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2-66
Safi Units 1 & 2 Specification Part B
Sargern: & Lundy • • • 1,320 MW Gross Generating Facility
Globe! lnervy Conaulting TECHNICAL SPEClFICATIONS

The potable hot water and the return circulation systems will supply hot water to all the above-
mentioned fixtures requiring hot water. The hot water systems originate in the domestic hot
water heaters (one for each building requiring hot water) and will distribute water at
approximately 54°C; pump circulation will maintain temperature within reasonable limit.

The potable hot water system will include electric hot water storage heaters capable of
providing sufficient hot water storage and recovery capacity to meet the maximum probable
demand requirements.

All hot and cold piping shall be insulated.

The interior potable water distribution system will be valved for proper control of all sections,
without shutting down the entire system.

2.9.7 Water Metering System

The makeup water system, demineralizer system, potable water system and waste water
systems shall have a water consumption meter to monitor the water consumption of each
system and the total waste water produced..

2.10 COAL UNOLADING AND HANDLING SYSTEM

2.10.1 System Description and Scope Overview

Coal will be delivered to the Project by the Owner by ship and by train. . The Contractor shall
provide the coal unloading, handling and storage systems to supply the Project's fuel needs. A
conceptual arrangement of the coal receiving and storage system is provided in Exhibit B,
Section 7, Appendix A and Exhibit B, Section 7, appendix 0 ..

The coal handling system shall utilize standard components where ever practical and the
engineering design shall provide convenient operation and maintenance and high availability
and reliability.

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2-67
Safi Units 1 & 2 Specification Part B
Sargent & Lundy' ' ' 1,320 MW Gross Generating Facility
Global En• rgy Consulting TECHNICAL SPECIFICATIONS

2.10.2 Coal Storage

The Contractor shall provide all conveyors and transfer houses required. A traveling stacker
conveyor will form two parallel storage piles, with a total useful automatically reclaimable
storage of 450,000 tonnes for the two piles (based on Exhibit H). The traveling stacker shall be
of the slewing type and shall serve both coal piles. The Contractor may adjust the locations
and dimensions of the piles from that shown in Exhibit B, Section 7, Appendix A, subject to
the Owner's approval.

The off-site conveyor will deliver coal at a rate of 4800 tonnes per Hour. The stacker and on-
site conveyors shall be designed for the same capacity.

The coal piles shall have walls or fences to minimize fugitive dust emissions. The design shall
be in accordance with the Environmental Impact Assessment.

2.10.3 Reclaiming System

The reclaim and conveying system shall be capable of supplying coal at a rate of 1200 tonnes
per Hour to each unit.

From the storage piles, the coal shall be reclaimed by two traveling portal reclaimers and
discharged onto the plant supply conveyor system. The portal reclaimers shall each have a
single reclaimer boom, with traversing scraper chain and scraper flight that travels a horizontal
runway. The reclaimed capacity shall be controlled by varying the travel speed of the machine.

The conveying system, consisting of two parallel trains of conveyors, will supply coal from the
coal pile to the coal silos at the boilers. Only one train of conveyors is required to supply coal to
both Unit(s). However, both trains may be operated simultaneously. The system description
for operating both trains of conveyors simultaneously is as follows:

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2-68
Safi Units 1 & 2 Specification Part B
Sargent & Lundy << ' 1,320 MW Gross Generating Facility
Global ,E n•I!IIV Concultlng TECHNICAL SPECIFICATIONS

. Each conveyor system will consist of a belt feeder, a crusher, a transfer conveyor to the boiler
house, and tripper conveyor. Diverter gates and bypass chutes shall be provided at the crusher
if size reduction is not required . A free- standing, self-contained, modular type "as fired"
sampling system will obtain samples from the transfer conveyors that supply the boiler house.
Both tripper conveyors will traverse over all the in-plant silos for full redundancy.

The coal piles shall be equipped with a water spray dust suppression system. Dust
suppression systems shall also be provided for conveyor transfer points. Dust collection
systems shall be provided for the crusher house (pulse jet collector), and coal silo ventilation
and the tripper conveyor room at the power plant (wet dust collectors).

In Exhibit R, Contractor shall provide a process flow diagram of the coal handling system,
showing capacity ratings of the conveyors and crushers.

The complete coal handling system shall be controlled from the coal handling control room
located within the coal handling building adjacent to the last transfer tower or crusher house.
The overall control shall be by programmable logic controller (PLC) system. The control
boards shall include the controls, graphic display, and annunciator sections to allow
remote operation of the coal handling system. The coal handling building shall also
house the necessary electrical equipment to distribute power to the coal handling equipment.

2.10.4 List of Major Coal Handling Equipment and Structures

- All conveyors and transfer towers as required

- Sampling systems

- One traveling stacker conveyor

- Two coal piles (450000 tonnes useful automatically recla imable storage) with liners.
Each pile must be divided by heaps in order to cut the propagation of fire (in accordance
with standards and the best industrial practices)

- Two traveling portal reclaimers

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2-69
Safi Units 1 & 2 Specification Par t B
S a rge n t & Lund y • •' 1,320 MW Gross Generating Facility
Globai•Ener.vy Cons ulting TECHNICAL SPECIFICATIONS

- Two reclaim conveyors to crusher house

- Crusher house, with adjoining electrical equipment and control rooms

- During blending both scraper reclaimers are to be operated and maximum two coal sources
can be blended at a time. The blending ratio of each source shall be controlled by varying
or controlling the travel speed of the machine and depth of cut of scraper blades. For
adjusting the depth of cut, each time the chain (mounted with scraper blades) will be
lowered to required level. The blend ratio can be adjusted between 30%-70%. The
tonnage of coal source reclaimed by each scraper shall be read by incorporating belt
weighing scales in each of the yard conveyor and using this reading the travel speed and
depth of cut will be varied

- Crushers

- Belt feeders

- Diverter gates

- Splitter gates

- Belt scales

- Magnetic separators

- Two transfer conveyors to boiler house

- Two tripper conveyors

- Dust collection systems

- Dust suppression water spray system

- Fire protection systems

- HVAC equipment

- Control system

- All foundations and structural materials and work

- All electrical materials and work

Miscellaneous services (service water, compressed air, lighting, vacuum cleaning,

washdown systems, etc.)

- Lot miscellaneous chutework, abrasion-resistant and stainless steel liners, skirtboard,

diverter chutes, guards, etc.

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2-70
Safi Units 1 & 2 Specification Part B
Sargent: & Lundy ' " 1,320 MW Gross Generating Facility
G lobal ~'"'riiY Consulting TECHNICAL SPECIFICATIONS

- Lot local safety and control devices, belt position switches, emergency pull stop switches,
local start-stop-jog stations, plugged chute switches, takeup limit switches, motion
detection switches, and warning horns
- Lot hoists, trolleys, and hoist beams to be located at all transfer points
- Sump pumps and piping

All miscellaneous equipment not specifically listed above for a complete and operable system
shall be provided.

Conveyor components shall conform to the standards of the Conveyor Equipment

Manufacture's Association (CEMA). Conveyors shall be standard troughed type and shall
include belting, idlers, pulley assemblies, belt cleaners, loading skirts, safety switches, enclosed
conveyor galleries or 3/4 hood covers, and fabricated steel supports, including maintenance
walkway. Conveyors between the crusher house and the power plant bu ilding will be located in
an enclosed walk through gallery. All other outdoor conveyors will have open galleries with
conveyor hoods. Walkway gallery shall be provided for all conveyors located above ground level
(on both sides of conveyor and in between conveyors) for conveyor maintenance purpose. All
conveyors must be fully enclosed with wind breaker, hood cover and bottom plate except for
some sections of conveyors in the stockyard: 1) the reclaimer conveyor within stockpile length is
open type and the remaining length up to transfer tower is provided with wind breaker and belt
hood, and 2) the stacking conveyor is fully open type. The conveyor at jetty is provided with wind
breaker in loading area, and with additional hood cover for the remaining part. All other
conveyors are provided with belt hood with open type girder and walkway.

Hopper and transfer points shall be lined with abrasion-resistant or stainless steel liners.
Transfer points shall include hoods, chutes, doors, and skirts to minimize fugitive dust.

2.10.5 Design and Operating Conditions

The crusher house will house two 100%-capacity crushers to crush coal being sent to the in-
plant silos. During normal operation one crusher is required to supply the plant, although both
crushers will be able to operate simultaneously.
Two traveling tri ppers will receive coal from the crusher house and be capable of filling the in-
plant silos.
The coal characteristics shall be as follows:
- Average bulk density of stacked coal: 0.80 tfm3
- Average bulk density for compacted coal: 1.1 tl m3
LONDON - 131183.03
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2-71
Safi Units 1 & 2 Specification Part B
Sargent & Lundy • •' 1,320 MW Gross Generating Facility
Global ~nergy Consulting TECHNICAL SPECIFICATIONS

- Angle of stacking: 38°

- Maximum moisture content% (see coal analysis in Exhibit H)

- Coal contains small quantity of impurities such as iron block, pyrite, log, etc.

2.10.6 Trippers

Traveling trippers shall be provided on two conveyors above the silos. Each tripper shall be
motor driven, self-propelled, self-reversible, dustless type and designed to discharge coal from
one side of the belt.

Each tripper shall have a lighted belt crossover gallery, suitable access platforms, dust tight
access doors, and receptacles for maintenance of equipment.

2.1 0. 7 Crushers

The crushers shall be capable of crushing coal to 25mm x Omm size.

2.10.8 Belt Scales

The equipment shall be suitable for the operating and service conditions specified and shall
also be warranted accurate from 1/3 to full load. The belt scale for the coal receiving system
shall have an accuracy of ± 1/8%, suitable for commercial purpose. The belt scales for the
reclaim system shall have an accuracy of± 1/4%.

Belt scales shall be of the electronic type and furnished with a test weight if required for
accurate calibration.

2.10.9 NA

LONDON • 13 1183,03

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2-72
Safi Units 1 & 2 Specification Part B
Sargent & Lundy " ' 1,320 MW Gross Generating Facility
Global Ene1'9y CanSiultlng TECHNICAL SPECIFICATIONS

2.1 0.10 As Received Sampling System

A fully automatic as-received sampling system shall be provided to sample coal from the Project
supply conveyors. It shall be a three-stage system consisting of following equipment complete
with all appurtenances:

• Sweep type primary cutter

• Primary belt feeder

• Sample crusher

• Secondary belt feeder (if required)

• Secondary sample cutter

• Reject belt feeder

• Tertiary sampler

• Sample collector

• Plugged chute detectors

• Chutework and support steel

All work shall conform to the applicable requirements of latest issues of ASTM 02234 and
ASTM 02013.

2.10.11 As Fired Sampling System

A full automatic as-fired sampling system shall be provided to sample coal from the transfer
conveyors to the boiler house. Two sweep type primary sample cutters shall extract samples
from these transfer conveyors. The balance of the system shall be modular type and common to
both conveyors.

It shall be a two-stage system consisting of following equipment complete with all

appurtenances as follows:

• Two sweep type primary cutters

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2-73
Safi Units 1 & 2 Specification Part B
Sargent & Lundy ' ' ' 1,320 MW Gross Generating Facility
GlobahEn•rVv Con•ultlng TECHNICAL SPECIFICATIONS

• Primary belt feeder

• Sample cursher
• Secondary sample cutter
• Reject belt feeder
• Sample collector
• Plugged chute detectors
• Chutework and support steel

All work shall conform to the applicable requirements of latest issues of ASTM 02234 and
ASTM 02013.

2.10.12 Dust Suppression System

A water spray dust suppression system shall be provided at the coal storage pile area and
supplied from the service water system. Spray header assemblies shall be arranged around
the perimeter of the coal pile area to spray the piles to control dust emissions. The spray can
be activated either automatically (based on the position of the traveling stacker) or initiated
manually by the stacker operator.

Dust suppression systems shall also be provided for the receiving hoppers, and all conveyor
transfer points where there is no dust collection system provided.

2.10.13 Dust Collection Systems

The coal crusher house and tripper room shall be provided with a dust collection system to limit
the dust content in the air. The system shall collect dust at locations where it is generated.

The allowable dust content of the air within the tripper room shall not exceed:

• 2 mg/m3 when the coal contains above 10% free Si02

• 10 mgfm3 when the coal contains below 10% free Si02

The concentration of discharged powder content in air shall not exceed 150 mg/m3.

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2-74
Safi Units 1 & 2 Specification Part B
Sargent & Lundy'' ' 1,320 MW Gross Generating Facility
G6obal En•rgy Consulting TECHNICAL SPECIFICATIONS

All dust collectors shall be sized to permit simultaneous operation of the two belt conveyor
system.

The coal silos dust collecting system is to dilute or extract the methane accumulated at the
upper portion of the silo and keeps the silo always under negative pressure to reduce dust
dispersing during unloading coal. The fans and motor shall be explosion-proof.

The tripper room dust collecting system shall not be interlocked with the associated coal
handling equipment. It shall operate all the time. Local air shall serve to supply the make-up of
the collecting system.

The collected dust shall be returned to two silos by gravity through a rotary valve on the dust
collector hopper and diverter gate.

2.10.14 Programmable Logic Controller-Based Control System

The coal handling control system shall control the operation of the coal handling equipment,
dust collection equipment, coal sampling system equipment, HVAC equipment, etc.

The system control shall, as a minimum, consist of the following :

• Coal handling control panel

• Local control panels near the equipment (dust collectors, HVAC, coal sampling, etc.)

• Local control stations

• System controls

PLCs shall be furnished to provide the motor and sequential control logic for all bulk handling
equipment.

2.10.15 Coal Handling Control Panel

The bulk material-handling operation will normally be controlled from the coal handling control
panel (CHCP). The CHCP will be located in the coal handling room.

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2-75
Safi Units 1 & 2 Specification Part B
Sargent & Lundy • • • 1,320 MW Gross Generating Facility
OlobahEn•rgv Cona ultlng TECHNICAL SPECIFICATIONS

The CHCP shall contain, but not be limited to, the following:

• Mimic and graphic of system flow

• Control switches

• Indicating lights

• Meters

• Annunciator

• Miscellaneous devices as required by the system

2.10.16 Material Handling Local Control Panels

Package systems such as dust collectors, hydraulic package units, etc., consist of a quantity of
motors, solenoid valves, etc. In lieu of individual control switches on the CHCP, one system
STOP/START switch shall be provided for the entire package system. This single control switch
shall start, in proper interlocked sequence, all required equipment. Local panels shall provide
individual control switches as required.

2.10.17 Local Control Stations

Local stop/start stations shall be provided for all equipment that can be operated independent
of the bulk material handling sequential controls.

Each of these equipment items shall be provided with a local control panel containing sufficient
control devices for a local operator to initiate a startup or shutdown sequence.

2.10.18 System Controls

The PLC shall be programmed in relay logic from schematics. The ladder diagrams shall use
alphanumeric designations in addition to relay programming numbers.

Rope pull switches and emergency stop stations shall be hard-wired to stop the respective
conveyor, feeder, etc.

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2-76
Safi Units 1 & 2 Specification Part B
Sargent & Lundy ' ' ' 1,320 MW Gross Generating Facility
Globai·Ene rgy Consulting TECHNICAL SPECIFICATIONS

All equipment shall be fully interlocked so as to prevent overloading , spills, and equipment
damage. Tripping an item of equipment shall trip all upstream equipment.

2.10.19 Service Water System

In addition to supplying the dust suppression system and service water, service water
connections for washdown will be provided at each floor in the following locations:

• Crusher house and junction house(s)

• Enclosed conveyor galleries

• Tripper room

2.10.20 Service Air System

The coal handling system shall have a dedicated service air system that is separate from the
main plant service air system, with two 100% capacity air compressors.

2.10.21 Electric Operators

The coal handling system shall use electric operators rather than pneumatic operators and not
require instrument air.

2.11 ASH HANDLING AND ON-SITE STORAGE SILOS

2.1 1.1 Bottom Ash Handling

The bottom ash handling system shall provide for the collection and removal of bottom ash from
the two steam generator (pulverized coal type) furnaces. A submerged drag-type chain
conveyor shall provide the means for removal of the bottom ash. The submerged drag-type
chain conveyor (one for each unit) shall transport the bottom ash up an inclined dewatering
ramp prior to discharging through a crusher. The crusher shall discharge to a vertically inclined
drag-type chain conveyor for transport to a bottom ash storage pit.

LONDON · 131183.03