO tanks
Fuel oil transferring pumps
6.1.2.9
Two 100 per cent capacity volumetric type fuel forwarding pumps will be
provided.
The pumps will transfer oil from the Certificate tanks to Treated tanks or
to Raw HFO tanks.
The Contractor will take into consideration all pressure drops in the
system caused by elevation differentials, friction in the pipeline, filters,
heaters, meters, strainers and control valves.
Each pump will be protected by a relief valve set so that the minimum
flow requirements of the pump are met at all times, the discharge of the
relief valve will be returned to the suction side of each pump.
The Contractor will submit performance curves and supporting
calculations to substantiate the pump selection with his detail design.
The fuel oil forwarding pumps will be located in a sheltered area adjacent
to the fuel oil storage tank area. The Contractor will provide suitable trays
or containment for the collection of any seepage emanating from the
pumps.
Duplex self cleaning strainers will be provided at the suction of the fuel
oil transferring pumps, designed to provide for uninterrupted flow of oil
during cleaning of a strainer. All strainers will have pressure ratings
appropriate for the service intended, but in no case, less than 1.5 times
the maximum service pressure. Each strainer will be provided with local
differential pressure indication and a transmitter for remote indication. An
alarm will be installed to remotely indicate when the maximum allowable
pressure drop is reached.

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6.1.2.10 Fuel oil pipework, valves and fittings


All fuel oil pipework will be designed, constructed, installed and tested in
accordance with ANSI B31.3 or equivalent internationally recognized
standards.
All buried fuel oil pipework supplied by the Contractor will be
accommodated in trenches which will be excavated, prepared and
backfilled by the Contractor in accordance with the latest issue of
applicable Standards and Codes, accepted International Standards and
other local laws and regulations, including any applicable regulations as
reported in Chapter 4 of this Specification.
All isolating valves in the fuel oil systems will be of the non-lubricated ball
type with Teflon seals and resilient faces, where applicable. The valves will
be of the fire-safe design.
Threaded valves will only be used where required for equipment
compatibility. Cast iron valves will not be used for oil service.
All piping and equipment will be protected against excess pressure
utilizing pressure relief valves. Over pressurization of blocked or isolated
pipelines and equipment by solar heating and ambient temperature
changes will be considered in the design. Relief valve discharge will be
piped to the return header or pump suction, as required.
Vents and drains equipped with a ball valve will be provided at strainers
and all high points and low points respectively. In addition, connections
required for periodic tests will be equipped with valves and threaded
nipples which will be protected by threaded caps.

6.1.2.11 Auxiliary boiler


Auxiliary boilers (2x100%) will be designed to supply adequate heat
transfer fluid to trace heating system and to heat exchangers for fuel oil
system.. The auxiliary boiler will be designed considering 60C as Fuel Oil
design temperature to be maintained whatever the minimum site
temperature
Boiler will be designed to be feed with Light Distillate Oil or fuel gas.
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Boiler will be complete of all ancillary system (pumps, expansion vessel,


valves, etc), interconnecting piping from boiler to all users,
instrumentation and safety devices in accordance with the latest issue of
applicable Standards and Codes, accepted International Standards and
other local laws and regulations, including any applicable regulations as
reported in Chapter 4 of this Specification.

6.2 Water supply and waste water systems


6.2.1 General
River water to the plant will be supplied by Contractor including Design,
Procure & Construct a complete water intake 2x100% (Pump station ,
Pipes, Valves,basins,tanks, electrical & control ..etc.)
With pretreatment (screenfilter,settlement,clarification,dosing,
filteration ..etc)

River water supply conditions are provided Chapter 2.


The Contractor will be responsible for designing and installing water
handling, storage, treatment and distribution systems as necessary to
provide the requisite flow and quality of water as required for the
complete power station.
Raw water will be used to supply all the process water requirements of
the power station, including fire water, demineralized water, and potable
water for domestic purposes.
A comprehensive site water balance showing all water demands and
effluent discharge pathways will be provided to demonstrate the
adequacy of the plant provision.
6.2.2 Detailed Scope of work
Detailed Scope of work for Project
6.2.2.1
The complete water supply system, from the River water supply at
terminal point to all water consumers and waste water system to the final
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delivery point at the boundary line on the fence will be the responsibility
of the Contractor.
The scope of the water systems will include but not be limited to the
following:
Service water system.(pretreatment system)
Demineralization treatment plant.
Demineralized water distribution system, including, storage,
pumping and distribution
Potable water system, including water treatment plant, storage,
pumping and distribution
Waste water system, including treatment, storage, monitoring and
disposal.
Notwithstanding the above list, it will be the responsibility of the
Contractor to provide all equipment and services whether specifically
detailed or not, to effect a fully functional water supply
6.2.2.2 Design requirements
All equipment will be adequately sized and of material properly selected
for the water supply as specified, and will be designed, manufactured and
installed in accordance with the latest issue of applicable Standards and
Codes, accepted International Standards and other local laws and
regulations, including any applicable regulations as reported in Chapter 4
of this Specification.
The fluid conditions and characteristics at all interface points with
SIEMENS scope of work will be compliant with prescriptions reported in
SIEMENS documents.
All equipment and materials will be easily accessible and suitable for
outdoor installation. The Contractor will provide all necessary access
platforms, stairways and ladders to meet this requirement.
All equipment will be designed with the primary consideration being
reliability, ease of operation and a minimum of maintenance attention
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and will operate satisfactorily under the full range of operating


conditions.

6.2.3 Raw water supply


6.2.3.1 Raw water supply
Raw water will be transferred via a pipeline from the terminal point on
the boundary fence line to the raw water storage tank at the site. Raw
water will be used as the source for production of service water,
demineralized water, cooling water and potable water for the plant.. An
indicative analysis of the raw water is included in Chapter 2 for
information. The Contractor is responsible for obtaining any additional
raw water analyses as the basis for his design of water treatment plant
and storage facilities, including all necessary explorations, sampling and
analysis in order to ensure that the proposed plant design is appropriate
to the supply conditions.
Service water storage
6.2.3.2
A service water storage tank will be provided to supply buffer storage
capacity in the event of a temporary loss of raw water supply. The tank
will be vertical cylindrical type with conical fixed roof, designed in
accordance with API650 and installed on a concrete foundation.
The tank will be constructed of carbon steel and will be painted fully,
inside and outside (including underside of bottom plate), the painting
system will be in accordance with Paragraph 6.5 of this Chapter. The
minimum thickness of steel plate will not be less than 8 mm including
corrosion allowance. The tank will be provided with flanged connections
for all external piping. All tank connections will be protected by suitably
reinforced rubber expansion joints, and will be cathodically protected in
accordance with Paragraph 6.5 of this Chapter.
The tank will be located adjacent to the water treatment plant and will
be complete with all necessary connections for make-up, overflow, vent
and drain, water treatment plant suction, pump re-circulation and testing,
level indicator, level transmitters and high/low level switches for
control/alarm/trips as necessary, access manholes in side wall and roof,
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complete with access ladder, handrails, and a dosing system to inhibit


microbial growth.
The tank vent(s) will be sized to cover the air ingress commensurate with
the maximum tank inflow/outflow conditions.
Service water distribution
6.2.3.3
The Contractor will provide a fully functional service water distribution
system that is sized and arranged to support all plant requirements for
wash down and make-up throughout the plant.
The service water system will comprise two 100 per cent capacity service
water pumps, together with all necessary piping, valves and fittings to
distribute service Water throughout the plant.
Appropriate shelter will be provided to house the pumps etc to enable
ease of maintenance and afford general protection from the environment.
Hoists and other equipment needed to maintain these pumps will be
supplied by the Contractor.
The system will be suitable for continuous full load operation under all
climatic conditions, and all materials used will be carefully selected to
resist to the greatest extent possible the erosive and corrosive effect of
the water used in the system.
The pump casing will be constructed of cast iron and the pump impeller,
wear rings, shaft and shaft sleeves will be constructed of 316L stainless
steel unless otherwise approved by the Owner/Engineer. Pumps will be
protected by suitable duplex filters and will include all valves and
instruments to alarm and facilitate changeover on load.
Pumps will be arranged for automatic starting in the event of a loss of
duty pump.

6.2.4 Demineralized water


The Contractor will provide a complete containerized demineralization
plant designed to comply with the quality and quantity requirements of

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demineralized water for the complete power plant. The Contractor will be
responsible for design, construction and commissioning of the demi plant.
The treatment plant capacity will include adequate provision to supply
demineralized water for potable water treatment, NO x water injection,
HFO washing , washing of each gas turbine compressor (based on washing
each turbine once per week), and for filling and make-up to the closed
circuit cooling water systems located in the power plant. The water
treatment plant design will be based on not less than two 100 per cent
streams. Details of the water treatment plant design, including water
balance at each stage in the chosen demineralization process together
with storage facilities will be provided to demonstrate the adequacy of
the plant provision.
The treatment plant will be fed by service water .
pretreatment System will provide water with quality that is suitable for
feed to the Demineralized Water Treatment System. A typical service water
quality is provided below:

Reference
Species value Units
pH Range 7.6 -
Alkalinity M 196 ppm as CaCO3
Chloride as Cl 20 ppm as CaCO3
Calcium as Ca 98 ppm as CaCO3
Magnesium as Mg 45 ppm
Iron, Total 0.075 ppm
Sodium, as Na 121 ppm as CaCO3
Silica, Total, as SiO2 0.546 ppm
Boron, as B 1 ppm
Silt Density Index<5 -
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(SDI)
Turbidity 0 NTU
Total Organic
Carbon (TOC) <3 ppm as C
Total Suspended
Solids (TSS) <0.5 ppm
So4+2 700 ppm
Total Dissolved
Solids 2000-2500 ppm

The plant will be designed considering use of Multimedia filter, Reverse


Osmosis and Electrostatic Deionizer technologies.
If the plant is going to be upgraded to combined cycle in the future
consideration should be given to meeting the following water quality:
Sodium, ppb ...................... <5
Chloride, ppb .................... <3
Sulfate, ppb ....................... <3
Reactive Silica, ppb ......... < 10
Iron, ppb ........................... undetectable
TOC, ppb ......................... < 100
Dissolved Solids, ppb ...... < 50
Conductivity, S/cm ........ < 0.1

Minimum Demi water quantity to be 117+ 20 cubic meters per hour for
the plant.

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Adequate monitoring and control instrumentation will be installed to


allow automatic operation of the plant and demonstrate the quality of the
final product water. Normal operation of the plant will be from the
Monitoring and Control System operator interface to the CCR. Manual
override will be possible from a local control panel. Alarms and
indications will be displayed both locally and in the CCR.
In addition to the automatic valves, manually operated lockable isolating
valves will be provided to allow any plant stream to be taken out of
service while parallel streams remain in service.
A final water quality monitor (conductivity) will be included that can
activate an interlock system to prevent the forwarding of poor quality
water. A silica monitor will be included on the final treated water outlet.
Plastic pipe will not be used to convey chemical reagent solutions of >5
per cent w/w strength or where the fracture of the pipe could pose
danger to personnel.
Effluent storage facilities will be capable of receiving the wastewater from
the demineralization process for a minimum of 12 hours continuous
operation. Details of the quantity and quality of effluents produced will
be given. Details of the disposal route for the effluent will be provided.
The Contractor will build-in sufficient redundancy such that repair,
maintenance and isolation of plant may be carried out without process
interruption.
Adequate manual sampling points will be provided to allow monitoring of
the plant's performance.
All precautions will be taken in the design and layout of the plant to avoid
danger to personnel. Adequate safety equipment (showers, eye baths)
will be provided at all locations where an occupational hazard exists.
Activation of any safety shower will initiate an alarm in the CCR.

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6.2.4.1 Demineralized water storage


The demineralized water storage tank will be vertical cylindrical bolted
steel or passivated stainless steel or epoxy coated carbon steel type,
designed in accordance with BS6399/AWWA D103 and installed on a
concrete foundation.
The tank will have a storage capacity to cover for not less than [72] hours
demineralized water consumption of the plant at maximum water
demand, based on all gas turbines operating at full load on fuel oil.
The tank will be complete with CO 2 filters, all necessary connections for
make-up, overflow, vent and drain, potable water treatment plant suction,
level indicator, level transmitters and high/low level switches for
control/alarm/trips as necessary, access manholes in side wall and roof,
complete with access ladder and handrails.

6.2.5 Potable water system


6.2.5.1 General
Potable water for domestic purposes will be based upon not less than
220 litres per person per day, with 200 personnel on site at any time. The
system will comprise, but not necessarily be limited to, treatment,
storage and distribution of potable water for the site.
The plant is to provide the total potable water requirements, with
adequate margins for all personnel within the power station under all
conditions of operation. Details of the plant design throughput sizing,
redundancy and potable water storage facilities will be provided with the
Tender to demonstrate the adequacy of the plant provision.
The potable water treatment system feed from the service water tank,
and will include equipment for disinfection and for the adjustment of pH
and hardness, as required, such that the supply conforms to WHO
guidelines. Adequate monitoring and control instrumentation will be
installed to allow automatic operation of the plant and demonstrate the
quality of the final product water. Normal operation of the plant will be
from the Monitoring and Control System operator interface in the CCR.
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Manual override will be possible from a local control panel. Alarms and
indications will be displayed locally with essential alarms and indications
conveyed to the CCR.
The equipment will be complete with all associated pipe-work, valves,
tanks, pumps, control and instrumentation necessary for the efficient and
safe working of the system.

6.2.5.2 Scope of supply


The Contractor will provide a comprehensive potable water system
designed to provide a reliable, clean and appropriate quantity of water to
all occupied buildings. The potable water system will include all necessary
pipework, tanks, filters, fittings, supports, metering and valves and will be
supplied in a fully commissioned and tested condition.
The Contractor will ensure that the system complies with all applicable
local water authority requirements and regulations.
This section of the Specification should be read in conjunction with
Chapter 10, which details earthworks, concrete, masonry, sanitary ware
and plumbing in buildings.

6.2.5.3 System description


The potable water treatment system will be fed from the service Water
tank, and will deliver water into a main potable water storage tank. From
the main tank, booster pumps will supply the potable water to points of
use in each building and roof mounted portable water tanks via a buried
pipework distribution system.
The potable water plant will be located in the water treatment area, and
will include redundant streams to ensure security of supply to the station.
The potable water supplies within the buildings are covered separately
under Chapter 10, civil plumbing.
Pressure gauges will be provided inside each building at the entry point
of the potable water pipework.
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6.2.5.4 Main potable water storage tank/booster pumps


GRP insulated/bolted sectional potable water storage tank or tanks will
be supplied for potable water storage, and located in the water treatment
building. The tanks will have a storage capacity to cover for not less than
48hours at maximum potable water demand with no make-up.
The tanks will be of reinforced fiberglass ribbed construction, complete
with openings and connections for cold water filling, overflow, drain, take
off points, vent pipe and access for cleaning and inspection. The access
cover will be securely fixed to the tank and will be fitted with a padlock
and hasp.
The design and materials will be suitable for a water temperature range
of 5C and 60C.
The booster pumps will be located adjacent to the tank, and will be
duty/standby configuration with facility to control the discharge pressure
between 3 to 3.5 bar.
6.2.5.5 Potable water distribution
Refer to the General Requirement in Chapter 4 for requirements in regard
to distribution piping, valves and fittings.
Before water distribution systems are placed in service all will be
completely cleaned by water, filling and flushed to ensure that no foreign
matter remains inside the pipe.
During the cleaning process the Contractor will disinfect the pipelines in
accordance with the AWWA Specification No C 601 and to the satisfaction
of the Owner/Engineer. The cleaning process will continue until the water
coming from the wash-outs or other branches is clear and free of taste or
smell.
The Contractor will supply all water, disinfection materials, equipment
and labour required for this work.
6.2.5.6 Potable water storage
Roof-mounted water tanks will be provided as required for all major
occupied buildings/facilities and plant areas.

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The tanks will be of reinforced fiberglass ribbed construction, complete


with openings and connections for cold water filling, overflow, drain, take
off points, vent pipe and access for cleaning and inspection. The access
cover will be securely fixed to the tank and will be fitted with a padlock
and hasp.
The required material will be suitable for a water temperature range of
0C to 60C and covered by a minimum 10 year guarantee.
The tank filling connection will be connected to a float operated valve
which will be accessible from outside the tank for maintenance. The
metal parts will be corrosion resisting gunmetal, rubber components will
vulcanized rubber. The float will be suitable for operating in temperatures
in excess of 60C. A tank bypass connection will be provided to allow
mains water to supply directly all points of use when the tank is out of
service. The control valve will be lockable.
An emergency fill connection for water tanker use will be provided for
each building/facility, the fill connection will be provided with an isolating
valve in a stainless steel box.
6.2.6 Chemicals
A bulk chemical storage facility will be provided for reagents for use in
the Fuel Oil Treatment Plant, closed circuit cooling system, the water
treatment plant, potable water supply, all effluent treatments, the
laboratory, and raw water pre-treatment. The system design will
minimize chemical handling by site operators. A comprehensive site
chemical balance showing all chemical demands, details of chemical plant
design and strategic chemical storage facilities will be provided to
demonstrate the adequacy of the plant provision.
All bulk chemical reagents will be adequately stored and handled. Bulk
storage facilities will accommodate 60 days supply of chemicals at design
consumption in either bulk tanks, on pallets or 1m3 "Intermediate Bulk
Containers" (IBCs). The equipment will be compliant with appropriate
International Standards. The storage facilities should be sufficiently
labelled to identify the type of chemicals stored. Material Safety Data
Sheets will be made available for all purchased proprietary products.
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The system design will minimize chemical handling by site operators. All
bulk storage chemicals and filling points will be located in bunded areas.
The bunds will be sized to accommodate 110 per cent of the chemical
contents as a minimum. The bunds will be coated with a suitable
protective lining on the inner surfaces. Facilities will be included for the
controlled emptying of the bunded areas. The floor drainage system will
be designed to accommodate an accidental release of chemicals from the
delivery tankers during discharge to the storage tanks. The drains system
will be designed to avoid the accidental mixing of incompatible
chemicals. Information on the drainage facilities will be provided.
Incompatible chemicals will not be stored in the same bunded area. The
storage facilities will , if required, be fitted with access ladders, platforms,
vents and access ports. Level and contents gauges will be visible from the
unloading point.
Adequate vehicular access will be provided to the storage facility to allow
safe access of delivery tankers.
All pumps used for the mechanical forwarding of chemicals will be
housed within the respective tank bunded area on raised platforms to
avoid any possibility of flooding. The pumps will have adequate access
and be suitably protected from the elements.
A demineralized water supply will be provided for service use at the
storage stations.
Storage facilities will be fitted with suitable fume dispersion equipment as
necessary.
All precautions will be taken in the design and layout of the plant to avoid
danger to personnel. Adequate safety equipment (showers, eye baths)
will be provided at all locations where an occupational hazard exists.
Activation of any safety shower will initiate an alarm in the CCR.
6.2.7 Waste water systems
A site effluent disposal system is required to ensure that all potentially
contaminated wastes generated by the construction, operation and

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maintenance of the power station will be controlled in accordance with


World Bank guidelines and local legislation.
The plant will comply with the latest issue of applicable Standards and
Codes, accepted International Standards and other local laws and
regulations, including any applicable regulations as reported in Chapter 4
of this Specification.
The waste water generated by the water treatment plant will be
controlled prior to discharge to the surface water drainage system as
defined in the water treatment section of this specification. Effluent from
the drains of the laboratory, battery room, and chemical dosing drains will
also be suitably treated.
Effluent coming from HFO treatment plant will be treated in a dedicated
plant. Water coming out of this plant will be conveyed by the Contractor
to oil/water separator for surface oily water.
Surface water with the potential of oil contamination will be directed to
an oil/water separator prior to discharge. All waste oil will be collected
for off-site disposal.
Gas turbine compressor wash effluent will be segregated and stored in
concrete pit for off-site disposal Sampling and instrumentation will be
included in the final discharge to ensure compliance with the
requirements of relevant legislation. As a minimum, this will include
equipment to measure flow, temperature and pH. Provision to take a
manual sample will be provided.
Discharge of wastewater outside agreed limits will be prevented by the
local control system.
For further details of the site waste water systems, refer to Chapter 10 of
this Specification.
6.2.7.1 Packaged sewage treatment plant
A packaged sewage treatment plant will be provided to cater for the total
foul water treatment requirements of the station, with adequate
margins, under all conditions of operation. The plant will be complete
with sanitary drainage piping, manholes and grease traps required for
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conveying sewage, comminutor and bar screen, pre-engineered activated


sludge modules, chlorination equipment, treated sewage holding facility,
treated sewage transfer pump sets, interconnecting piping valves and
supports, associated instruments and controls, associated electrical work,
associated civil work and all tanks will be fitted with access ladders,
platforms, vents and access ports. Level and contents gauges will be
located for operational convenience.
The plant will be capable of treating 500 litres per day of raw sewage per
person during normal operation together with a provision for peak
demand at 2.5 times normal operational flow.
The quality of the final effluent will be:
Total suspended solids less than 30 mg/l
Total BOD less than 20 mg/l
The chlorination facility will be capable of providing a free chlorine
residual of 1 ppm; however, final discharge levels will not exceed World
Bank or local guidelines.
Where no discharge of the product affluent is available the treated
discharge will be pumped to an evaporation pond. The civil engineering
requirements are defined in Section 9 of this Specification.
Adequate monitoring and control instrumentation will be installed to
allow automatic operation of the plant and demonstrate the quality of the
final product water. Normal operation of the plant will be from the PCS
operator interface to the CCR. Manual override will be possible from a
local control panel. Alarms and indications will be displayed locally with
essential alarms and indications conveyed to the CCR.
Details of the disposal route for the solid effluent will be provided.
The Contractor will build-in sufficient redundancy such that repair,
maintenance and isolation of plant may be carried out without process
interruption.
Adequate manual sampling points will be provided to allow the
monitoring of the plant's performance.
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All precautions will be taken in the design and layout of the plant to avoid
danger to personnel. Adequate safety equipment (showers, eye baths)
will be provided at all locations where an occupational hazard exists.
Activation of any safety shower will initiate an alarm in the Central
control room (CCR).
6.3 Fire protection and detection
6.3.1 General requirements
All plant and buildings will be designed and arranged to minimize the
possibility of fire hazards originating from them or spreading to them
from a fire in the vicinity. Plant and cables will be segregated to reduce
fire risk, damage and multiple shutdowns.
Electrical equipment located in hazardous areas will be explosion proof,
flame proof, intrinsically safe or otherwise designed to be suitable for the
location zone.
The Contractor will provide all calculations for all of the fire protection
systems; conduct the design, procurement, equipment and system
installation and subsequent testing. All will comply with the applicable
NFPA and related Code requirements, applicable national and local Codes
and Standards and local Fire Department (FD) regulations and will be
subject to approval by the Owner/Engineer.
All equipment and valves etc will be FM and UL approved and listed.

6.3.2 Detailed scope of work


6.3.2.1Detailed scope of work for Project
The scope of the fire protection and detection system will include but not
be limited to
the following:
fire fighting water supply system, comprising fire water storage (dedicated
reserve of raw water tank), main electrical motor driven and standby
diesel engine driven pumps, jockey pumps, and Fire water mains;
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automatic water spray deluge protection for all oil filled transformers and
cable floors;
automatic water sprinkler system for stores and workshop;
automatic foam/water spray deluge protection for fuel oil pump house;
remote/local manually initiated foam protection for the fuel oil tanks and
the bund area and spray cooling water system for fuel oil tanks;
standpipe and hose reel/hose rack cabinet system in the buildings and
plant areas;
yard hydrants and yard hose cabinets;
gas extinguishing fire protection system for gas turbine enclosures,
switchgear rooms, panels, instrument room and control rooms. gas
detection system for fuel gas station;
portable extinguishers in all the buildings;
comprehensive site fire detection system with master alarm panel in
Control Room and repeater panel in gatehouse.
Heat detectors in the fuel oil storage tank roofs.
6.3.2.2 Design requirements
All equipment will be adequately sized and of material properly selected
for the raw water as specified, and will be designed, manufactured and
installed in accordance with the latest issue of applicable Standards and
Codes, accepted International Standards and other local laws and
regulations, including any applicable regulations as reported in Chapter 4
of this Specification.
.
All equipment and materials will be easily accessible and suitable for
outdoor installation. The Contractor will provide all necessary access
platforms, stairways and ladders to meet this requirement.
All equipment will be designed with the primary consideration being
reliability, ease of operation and a minimum of maintenance attention
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and will operate satisfactorily under the full range of operating


conditions.

6.3.3 Fire water supply


6.3.3.1 Fire water storage
Water for firefighting purposes will be Service water. A dedicated reserve
of water for firefighting will be stored in a fire water tank.
The capacity of the fire water section of the tank will be based on the
maximum anticipated flow rate for the largest single risk associated with
the power station plus the demand for two hydrant points, for a period of
two hours in accordance with the requirements of NFPA 850.
The tank will be constructed of carbon steel and will be painted fully,
inside and outside (including underside of bottom plate), the painting
system will be in accordance with paragraph 6.7 of this Chapter. The
minimum thickness of steel plate will not be less than 8 mm including
corrosion allowance. The tank will be provided with flanged connections
for all external piping. All tank connections will be protected by suitably
reinforced rubber expansion joints, and will be cathodically protected in
accordance with Paragraph 6.6 of this Specification.
The tank will be located adjacent fire water pump houses, and will be
complete with all necessary connections for make-up, overflow, vent and
drain, fire pump suction including vortex inhibitor, pump re-circulation
and testing, level indicator, level transmitters and high/low level switches
for control/alarm/trips as necessary, access manholes in side wall and
roof, complete with access ladder, handrails, and a dosing system to
inhibit microbial growth.
All necessary tank fittings, instrumentation and access will be provided in
accordance with NFPA 22.
The make up to the tank will be sized to comply with the fire water
storage replenishment requirements as laid down in NFPA 850, i.e.
capable of refilling the fire fighting capacity of the tank within 8 hours.

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The make-up valve will be operable from the CCR, with position
indication.
The tank vent(s) will be sized to cover the air ingress commensurate with
the maximum tank inflow/outflow conditions.

6.3.3.2 Fire water pumps


A Fire water pumping station compliant with latest issue of relevant NFPA
code will to be provided.
One 100 per cent duty electric motor driven pump and one 100 per cent
duty diesel engine driven pump will be supplied, each pump capable of
supplying water to all sprayers, sprinklers, hydrants or hose reels
associated with the largest single fire risk and comply with the
requirements of NFPA 20.
The pumps will be of the horizontal axis centrifugal type with flooded
suction. Details of the pump characteristics will be submitted for
approval.
The design of the diesel engine, in particular its lubricating system, will be
such that periods of long standing will not affect the starting up of the
diesel engine.
The fuel supply tank will have a capacity such that the diesel engine can
be run at full load for at least eight hours. The outlet from the tank will be
at a height of not less than 600 mm above the inlet to the fuel injection
pump on the engine.
A trickle charger system will be provided suitable for keeping the starting
battery fully charged.
In the event of fire water demand within the site the duty electric pump
will start on sensing low pressure in the main. The diesel pump will start
if the pressure remains low after a 5 second delay, or falls due to high
demand.
Each pump discharge will be fitted with a full flow recirculation line to the
storage tank to facilitate pump testing. Isolating valves normally locked
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closed will be fitted to these recirculation lines. Pressure relief devices


will be provided to protect the pumps under low flow conditions.
Jockey pump(s) will be provided to maintain the fire main under pressure
and to cater for minor usage/leakage.
The status of each pump will be indicated on the master fire alarm panel.
The fire pumps will be located within a building to give adequate
protection from the environmental conditions.
6.3.3.3 Fire main
The pressurized fire main will be designed on a ring main basis and sized
to cater for the maximum water demand in accordance with NFPA 24.
Valves (normally locked open) will be fitted at appropriate points in the
main to allow isolation of discrete sections of the site. All thrust blocks (if
required), valve pits, vent and drain connections and corrosion protection
measures are to be provided.
The capacity and layout of the main, and the position of hydrant outlets
will be submitted for approval.
Above ground piping will be ASTM A106 seamless carbon steel or
approved equivalent, galvanized and painted in red. The pipe size up to 50
mm will have pipe schedule 80 having screwed joints and above 65 mm
to be standard schedule with flanged joints. The pipe material including
fittings, flanges and bolting etc. will meet the appropriate codes
requirement of ASTM and ANSI standards. The valve material will be steel
body and bronze trim and will meet the design rating of the system.
The material for buried pipework, valves and fitting up to the above
ground connection point at the valve station will be ductile iron (ISO
2531) with mechanical joints, cement lined (AWWA C104) with external
bituminous coating and polyethylene wrapped (AWWA C105). Buried
valves will be grey cast iron body complying with the requirement of MSS
SP70 and ANSI B16.1.
All buried pipework will be accommodated in trenches which are
excavated and backfilled in ground level with the requirements of relevant
Code.
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6.3.4 Fire fighting systems


6.3.4.1 Automatic water spray deluge system
Each individual oil filled transformer will be provided with a separate
water spray deluge protection system, all in accordance with the
requirements of NFPA 15.
Deluge system for the transformers will be operated by a pneumatic
detection systems.
The pneumatic detection system will derive instrument air from the
compressed air distribution system. The alarm system will be as
described in Section 8.
Local manual push button release of deluge valves will also be provided.

6.3.4.2 Automatic wet pipe sprinkler alarm system


A wet pipe sprinkler and alarm system will be provided for the workshop
and stores buildings. The sprinkler systems will operate on the
Quartzoid bulb principle and will detect an outbreak of fire and
distribute water automatically over a predetermined area.
The installation will be in accordance with NFPA 13 and local Fire
Department (FD) regulations for sprinkler installations. Alarm valves will
be provided with a retarding chamber.
Operation of each individual sprinkler zone will initiate an alarm after a
time delay on the fire alarm system specified in Section 8. The alarm will
be initiated by a suitable flow switch type alarm valve.
6.3.4.3 Automatic foam/water spray deluge systems
The design of these systems will be in accordance with NFPA 11 or 11A as
appropriate and FD regulations and water will be taken from the
underground hydrant ring main.
Balanced pressure proportioning system. The fuel oil pump house will be
provided with balanced pressure proportioning system with aqueous film
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forming foam (AFFF), capable of a 3 per cent mixture in service water, will
be stored in the foam concentrate storage tank. The capacity of the
tank(s) will be twice the size of the calculated foam charge.
Two positive displacement foam concentrate pumps (duty and standby)
with automatic regulating valves will draw foam and inject into the water
supply via proportioners.
The thermal detectors located in the fuel oil pump house will initiate
operation of the deluge valve through the fire alarm panel. Operation of
the deluge valve will start the foam concentrate pump and open the
foam concentrate motor operated isolating valve. Local manual push
button station will also be provided.
Diaphragm pressure proportioning system. The diesel engine fire pump
including its fuel oil day tank will be protected by foam/water which will
be provided from a diaphragm type foam concentrate proportioning tank
via an in line injector.
The water supply for automatic foam/water system for the fuel transfer
pump house will be fed from the fire main. An automatic control panel
located in the gas turbine control room and a manual push-button station
with complete alarm indication/annunciation to the master fire panel will
be supplied.
The size of the foam tank will be suitably sized. The foam concentrate will
be aqueous film forming foam (AFFF) capable of a 3 per cent mixture in
service water.
The thermal detectors located in each protected area will initiate through
the firm alarm panel, the operation of the deluge valve and solenoid valve
which will open a piston operated ball valve to pressurize the bladder and
eject foam through the proportioner. Local push button stations will also
be provided.

6.3.4.4 Remote/manual foam system and water spray system


The fuel oil storage tanks and bund area will be protected with a
remote/manual foam system, comprising foam injection system, bund
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pourer system, and foam monitor system (located on the fuel oil tank
bund wall), and a remote/manual spray water cooling system, sized to
cool a full tank.
All systems will comply with the requirements of NFPA 11 or 11A as
appropriate and 16.
The foam systems will be supplied from the foam station comprising
foam concentrate tanks, foam concentrate pumps, motor operated valve
and proportioning equipment. The fire water supply will be obtained
from the underground ring main.
The oil tank foam injection, bund pourer, foam monitor and cooling water
spray systems will be controlled remotely from the foam station.
Operation of the deluge valve will automatically start the foam
concentrate pump and open the foam concentrate isolating valve. Local
manual release push button station will also be provided. . Activation of
the fuel oil storage tank foam system will be automatic via a two out of
three signal (as a minimum) from any storage tank heat detection system

6.3.4.5 Tank foam injection system


The foam concentrate will be fluoroprotein foam capable of a 3 per cent
mixture in desalinated water.
One foam station will be provided for the injection of foam into the fuel
oil tanks.
The foam station will comprise one concentrate storage tank, two
positive displacement concentrate delivery pumps (duty and standby),
one balance pressure proportioner and all associated pipe work, motor
operated valves and deluge valves.
The design and capacity of foam pumps and chambers will be based on
foam concentrate injection rate calculated in accordance with the codes.
The foam concentrate storage tank will be sized to hold two times the
calculated foam charge to protect the fuel oil tank.

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Each foam chamber mounted on the fuel oil tank will have a rupture disc
assembly provided on the foam discharge outlet, to ensure that the foam
system is not contaminated by oil should an overflow occur.

6.3.4.6 Tank farm bund area foam pourers


The oil tank bund area will be provided with foam pourers, equally
spaced along the bund walls of each oil tank bund area which will be
capable of covering with foam/water the entire bund area (including the
oil tank) and will be supplied with foam water from the main pipe work
ring located outside the bund.
The details of the system will be as described for the Tank Foam Injection
system.

6.3.4.7 Foam monitors system


Motor operated oscillating type foam monitors complete with pipe work
and valves will be provided and placed on the bund walls. At least three
monitors will cover the tank and its bund area. Monitors will be capable
of operating at the fire system pressure and reaching the top of oil tank
from any direction.
Monitors will have horizontal and vertical movement in any combination
thereof to give a complete arc of operation over the bund area with
locking facilities to allow manual operation from any position. Monitors
will be of stainless steel construction and be provided with motor
operated valves.
Access platforms and ladders will be provided as necessary to facilitate
operation and maintenance of all monitors, valves and equipment.
One foam station will provide the bund pourers and foam monitors
located on the tank bund wall. Each system will be fitted with motorized
isolating valve.

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The foam concentrate storage tanks for foam pourers and monitors will
be sized to hold two times the calculated foam charge to protect one gas
oil tank.

6.3.4.8 Spray water cooling system for the fuel oil tanks
The fuel oil storage tanks will be protected by a remote/manual
controlled spray water cooling system.
The system will be supplied with water from the underground site
hydrant water supply system.
The design and construction of the cooling system will comply with the
requirements of NFPA 15. Run off spray water will not be taken into
account in the design of the cooling system.
The system provided for the tank will be divided equally into four
hydraulically balanced quadrant systems, the operation of any one
quadrant or combination of quadrants being individually controlled
automatically and also from local manual release push button stations.
Each tank quadrant will be provided with headers individually piped to a
motorized control valve position suitably located outside the bund wall.
A number of frangible bulb temperature detectors will be provided on
the external periphery of the tank shell adjacent to the tank roof to
activate the cooling water spray system and to raise alarm on the main
fire alarm panel located in the control room. Each control valve will be
provided with all fixtures necessary for test, and operation, and will
include manual override facility for emergency manual operation.
Pressure switches will be provided for each deluge valve to provide
system activated signal to the fire alarm panel located in the Control
Room.

6.3.4.9 Standpipe and hose cradle/reel cabinet system


Each building will be provided with a standpipe system complying with
NFPA 14 and designed to give Class III service.
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The Contractor will provide fire hose reels and hose cradles in each
building.
Fire hose reel cabinets will be equipped with a 30 meter length of 25 mm
diameter double braded rubber, non collapsible hose mounted on reel
drum which will be of the swinging arm type. The hose reel connected to
the water supply will be supplied with 25 mm NB isolating ball valve and
25 mm NB pressure reducing valve and adjustable spray/jet nozzle.
Hose cradles will consist of a 30 meter length of 40 mm lined, collapsible,
synthetic hose mounted on a hose rack which will be of the swinging arm
type.
Both hose reels and hose cradles will be equipped with quick coupling BS
336 type of gun metal with adjustable jet/spray nozzles.
A single 65 mm automatic pressure regulating valve with female
instantaneous coupling connection will be provided in each hose
reel/hose rack cabinet, connected separately to the water supply inside
the cabinet and available for the connection of Fire Brigade hoses even
when the hose reel/hose rack is in use.
The hose reel/hose rack cabinet will be made from galvanized steel with
double glass door clearly labelled FIRE in Arabic and English and painted
red with white lettering to an approved procedure. Each hose reel/hose
rack cabinet will also be supplied with one (1) unit of 9-10 kg dry power
fire extinguisher for class ABC fires.

6.3.4.10 Site fire hydrant system


6.3.4.10.1 Fire hydrants
The arrangement of the site fire hydrant system will comply with the
requirements of NFPA 24 and will generally comprise a buried
sectionalized ring main, distribution pipe work complete with post
indicator valves, isolating valves wash-out valves and valve pits. The
distribution network will provide supply of water to each standpipe
system, automatic spray foam and water deluge system, fire hydrants

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positioned around the power station site and the main oil tank area fire
protection systems.
All fire hydrants will be installed at a spacing not greater than 60 m and
will comply with local Fire Brigade requirements. Fire hydrants will be
constructed from cast iron (150 mm) with two 65 mm globe valve (BS 336
or equivalent) couplings, cap, chain and a 100 mm connection for fire
engine pump suction. Each fire hydrant will be provided with an auxiliary
valve with curb box. Valves will be 175 lb cast iron, bronze trimmed, 150
mm non-rising stem gate valve with flanged joint. Curb box will be cast
iron, 130 mm diameter with box extension piece stainless steel valve stem
extension with square nut and stainless steel covers. Curb box assembly
will be cast in concrete at grade and depth of cover will be adjusted to
the proper depth of pipe. The valve will be key operated with an
operating key provided at each outdoor hydrant cabinet.
Each fire hydrant and post indicator valve position will be protected from
damage by four vertical guard rails painted with red and white bands.
Where direct buried these will be protected by suitable sleeving and
backfilled with selected material approved by the Owner/Engineer.
Post indicator valves will be 175 lb butterfly type and provided at all
branch lines and for sectionalizing portions of the water network and will
meet UL design requirements. The stem length of the post indicator
valves will match the site gradient and hydrant main invert.

6.3.4.10.2 Outdoor hose storage cabinets and equipment


The Contractor will provide one outdoor hose storage cabinet at each
hydrant location, comprising weatherproof steel cabinet complete with a
break glass lock mechanism. Each cabinet, mounted on a concrete
foundation will contain, as a minimum:
One (1) hydrant turnkey and bar
One (1) 65 mm hose standpipe with instantaneous outlet connections
Three (3) 25 m lengths of 65 mm light synthetic fibre imperviously
jacketed
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hose with light alloy instantaneous couplings


One (1) Jet/spray on/off nozzle
One (1) 65 mm hose branch pipe 22 mm bore nozzle
One (1) Fire axe and crowbar

6.3.4.10.3 Fire hose


The fire hose will be light and flexible besides being resistant to abrasion
and damage due to contact with chemicals or oil..
The bursting pressure of the hose will not be less than twice its working
pressure.
Hose is to be 65 mm gauge and supplied in 25 m lengths with male and
female instantaneous couplings compatible with local
requirements/regulations.

6.3.4.10.4 Jet/spray on/off branch pipe nozzle


These nozzles will emit a powerful straight jet, atomized spray or a wide
spreading cone of solid water and will include fog and shut off features.
The type of spray will be adjusted by twist control.
Nozzles are to be manufactured in light alloy and fitted with a stainless
steel valve cone and designed for maximum velocity at the minimum
restriction to flow. The inlet will be a male instantaneous coupling.

6.3.4.10.5 Standard water branch pipe


Branch pipes will comply with BS 446 or equivalent. The inlet will be a
male instantaneous coupling. The outlet will be 5/8 diameter to give a
high power straight jet of water.

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CO2 protection systems


6.3.4.11
Each gas turbine will be supplied with an independent CO 2 system to
protect the turbine enclosures.
This system is supplied by contractor with the piping between CO 2 bottle
rack and GT enclosure. This interconnecting pipe line will be designed in
detail by contractor and supplied by the Contractor.

Pipe work for CO2 systems


6.3.4.11.1
The Contractor will supply piping connection between CO 2 bottle rack and
GT enclosure. After site installation a check of pipe routing will be
conducted in order to request , eventually, some modification to nozzles
inside GT enclosure, before to realize the concentration test with CO 2
release.
A relief valve will be fitted to each gas manifold to vent to atmosphere
any small leakage of the agent when the system is not in operation. These
valves will close immediately under pressure in the event of the fire agent
system being operated.
The Contractor will submit all operating/safety procedures for approval
by the Owner/Engineer.

Fuel gas station system


6.3.4.12
The station will be protected by the yard hydrants which will be located
near this area at spacings as specified.
The area will also be provided with a fire detection system as described in
Paragraph 8 of this Chapter.

6.3.4.13 Portable extinguishers


The following types of portable fire extinguisher equipment complying
with NFPA 10 will be provided and installed at agreed locations including
wall mounting, in the plant and building areas.

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9-10 kg capacity dry power extinguishers for use against oil fires
associated with electrical equipment. The powder will be expelled from
the extinguisher by compressed CO2 gas and controlled by a pistol grip
nozzle attached to the discharge hose.
9-10 kg and 6 kg capacity CO2 extinguishers for use against fires associated
with electrical equipment. The extinguishers will be provided with fixed
discharge horn and trigger valve control and trolley where required.
9-10 liters/capacity CO2 gas pressure operated water extinguishers for use
against ordinary small fires. The discharge nozzle will be supplied with
flexible hose and the control will be such that intermittent control is
possible.
9-10 litres capacity foam extinguishers for use against small oil fires. The
extinguishers will be pressurized with CO2 gas.
Foam mobile trailer
The number and types of extinguisher per building are to be advised in
the Tender and will be in accordance with the recommendations given in
NFPA 10 and will be to the Owner/Engineers approval.

6.3.4.14 Fire detection and alarm system


The fire alarms system will be complete in all respects and will include
the main and local fire alarm/control panels, the fire detection system,
the alarm contacts for local and remote signaling, all cabling between the
fire detectors and alarm contacts and the local and main fire
alarm/control panels.
Refer to Chapter 8 for details regarding the fire and gas detection and fire
alarm systems.

6.4 Instrument and service air systems


6.4.1 General

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A compressed air system will be provided to accommodate the


requirements of both instrument and service air as appropriate for the
complete power station excluding GT service. The compressed air system
will be capable of meeting all plant requirements excluding GT service
during any operating condition, including start up, shutdown and trip.
The standby compressor will start up automatically in case of air pressure
abnormally decreasing. Moreover, a valve in the service air supply main
header will shut automatically in case of very low air pressure to ensure
continuity of instrument air supply which has priority over service air
supplies.
The air for the service air systems will be dried and filtered.
The filter/dryers supplied as part of the instrument air system will be
sufficient to condition the air required by the plant whilst the second train
of filter/dryers is in standby mode.
Air storage volume, compressor running periods and compressor control
method are closely interdependent. The system designs will be optimized
for minimum total costs. The optimization calculations will be submitted
to the Owner/Engineer for approval.
System design and equipment will conform to the requirements and
recommendations of the appropriate Codes and Standards.

6.4.2 Detailed scope of work

Detailed scope of work for Project


6.4.2.1
Main equipment will include, but not be limited to the following:
two (2) x 100 per cent capacity air compressors, designed to operate on a
duty/standby basis, each complete with suction air sand separator and
filter/silencer, intercooler and aftercooler with moisture separators;
two (2) general service air receiver of sufficient capacity to facilitate safe
shutdown in the case of emergency, with all other provisions considered;

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two (2) x 100 per cent capacity instrument air receivers of sufficient
capacity to facilitate safe shut-down in the case of emergency, with all
other provisions considered;
two (2) x 100 per cent instrument air filters;
two (2) x 100 per cent instrument air dryers;
Instrument air distribution system, including instruments, valves, piping
and supports;
Service air distribution system, including instruments, valves, air-line
couplings, piping and supports. A priority valve will be included,
operable from the CCR, to shut off the supply from the air compressors to
the service air system in the event of low pressure in the instrument air
header.

6.4.2.2 Design requirements


All equipment will be adequately sized and of material properly selected
for the raw water as specified, and will be designed, manufactured and
installed with the latest issue of applicable Standards and Codes, accepted
International Standards and other local laws and regulations, including
any applicable regulations as reported in Chapter 4 of this Specification.
The Tenderer will provide a list of consumption points with quantities and
pressure for both instrument and service air with an adequate margin for
unaccounted losses that may occur through the life of the plant. The
Contractor will submit a design basis document with regard to the
selection of type, capacity and discharge pressure of the compressor for
Owner Engineers review and approval.
All equipment and materials will be easily accessible and suitable for
outdoor installation. The Contractor will provide all necessary access
platforms, stairways and ladders to meet this requirement.
All equipment will be designed with the primary consideration being
reliability, ease of operation and a minimum of maintenance attention
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and will operate satisfactorily under the full range of operating


conditions.
6.4.2.3 Sand separators
Dust and sandstorms may occasionally occur at site. Occurrence of dust
and sandstorms must not compromise compressor operation. One
cyclone or equivalent inertial type sand separator per compressor will be
installed.
A special motor driven valve for releasing the dust out of the collector and
a collecting drum with a minimum volume of 1 m3 will be furnished with
each dust collector.
Indication of the dust level inside the sand separator and pressure
differential indication will be supplied.
The sand separators and the suction duct will be installed in such a way
that neither dust from ground nor rain water can be drawn into the
separator.

6.4.2.4 Suction air filters/silencers


The suction air filters on each compressor suction side will retain all dust
and sand not collected in the sand separator. They will be designed for
low pressure loss and the compressor design will be on the basis of the
filter being obstructed up to the maximum allowable differential pressure.
The suction air filters will be of the single element dry type. Filter screens
will be quickly changeable or cleanable. Means to indicate when cleaning
or replacement is needed will be provided.
The silencers will be the manufacturers standard, specially designed to
dampen the low frequency compressor intake noise.
The suction air filter/silencers will be designed for low pressure loss. The
compressor design will be based on the filter being 50 per cent
obstructed.

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6.4.2.5 Air compressors


The compressors will be of the electrical, direct driven, multi-stage rotary
type. Oil lubrication of the instrument compressor parts in contact with
compressed air is not acceptable.
Each compressor will include a motor, coupling, base plate, lubrication
system, water cooling system and all appurtenances.
One (1) set of special maintenance tools for compressor overhauling will
be provided.
Each compressor will have the following design features:
The period between two inspections for maintenance will be not less
than 10 000 operating hours.
The compressors will be of heavy duty construction and designed for
continuous and intermittent operation at full and low capacity.
The compressors and associated equipment will be mounted on a
fabricated skid base. All piping leaving the skids will have flexible
connections to approval and the piping will be adequately supported to
prevent transmission of vibration and noise.
The compressors will be of two or three stage configuration water cooled
type with intercoolers.
The impeller will be manufactured from stainless steel.
Bearings will be lubricated with oil. A lubrication system with a shaft
driven pump and an electrically driven pre-lubrication pump will be
supplied.
Modulating control will apply over the full operating range.
The noise level of the compressors will not exceed 85 dB(A) at 1 m from
the source

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6.4.2.6 Air compressor control


Each compressor will have automatic start and stop controls which will
include an unloading device to unload the compressor when it is stopped
and maintain that condition until the motor is again up to speed. The
compressor will also be provided with controls which will unload the
compressor when the pressure in the receiver reaches a predetermined
level and load the compressor when that pressure drops below a
predetermined level without stopping the motor. The pressure controls
will be adjustable over a wide range and will operate with a maximum
pressure change of 0.2 bar.

6.4.2.7 After-coolers
One pipeline type after-cooler per compressor with cyclone type water
separators will be provided. The approach temperature, i.e. difference
between outlet air temperature and inlet water temperature will be 6C
for the after-coolers.
Cooling water will be inhibited demineralized water and will be cooled in
a dedicated fin-fan cooler, part of the system.
Easy access for inspection and cleaning will be provided. Drains will be
provided.
Each cooler will be equipped with a relief valve.
The after-coolers will be suitably mounted so as to be accessible for
maintenance and inspection.
Fouling factors will be as recommended by TEMA

6.4.2.8 Air receivers


The air receivers will keep an ample amount of air available during short
time air consumption peaks to reduce the frequency of compressor
cycling whilst maintaining air pressure supplies at or above an acceptable
minimum level.

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Each instrument air receiver will be designed for a storage capacity,


without any additional air makeup supply, which is the larger of:
Ten minutes storage on normal plant operation or,
The capacity to run down the generating units and station service
auxiliaries from full load operating condition to non-operation condition.
Each receiver will have a pressure gauge and code stamped relief valve(s).
Design temperature will be compressor discharge temperature without
after-cooling.
Each receiver will be furnished with one (1) snap-action type moisture
trap. Each trap will be provided with a bypass valve.
Easy access to the drain valve will be provided. The bottom of the vessel
will be at least 300 mm above the floor.
Each receiver will conform to the appropriate Codes and Standards and
will be suitable for the site ambient condition specified in Chapter 2 of
this Specification.

6.4.2.9 Instrument air dryers


Two 100 per cent capacity air dryers will be provided to dry the
instrument air. The dryers will be of the dual tower, regenerating
desiccant type each capable of meeting the requirements of the unit
instrument air demand and of removing moisture from the instrument air
over the range of design ambient conditions specified in Chapter 2 of this
Specification for the design instrument air dewpoint of -20C.
Visual indication of dewpoint will be given by means of colour change
indicators.
The dryers will be packaged self-supporting units, shipped completely
piped and wired.
The dryer will have a control cabinet and multiport valves for automatic
transfer of air between towers.

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Each drying vessel will have a drying capacity equal to ten hours at the
rated output and regeneration, including vessel cooling, will not be more
than 6 hours.
Moisture will be removed during regeneration by internal electric heaters
and/or purge air and expelled from the vessels to atmosphere by a stream
of purge air. The towers will be fully insulated.
In the event that a dryer is supplied without heaters the compressor
capacities will be adjusted for the increased purge air flow. No provision
will be made for by-passing the air dryers.
The pressure drop at full load conditions and across the complete
dryer/filter package will not exceed 0.5 bar when clean.

6.4.2.10 Pre and after-filters


Each instrument air dryer will be provided with a pre-filter and after-filter.
The pre-filter will protect the desiccant of the dryer from contaminants
such a liquid (water), pipe scale and dirt; while the after-filter will prevent
desiccant fines of the dryer from entering the instrument air supply
headers.
The filters will be compatible with the dryers in all respects. The water
mist removal capacity of the pre-filter will be not less than 99 per cent
and the after-filter will removal all particles greater than 1.0 micron in
size. The pre-filters will have coalescing elements which will concentrate
water mist to bulk liquid for removal by traps. The filters will have
sufficient area so that replacement of cleaning will be required only at
reasonable intervals. Each filter will be provided with a differential
pressure gauge.

6.4.2.11 Drains
The compressed air systems will have drains on all low points. Snap-
action type traps with inlet strainers will be provided. The minimum size
will be 20 mm.

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Drains from all low points in headers, water separators and air receivers
will empty into a waste funnel connections.

6.5 Painting and protection against corrosion


All material and equipment will be effectively protected against corrosion
during transit and while being stored at site. All materials and equipment
will be protected by the application of anti-corrosion agents in a mineral-
oil base.

6.5.1 Painting
All surfaces to be protected will be coated in accordance with the
requirements of ISO12944: 1998 or other Standard or Code as reported in
Chapter 4 of this Specification.
Preparation grade for surfaces will be a minimum of Sa 2.
All exterior surfaces, including buried and aboveground pipe work, will be
of high durability (>15 years) and appropriate to a C5-I (very high industry)
environment as appropriate. Interior surfaces will be of high durability
(>15 years) and appropriate to a C4 environment.
High temperature and intumescent coatings will be in accordance with
manufacturers guidelines.
The method of application will be to the approval of the Owners
Engineer and will be taken to ensure mechanical and electrical
compatibility with the factory applied coating and the cathodic protection
system.
.

6.5.2 Galvanising
Where employed, galvanizing of surfaces will be in accordance with the
requirements of BS EN 10142 : 2000 or alternatively BS EN 10 147 : 2000
(for bolted tank) or ASTM A123/A123M-01a. Bolt fixings will be
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galvanized in accordance with the requirements of ASTM A153/A153M-


01a.
Preparation grade for surfaces will be Sa 2.
Where the galvanized surface is rendered discontinuous for any reason,
the ungalvanized surface will be thoroughly cleaned to bright metal and
painted to the requirements of EN ISO 1461 or ASTM A123/A123M-01a.

6.6 Cathodic protection


A complete and fully automatic cathodic protection system will be
provided in accordance with the latest issue of NACE International, IEC,
and any applicable local or national code as reported in Chapter 4 of this
Specification.
A cathodic protection system will be applied to metal piping buried in the
earth, bottoms of above-ground pad mounted steel tanks and interior
surfaces of designed steel water storage tanks.
An impressed current system will be preferred and will include but not
be limited to: distributed anode ground beds, transformer rectifiers,
distribution panels, wiring and monitoring. Where appropriate, smaller
structures may be protected by sacrificial anodes.
The cathodic protection system will be brought into operation
immediately upon completion of construction of the plant to be
protected. The Contractor will undertake all necessary precautions to
ensure that the current density is appropriate to guarantee protection.
Particular note will be taken of the presence of other buried services in
the area of the protected plant.
The Cathodic protection system will have a design life of 25 years.
The Contractor will provide a schedule detailing all vessels, tanks,
structures and submerged/buried pipelines to be protected by a cathodic
system to demonstrate the adequacy of the provision.

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6.7 Cranes and lifting equipment


6.7.1 General
Sufficient cranes and lifting equipment will be provided throughout the
power station for the maintenance of all equipment.
A list of all cranes and lifting equipment will be provided in the Tender.

6.7.2 Electrical overhead travelling cranes


A pendant operated overhead travelling crane will be provided in the
Workshop, and in other plant buildings if required for maintenance of the
plant.
The crane will be designed and constructed in accordance with the
requirements of BS 466 and BS 2573, and will be complete in all respects
for safe and efficient operation.
The capacity of the hoist will be sufficient for the heaviest expected
maintenance lift in these areas but in no case less than five tonne
capacity.
The bridge or gantry, trolley and hoist movements will be controlled by
suitable reversible controllers. The bridge trolley and hoist control
schemes will permit variable speeds in both directions of travel. Limit
switches will be provided at end limits of bridge, trolley and hoist travel.

6.7.3 Runway beams and lifting facilities


All heavy parts of the plant supplied under the Contract will be provided
with arrangements for lifting, slinging and handling during erection and
overhaul. All parts normally lifted during periods of maintenance and
weighing one tone or over will be appropriately marked with their
weight.
Runway beams will be provided to facilitate handling of the various parts
of the plant which require to be removed for cleaning and overhaul. The
beams will be supplied with trolleys for the attachment of blocks and
lifting tackle and a range of suitable blocks and tackle will be supplied.
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The runway beams will comply with the requirements of BS 2853 and will
be tested after erection.
The Contractor will be responsible for the provision of the appropriate
test certificates which must be in accordance with applicable Codes and
Standard.
All necessary lifting beams and slings will be provided

6.7.4 Testing
All cranes and lifting equipment will be proof load tested, mechanically,
electrically and operationally in accordance to FMI Code. The Test results
will be recorded on certificates, copies of which will be submitted to the
Owners Engineer.
The safe working load will be clearly marked on all cranes and lifting
equipment.

6.7.5 Use of cranes for initial erection


All cranes used during the initial erection of the plant will be refurbished
to their "as new" condition before they are taken over.

.
6.7.6 Chemical Laboratory

A laboratory will be provided and be fully equipped to safely monitor all


of the parameters required for the efficient operation of the power
station.
All furnishings including bench-space, seating, services, fume-cupboards,
facilities, security and instrumentation will be provided. All consumable
items including chemicals, reagents and batteries required up to takeover
will be supplied. Secure storage for chemicals will be included. The
laboratory will contain equipment to enable all monitoring, investigative
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and quality requirements of the power station to be carried out. It will


include the condition and quality of all effluents, water quality,
atmospheric emissions and the condition of lubricating, hydraulic and fuel
oils.
Portable equipment will be provided for testing and sampling.
All precautions will be taken in the design and layout of the laboratory to
avoid danger to personnel. Adequate safety equipment (showers, eye
baths) will be provided at all locations where an occupational hazard
exists from chemical handling. Material Safety Data Sheets will be made
available for all purchased proprietary products and reagents.

The laboratory equipment will consist, as minimum, of:


Apparatus, one piece of
Spectro photometer UV/VIS
Conductivity meter portable
pH meter portable
silica meter
Membrane filter filtration device
Analytical balance, including balance table
Precision balance
Heating bath
Drying cabinet
Furniture, one piece of:
Fume cabinet including an extraction fan mounted outside the laboratory
building

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Storage for hazardous substances, chemicals, etc.


Wall mounted work bench (length app. 3 m)
Equipment, one set of:
Laboratory chemicals and reagents
Small hardware such as cylinders beakers, burettes, pipettes, bottles, etc.
Equipment for Fuel Analysis :
Spectrometer m/f for oil test
Muffle furnace
Bomb calorimeter
Electric oven for fuel analysis
Hardgrave grind ability tester
Apparatus for ultimate analysis complete with accessories
Apparatus for oxidation
viscometer from grabner or spectro inc.
densitymeter from roudulph
Flash point detector from Grabner
Water content detector from G R Scientific
Flash point apparatus.
General Equipment
Vacuum pump
Noise level meter
Wind anemometer and wind vane
Dial type barometer
Stack monitoring kit
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Hygrometer
Dry & wet bulb thermometer
Dew point tester
Environmental Laboratory Equipment.
Sufficient quantity of required instruments will be supplied to meet the
statutory requirement Continuous ambient air Quality monitor for SOx
and others.
High Volume Samplers for Ambient Air Monitoring Workshop compressed
air system

6.8 General mechanical requirements


6.8.1 General
The Contractor will be responsible for the detailed design and
engineering of the plant and systems. The requirements specified herein
will form the minimum basis for the design and scope of work and
working practices, manufacturing, testing and erection.
Selection of materials, components, methods of construction and erection
will be made with due consideration to the requirements and capabilities
of the equipment served, as well as the reactionand thermal, chemical, or
other effects of the medium being handled by each system or component.
Corrosion allowance for piping will be 1.5mm unless otherwise specified.
The equipment, material sand services provided by the Contractor will be
consistent with the need to develop a safe, dependable, and adequate
installation. The Contractor will ensure that no individual element or
system will set a limit on the station capability, or will disturb its
architectural appearance when completed.
6.8.2 Piping systems
The design, manufacture, installation and testing of piping systems will be
in accordance with approved codes, such as BS/ISO/ANSI or equivalent
internationally recognized codes.
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During the design engineering, the Contractor will supply to the Engineer
schedules of the piping systems provided under this Contract. The
schedules will state, for each piping system, the designcode, pressures
and temperatures, the piping materials and contents, the valve type and
materials, corrosion allowances, piping supports and insulation proposals
and any other data relevant to the mechanical design of the piping system
or part thereof.
Unless otherwise specified or approved, all pipes will be of seamless
drawn carbon or alloy steel.
In any one system or piping service all piping and fittings will be of the
same material or similar analysis.
All piping will be routed to provide a neat and economical layout so that
full access is provided for the operation and maintenance of equipment
and that removal or replacement of equipment can be achieved with the
minimum dismantling of piping.
The number of joints will be kept to a minimum necessary. Tees and
bends will be to standard dimensions. Bends will be of the pulled type or
forged. Hot bending with packing may be used for larger sizes according
to facilities available, but hot bends in alloy or stainless steels will be
subject to approval of the Engineer. No crimping or flattening of the bend
will be accepted. Where employed for low pressure piping, gusset or
mitre bends will be designed to the relevant piping code.
Where piping is subject to mechanical cleaning (pigging) the bend radius
will be not less than 5 pipeDiameters
6.8.3 Valves
All valves will be manufactured from first quality material, have superior
designed parts, dust-tight construction, and have easily maintained
lubricating systems. All valve parts will be arranged for ease of
accessibility in the installed position.
The design and manufacture of all valves will be to the approval of the
Owner/Engineer. Valve information will be detailed in the appropriate

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technical data sheets to be included in the Tender and will include


operating pressure range, nominal set pressure, and type of actuator.
Valves will be suitable for the service intended, with materials suitable for
the medium to be handled, and certified as acceptable by relevant codes
and standards for the service and duty intended. For the gas turbine
package, the Contractors Standard will be considered.
Manually operated valves with a nominal size greater than 250 mm, which
have to be opened or closed very quickly or with minimum manual effort
will be provided with a suitable gear system.
All isolating valves which are required to open or close during normal
operation of the plant, including start up and shut down will be equipped
with an installed actuator and will be capable of being locked in both the
open and closed positions. The Contractor will provide the necessary
devices and locks.
The internal diameter of all valves at the ends adjacent to the pipes will
be the same as the internal diameter of the pipes to which they are
jointed unless otherwise approved by the Owner/Engineer.
Valves will have butt weld or flanged ends in accordance with the piping
system requirements.
Butterfly valves will only be used when specifically approved.
Cast iron, bronze or brass valves are not permitted for any piping system
except as specifically mentioned herein.
All valves and pipe fittings material will be as indicated in ASTM code or
approved equivalent.
All valves of sizes up to and including NB 65 will be globe valve type and
will have an ANSI Class 600 rating for all services. Where globe or angle
style valves are used they will be installed with the normal flow entering
beneath the disc.
Check valves will be of the inner-shaft type and no stuffing box or
counterweight type check valve will be permitted. Check valves will be
non-slamming type. Examination and/or replacement of parts will be
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possible without removing the check valve from the line. Check valves in
vertical pipe runs should be avoided, however, where necessary these will
be provided with by passes and drain valves.
Cast or steel-forged bodies will be used for high-pressure valves >25 bar)
with a nominal bore larger than NB 65, and for smaller bore, steel forged
bodies will be used. For low-pressure valves (<25 bar) with a nominal
bore larger than NB 250, cast-steel bodies will be used.
Carbon steel will be used for temperatures below 400 C. For
temperatures above 400 C, alloy steel will be used unless agreed by the
Owner/Engineer.
All valves will be designed to prevent erosion of the valve seats when the
valves are operated in a partially open position In areas with increased
hazard valve actuators will be driven by air with spring to close feature.
Only in well justified cases the use of electric actuators will be accepted in
those areas. In this case explosion proof design is mandatory.
Spring load for pneumatic actuators will be employed to facilitate safety
during air failure, i.e. the valve is closed by spring force. However, in the
case of the main inlet fuel system blocks and bleed valves, if there is a loss
of air or electric power the valve will lock in position. Only when there is
a fire signal will these valves fail close.
Valves with welding ends will have ready machined ends, which will
match exactly the dimension of the pipe to which the ends have to be
welded.
The welding ends will be of the same material as the pipe and will be
long enough to allow heat treatment after welding, without the risk of
damage to the valve by temperature increase.
All valves will be installed in such a way that they can be easily operated
by one person. Where required, valves spindles will be sufficiently long,
or extended in such a manner that the hand-wheel is at a level of
approximately one meter above floor or platform level, from which the
valve can be operated. Where required these will be provided with
headstocks and pedestals of rigid construction. Where extension spindles
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are fitted they will incorporate two universal joints. All valve pedestals
will be mounted direct on floor girders and not on floor plating. All floor
steelwork necessary for supporting pedestals will be included. Installation
with the valve stem oriented downwards/tilted is not acceptable.
All valve actuators will have local indicators fitted to show whether the
valves are in an open or shut position. In the case of valves being
equipped with extended spindles, indicators will be fitted to both the
extended spindle and to the valve spindle. Motor driven valves will have
position indicators in the CCR.
Plastic or bakelite valve hand-wheels are not permitted.
The stops limiting the travel of any valve in the "open" or "shut" position
will be arranged externally to the valve body.
All valves will be closed by turning the hand-wheel in the clock-wise
direction when looking on top of the hand-wheel.
The face of each hand-wheel will be clearly marked with the words
"open" and "shut" in English, with adjacent arrows to indicate the
direction of rotation to which each refers.
If, due to the use of a gear reducer, the valve has a spindle with a left-turn
thread, this should be clearly marked.
Each valve hand-wheel will be fitted with a name-plate of an approved
material, indicating in English the valve reference number and function.
The name-plate will incorporate the colour code corresponding to the
particular service of the piping.
Each valve will be permanently marked with the code designation of
valve, casing material, manufacturers serial number, nominal bore and
the nominal pressure/test pressure and temperature (operating pressure
and temperature from NP 63 onwards).
Hand-wheels equipped with electric servo motors, or hand-wheels of
valves to which a servo motor may be fitted, will not rotate when the
servo motor is in use and will furthermore, be able to be handled without
being mechanically connected to the servo motor.
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When determining the actuating forces, design pressure for one side and
zero (0) bar pressure on the other side of the valve disc (i.e. full
differential) will be assumed.
Eye bolts will be provided where necessary to facilitate handling heavy
valves or parts of valves.
Valves will be fitted with approved limit switches where required for
interlocking purposes and to implement the control scheme as necessary
for remote indication and control.
Spindles of valves for outdoor use will have weatherproof protection
covers. In general all valves exposed to the elements will be corrosion
resistant.
Test certificates for all valves will be issued by the Manufacturer duly
signed by the Inspection
Authority

6.8.4 Tanks and pressure vessels


Unless otherwise specified, tanks and pressure vessels will be of welded
construction, manufactured from carbon steel plate of accepted quality
and thickness, and designed, constructed and tested in accordance with
the appropriate BS, API, AWWA and ASME standards as applicable
The tank supports - if any - will be of such a height as to permit cleaning
and painting of the floor plate of the tanks from the tank bottom. Tanks
and vessels which are to be lagged will be provided with external lugs for
attaching reinforcement wire where necessary.
Prior to the application of internal protection the tanks and vessels will
be thoroughly cleaned, dried by hot air or other approved means and will
then be sandblasted and treated internally by processes as specified.
Arrangements will be made for the blanking off or removal of all valves or
pipe connections during sand blasting to prevent the ingress of sand or
other matter. The protective process will be applied also to any ferrous
fittings mounted inside the tanks.
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All tanks and pressure vessels will be painted externally, in accordance


with the specified provisions.
All equipment will be earthed and cathodically protected where
appropriate. Corrosion allowance for pressure vessels and tanks will be
3.0 mm unless otherwise specified.
Tanks where appropriate will be electrically isolated from cathodically
protected pipe by insulating flanges or dielectric unions.

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