Owner’s Requirements

6. General Requirements
6.1. Overall Plant

The Facility shall be designed taking into account the requirements of plant operation and shall be arranged to
facilitate ease of inspection, cleaning, maintenance and repair.

The design shall incorporate every reasonable provision and precaution for the safety of the operating and
maintenance personnel and for the correct, efficient and safe operation of the plant.

The Facility shall be designed to operate satisfactorily under all variations of load, pressure, and temperature as
may be met in normal usage under the variation expected in the site design parameters.

The various components and systems of the plant shall be designed to interface together, physically and
functionally, so as to provide a complete, cohesive and co-ordinated plant within the defined limits of the
Contractor's scope of supply, and to meet the specified interface requirements.

Notwithstanding any requirement specified herein, it shall be the Contractor’s responsibility to supply designs
and equipment which shall be fit for purpose, take into account the site conditions and location and be entirely
satisfactory for all operating and transient conditions applicable to the plant.

All material and equipment supplied by the Contractor shall be new and unused. All materials and their finishes
shall be chosen taking into account the expected normal and transient operating conditions of the component
and the environmental conditions at the site, and to ensure an efficient service life for each part of the plant.

Materials shall be selected to meet the requirements of an internationally recognised Standard, unless by
agreement with the Owner.

6.2. Design and Equipment

6.2.1.General

All designs and equipment supplied shall meet these Owner’s Requirements and shall conform to current Good
Utility Practice.

All equipment and systems shall have sufficient margin to cater for equipment and system wear, tear and
deterioration. The Contractor shall identify margins for main equipment and systems during engineering
submission, including margins for sizing/design of cooling water pumps, river water intake and discharge
structures, heat exchangers, HVAC systems, fire protection systems, transformer ratings, safety features
(including boiler safety valves), isolated phase bus rating, generator breaker rating, battery and UPS systems,
and blackstart diesel generator.

The plant and equipment shall be capable of withstanding without operating difficulties (eg undue heat, strain,
vibration, noise, corrosion or other damage) all stresses which may be experienced during normal operation,
cyclic load operation, part loading, overspeed, full and part load trips, sudden load swings and under all test
conditions. No part of the Works shall suffer from accelerated ageing as a result of exposure to the ambient and
operating conditions.

Equipment shall be protected against sunlight and heat exposure, airborne pollution (haze) and dust, humidity,
and water ingress. Anti-condensation heaters shall be provided in electrical panels and electric motors. Outdoor
equipment shall be weatherproof and capable of withstanding the site conditions.

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Equipment which may be subject to deterioration as a result of being at standstill for periods of up to three
months at a time or as a result of low utilisation shall be provided with appropriate protection from the elements.
6.2.2.Ingress Protection

Electrical and C&I equipment installations shall be provided with the following minimum ingress protection,
unless otherwise agreed:
· Outdoor Motors, Panels and Motorized Actuators – IP 54 (or IP 55 if subjected to water spray / jets from the
firefighting system)
· Indoor Motors and Motorized Actuators – IP 54;
· Indoor panels/equipment installed in air conditioned rooms/enclosures – IP 31;
· Indoor panels/equipment installed in non-air conditioned rooms/enclosures – IP 42;
· The generators of black start DG sets shall be rated for IP 54;
· Outdoor junction boxes – IP 65 except for GTG set for which IP54 is acceptable.

6.2.3.Electrical Systems and Equipment Design

Electrical equipment shall be constructed to withstand the maximum short circuit currents and duration without
the temperature exceeding the value permitted for the related class of insulation. The equipment shall be
considered as being operated at maximum permitted current prior to the inception of short circuit current.

All electrical equipment associated with the generator circuit shall be rated such as to enable the full and
unrestricted operation of the associated prime mover under all specified operating conditions and over the full
range of ambient temperatures. This shall include but not be limited to: generator and its associated equipment,
isolated phase busbars, generator circuit breaker, generator step-up transformer, high voltage interconnections
and switchgear.

The electrical equipment shall be designed to ensure continuity of operation of the main plant under all working
conditions. The Facility shall also be capable of meeting all transient, abnormal and load shedding scenarios.
The Facility shall be designed so that, in the event of a trip, it and its associated systems shall shutdown in a
safe manner without damage to equipment. All equipment shall be designed to permit safe shutdown on loss of
electrical power supply or on loss of control system. Plant shall be designed to be “fail safe” and all protection
devices shall be de-energised to trip.

All main switchboards, relay panels, control equipment etc. shall be provided with duplicate segregated power
supplies for protection, control and alarm purposes. It shall not be possible to close any circuit breaker if its
associated protection relays have operated and not been reset manually.

MV and LV switchgear controls, including those associated with circuit breaker tripping shall be hard wired with
DCS trip as a backup. The trip contact from the respective protection relay shall be used for the direct trip to the
circuit breaker. All the control and protection circuits of MV and LV switchgears shall be powered by DC. The
control power for the essential LV motor feeders shall be fed by DC also.

All electrical and control and instrumentation equipment - e.g. generator excitation and static frequency starting
equipment, governor, power centre, motor control centre, UPS and DC systems, batteries, DCS, wiring
cabinets, balance of plant MCCs and PLCs etc - shall be housed in an air-conditioned environment.

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The detailed design of all buildings shall include consideration of energy efficiency and minimising their energy
use requirements.
6.2.4.Electromagnetic Compatibility Requirements

Equipment shall comply with the requirements of the relevant Electromagnetic Compatibility (EMC) directives. In
general, individual items of equipment shall have the relevant approvals (e.g. CE marking or equivalent).
Alternatively, the Contractor shall demonstrate EMC compliance by submitting a technical construction file with
the appropriate declaration of conformity.

Equipment shall not generate electrical or electromagnetic interference (conducted or radiated) at a level that
can adversely affect the performance of other equipment or lead to hazard/discomfort to personnel. The
relevant parts of IEC 61000 and EN 55011 with the appropriate classification and grouping shall be used to
confirm this requirement.

Equipment shall be immune to electrical/electromagnetic interference from external equipment. The relevant
parts of IEC 61000 with the appropriate test severity levels suitable for a power plant application shall be used in
terms of impulse withstand, electrostatic discharge, radiated electromagnetic energy and voltage fluctuation to
confirm this requirement.

6.3. Equipment and Personnel Safety

6.3.1.General

In the laying out of the plant the Contractor will take account of and ensure the safety of the plant operating and
maintenance personnel and the safety of the equipment.

The plant shall be laid out to ensure that access to all operational areas is readily possible. Escape routes from
buildings shall be designed to be reasonably direct and shall be provided with emergency lighting. Elevated or
enclosed areas shall be provided with alternative means of egress should the main exit become blocked.

Equipment location and arrangement shall ensure that not less than two escape routes from any area, including
from the site itself, are available for personnel in case of fire or other hazard during normal operation and
maintenance procedures.

All accessible hot parts shall be lagged for personnel protection.

All moving parts accessible to personnel shall be protected and suitably guarded. Guards shall be designed to
facilitate easy removal for maintenance of the equipment, whilst providing a fully rigid cover to stop accidental
access to the rotating part.

Potentially hazardous plant shall be provided with all the necessary interlocks to ensure that the maintenance of
the equipment can only be carried out when the equipment is a safe state.

The design of areas where flammable or explosive gases can occur shall allow the safe and continuous
dispersal of any generated or leaked gas, and to prevent the accumulation or building up of gases.

Electrical equipment casings and other potentially live equipment shall be adequately earthed.

The design and layout of the plant will minimise the fire risk by identification and segregation of the risks and by
segregation of the risk from potential ignition sources. A comprehensive fire detection and
protection/extinguishment system shall be provided.

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Station warning alarms and evacuation alarms shall be arranged to be heard in all areas of the Facility. It shall
be possible to hear the alarms above the background noise level. In noisy areas the audible alarm shall be
supplemented by a visual alarm. The alarm signal types will be co-ordinated with the Owner.

In the layout of the plant structures/buildings suitable measures will be taken to ensure that the plant is safe for
personnel to operate. Typical measures include provision of:-
· adequate headroom/clearance of equipment and services over passages and access ways.
· hand railing on platforms and elevated access ways.
· kicking strips on elevated platforms and on openings through floors.
· an emergency lighting system to ensure safe evacuation.
· safety hoops on access ladders and rest platforms on stairs.

Equipment shall be protected with safety valves, relief valves, fusible links, fuses, interlocks, bursting
diaphragms and other such protective devices to prevent an unsafe or potentially damaging or dangerous
situation occurring with the equipment.

Vents and drains shall be discharged in a safe manner and shall not discharge on or in the close vicinity of
areas where normal personnel access is expected.
6.3.2.Exposure to Electrical Equipment

All electrical equipment shall be constructed such that all live conductors, are effectively shielded from contact
by personnel, unless access to such conductors is possible only by the removal of bolted covers using tools.
Where access to electrical equipment is required during normal operation, hinged doors with lockable handles
and multiple point locking mechanisms shall be provided. All live conductors, terminals and fittings within such
cubicles and behind the doors shall be effectively shrouded to prevent accidental contact.

Residual Current Devices to be provided at all electrical general purpose outlets.

6.4. Standardisation

The Contractor shall standardise equipment where possible so as to minimise the different types of equipment
used for similar applications across the plant. The aim of this standardisation is to improve the operability and
maintainability of the plant and to consolidate and therefore minimise the holding of spare parts required. In
particular this should extend to I/O devices, PLC, field instruments and devices, actuators, consumable items
(indicating lamps, recorder charts, printer papers, ink cartridges etc).

The requirement for standardisation need not be applied in the case where plant is procured as standard and
proven design packages, engineered modules, or assemblies from suppliers, despite these containing
components or equipment that otherwise are being standardised.

Where equipment is being provided as multiple trains of equipment, all similar components in each train shall be
interchangeable. Items of plant and equipment on different units throughout the plant shall be interchangeable
with each other and with their associated spare part without modification.

6.5. Layout

The Contractor shall design the Facility to facilitate economical and efficient operation and maintenance and to
permit safe, easy and unrestricted access to all locations.

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Escape routes for personnel from all areas of the Facility and in particular the central control room and
electrical/electronic rooms shall permit and ensure direct egress from the buildings without the necessity to pass
through the plant equipment area.

Buildings, enclosures and annexes shall be provided with emergency exit doors fitted with panic escape bars.
These openings shall be kept clear of all obstructions.

Buildings shall have sufficient space and areas for efficient maintenance of plant, equipment and components.
The layout and space for maintenance shall allow for the complete and simultaneous overhaul of all equipment
within the normal time required to complete an overhaul. There shall be sufficient lay-down areas near rotating
equipment to facilitate disassembly and rotor removal.

Trench covers shall be designed to accept the appropriate floor loadings according to their location and shall be
manually removable, wherever possible.

A 1.5m wide pathway shall be provided all around the buildings, enclosures, annexes etc (including the HRSG
structure). This shall be edged with curbs set in concrete and surfaced with pre-cast concrete paving slabs.

The area surrounding all buildings the HRSG and stack shall be surfaced with a concrete slab.

The Contractor shall finalise the layout, taking the following into consideration:
· Prevailing weather conditions.
· Access and operability of mobile cranes.
· The practical removal and replacement of all plant.
· The plant switchyard shall be generally in the location shown on the layout drawings in Annex 1.
· The Site shall have a boundary security fence with security lighting.

The Contractor shall demonstrate during the design review how these requirements have been achieved to the
Owner’s satisfaction and approval.

6.6. Access and Laydown

The Facility shall be fitted with suitable platforms, galleries and stairs for efficient access to plant and equipment
requiring operation, surveillance, lubrication and maintenance. Safe evacuation shall be provided by two
alternative means of egress.

Permanent access shall be provided to all equipment requiring inspection or operation a monthly or more
frequent basis.

Gauges, instruments, manholes, inspection points, lubrication points, actuators and fittings, and sample points
shall be easily accessible from permanent platforms such that operation and maintenance can be readily carried
out from floors, permanent walkways or permanent access platforms.

Valves, requiring immediate action, inspection, or operation on a monthly or more frequent basis shall be easily
accessible from permanent platforms such that operation and maintenance can be readily carried out from
floors, permanent walkways or permanent access platforms.

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The layout and arrangement of equipment shall be co-ordinated with the access platforms and walkways layout
to facilitate safe operation. Equipment shall be located so that no aspect of their positioning in anyway
constitutes a hazard to personnel.

All lubrication and sampling points shall be accessible without having to remove covers and without being
exposed to moving parts. Any components requiring manual lubrication shall be provided with easily accessible
greasing nipples. Lagging around equipment that needs to be overhauled shall be easily removed.

Stairways stairways shall be constructed of galvanized mild steel stringers with galvanized open steel treads,
reinforced at the leading edges, supported by substantial structural members. Galvanized handrails and
standards shall be provided on each side of the stairway. Stairs shall be located on at least one side of each
HRSG from grade to the highest operating level. Emergency escape ladders, with safety cages, shall be
provided from any platforms having a dead-end.

Platforms shall be constructed using galvanized open steel flooring to the relevant Standards and shall cater for
the relevant loadings for maintenance, the minimum acceptable size being 30mm deep, 3mm thick bars at
42mm bar spacing. The flooring shall be bolted to the framework using approved bolted clips. The platform
framework shall be galvanized.

The layout shall:

· Allow access for vehicles and equipment for all foreseeable maintenance tasks, including all scheduled
maintenance events.
· Include laydown areas for all foreseeable maintenance tasks, including all scheduled maintenance events.
The laydown areas shall be arranged and located to permit horizontal movement, in addition to vertical
access by overhead crane hooks. The need to pass major components over operating units shall be
minimised.
· Allow access for personnel and safe access routes for evacuation.

Access reserves, walkways, and routes for mobile equipment removal platforms (cherry picker, forklift,
equipment trolleys, etc.) shall be indicated on the general arrangements and comply with the following:
· Forklift truck ways shall have as a minimum the width, overhead clearance and turning radii sufficient for a
three (3) tonne forklift. However, the actual clearance provided for any type of mobile equipment access
aisle shall allow removal of the largest equipment component accessible from that aisle.
· Structural steel bracing, piping (including insulation), cable tray or conduit shall not impede access aisles,
equipment removal/access space, or personnel escape routes.

6.7. Provision for Handling

6.7.1.General

Parts subject to wear or which require inspection or repair shall be accessible and capable of reasonably
convenient removal for replacement or repair.

Equipment:
· Weighing more than 40kg; or
· Weighing more than 25kg and located more than 1.5m. above grade or a platform,

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shall be provided with rigging steel unless it is accessible by forklift, mobile crane or a permanently installed
crane. No engineered or field run piping, tubing, conduit, cable tray, light fixtures etc. shall be located in the
access and removal space between the trolley or rigging steel and the equipment.

Trolley and rigging steel shall be arranged so equipment components can be readily transferred to an
appropriate mobile maintenance platform positioned in the adjacent access way.

Equipment shall be arranged to allow safe access for condition monitoring.

6.7.2.Cranes

An overhead travelling crane sized to lift and transfer major items of plant within the turbine building shall be
provided. The crane shall be designed to lift the heaviest component required to be lifted during maintenance,
including for major maintenance and overhaul activities on the steam turbine and generator. This crane shall
have an auxiliary hoist.

Other cranes shall be provided in strategic locations in order to access other items of plant and equipment for
maintenance. The Contractor shall give consideration to the requirement to lift and remove all pumps,
compressors, motors, major valves and other associated equipment, which may require removal for
maintenance.

As a minimum, a lifting device shall be provided for the gas turbine air intake houses and at HRSG drum level
(per HRSG) and in the workshop. A hoist shall be provided in the firewater pumphouse.

All cranes shall be controlled remotely and via a wireless remote unit.

Each crane's hoist and controller shall have two speeds. Trolleys shall have three speeds: creep, slow, and
medium. Speeds shall be in each direction. All crane motors shall have reverse phase protection, jogging and
plugging controls for precision work and soft start/soft stop capability.

6.8. Cathodic Protection

All buried metallic pipework, tanks, vessels and any other metallic equipment in contact with the soil shall be
protected by a cathodic protection system. The scope of equipment protected shall include, where relevant, all,
potable water, borehole water and other buried water mains on site, including all fire fighting mains.

The system shall be complete with all necessary transformer rectifiers, control system, ground beds, anodes,
permanent test stations, permanent reference electrodes etc.

The Contractor shall determine the resistivity of the ground to be used in the design of the cathodic protection
system. The system shall have a design life of 25 years.

Any other buried metallic structures in the immediate area of the various pipelines shall be tested before and
after commissioning of the cathodic protection system. Any interference with any other buried structure shall be
rectified by approved means. In areas where interference problems may exist and where the use of sacrificial
anode systems may reduce the extent of the interference, sacrificial anode systems may be proposed.

6.9. Plant Identification System

The Plant Identification System shall be KKS (Kraftwerk Kennzeichnungs System) and shall be used to clearly
identify all equipment, systems and components of the Works. The system shall apply to the complete plant and

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should be used to identify equipment, areas and systems in all documents and drawings and shall be included
on equipment name plates and other on site identificaton devices.

The Contractor shall provide detailed training sessions and full documentation for the supplied Plant
Identification System prior to commissioning work. The Contractor shall supply soft and hard copies of the
component list for the plant and for all components on which maintenance must be carried out. The list shall
include: Reference Identification number, Plant Item, Reference Drawings, O&M Manual Reference and Spares
Reference.

6.10. Signage and Labelling

6.10.1. Signage

Signs and graphic designs for identification and directions will be provided. The sign system utilized will provide
simple and direct indications using graphics, colour, and/or test in accordance with internationally recognized
symbols. Where appropriate the sign legend shall be in English and the local language. The plant site sign
system will direct all users of the plant and visitors to the appropriate areas for their specific business at the
plant site. The signs will be designed to tie the various graphic elements of the plant into one visually contiguous
group.

Signs such as exits, fire escape diagrams, building labels, door labels for room use and pipe labels will be
employed for safety, ease of operation and direction. Wall mounted signs shall be provided at all floors,
platforms, etc. to indicate the allowable loadings and floor elevations. The Contractor shall provide similar
signage to indicate reduced headroom clearance, hazardous areas, warning signs and others as required by the
design review, HAZOP, and applicable Codes and Standards.

All warning and instruction notices shall be in Indonesian and English.

A colour banding scheme shall be used to identify pipework. The identification requirements and colours
employed shall be in accordance with the appropriate standard. Colour bands shall be painted on each side of
all valves and equipment on the piping systems. The use of adhesive-backed colour bands is not permitted.
Pipework shall be provided with plentiful large painted arrows and/or other secure and durable arrow markings
to allow the flows of fluids around the plant to be readily understood.

Identification signs, directional signs and traffic control signs, signals, lane divider markings, and painted
pavement marking within the boundary limits of the plant site for control of vehicles to and on the site shall be
furnished and installed. A plant identification sign will be furnished and installed at the main entrance to the
plant.

Type, design and location of all signs shall be acceptable to the Owner.
6.10.2. Nameplates and Labels

All nameplates on equipment shall be written in Indonesian and English. A consistent coding system shall be
used throughout. Those items of electrical equipment specified in the Sumatera Grid Code (Connection Code
Section) shall include equipment numbering and identification codes in accordance with the Connection Code.

Each item of plant including equipment, field devices and drives shall be durably and legibly labelled, indicating
the duty, size, purpose and full identification information and operation information. These nameplates will be
located securely on the equipment itself or, in the case of small equipment, on an adjacent pipe or structure.

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The description and number of each item of plant shall be consistently applied throughout all drawings,
manuals, documents and labels and across the plant. Each item shall have its unique plant KKS identification
number. Equipment descriptions shall be agreed with the Owner.

The labels shall facilitate effective operation and maintenance of equipment and shall be fitted so that they are
not readily lost or broken during routine operation and maintenance.

Labels shall be conspicuous without being obtrusive and should be capable of being read by the user when
viewed from a normal working position. Labels shall be of sufficient size to carry a full description of the plant
item and a unique item identification code. Labels should be made of durable material that is totally suitable for
their environment and operating condition and shall be either multi-layer laminated plastic material or metallic
and resistant to weathering and deterioration. Inscriptions on the label shall be permanent and an integral part
of the label.

For nameplates, notices and other signs, the form, size, background colour and colour of the inscriptions shall
be chosen by the Contractor so as to be readily visible to the operator and to provide differentiation between
informational or identification labels or notices and warning notices. This will be consistent throughout the
complete Works to ensure clarity and ease of identification and shall be subject to the Owner’s approval.

Warning labels shall be distinguished from informational labels by the use of red lettering instead of black.

All important equipment shall be provided with data plates, indicating the name of manufacturer, type, serial
number, year of fabrication, main characteristics and all further information for identification of the equipment.

All labels shall be firmly fixed to non-detachable parts of equipment using not less than two fastenings. Label
fixings shall be such as to allow ready replacement without damage to the label or the fixing.

Labels/signage for safety, confined space identification, hazardous and dangerous goods including flammable
and toxic gases, acids and alkalis shall be in accordance with OH&S requirements and relevant National
Standards.

All interconnecting pipes including those in trenches and all pipes carrying potentially hazardous substances
shall be colour coded and have pipe markings on the outer surfaces in accordance with the fluid contained
according to the defined power plant colour code. Colour bands shall be painted on the pipelines at each side of
all valves and equipment. The use of adhesive-backed colour bands is not permitted. Pipework shall be
provided with plentiful large painted arrows and/or other secure and durable arrow markings to allow the flows of
fluids around the plant to be readily understood.

Both ends and an adequate number of intermediate positions of all cables shall be clearly identified. Colours of
cable cores and wire colour used for the wires in all panels, cubicles and cabinets shall be according to
standard industry practices.

Where pipe work and/or cables are installed underground the Contractor shall supply and install reinforced
concrete marker posts at each change of direction point and at intervals of no greater than 30m along the route.
These marker posts shall indicate the directions and functions of the services involved.

Labels shall be provided on front and rear access doors of all cubicles. Labels shall also be provided inside
cubicles to assist the identification of apparatus and terminals.

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6.11. Vibration and Balancing - General

Plant shall be designed and constructed to operate throughout its operating range without vibration insofar as
the nature of the works shall permit.

All rotating parts of pumps, fans, motors and drives shall be statically and dynamically balanced.

Provision shall be made for the reduction of vibration transmitted to covers, cladding, platforms and structures
that are liable to vibrate.

Rotating elements shall be balanced in accordance with the relevant requirements of ISO 1940 and ISO 11342.

6.12. Lubrication

Any components requiring manual lubrication shall be provided with easily accessible greasing nipples or
lubrication points such that lubrication can be achieved without the disassembly of any covers, guards or any
other equipment.

6.13. Surface Preparation and Painting

The Contractor shall be responsible for all painting, including the painting of all equipment, plant, pipework and
structures supplied under the terms of the Contract.

The painting procedures shall be appropriate to the prevailing site conditions and in accordance with accepted
international Standards (e.g. ISO 8501). Prior to priming, preparation shall be in accordance with ISO 8501-1.
Surface irregularities shall be removed or made smooth prior to commencement of surface preparation. The
preparation of surfaces and painting shall be suitable for the operating environment.

After all machining, forming and welding has been completed, all steelwork surfaces shall be thoroughly cleaned
prior to any painting.

Surface preparation of new steel surfaces shall include the removal of all surface irregularities and mill scale
together with all rust and surface contaminants, such as grease, dirt and solid pollution. Surfaces shall be
prepared by blast cleaning to ISO 8504-2. Blast cleaning standards shall accord with ISO 8501-1 and ISO 8503-
2 (measurement of surface profile).

Surface preparation shall not take place when the relative humidity is greater than 80% or when the metal
surface temperature is less than 3°C above the ambient dew point or outside daylight hours on exterior
locations. Surface preparation shall be suspended when adverse weather conditions are likely to develop (rain
or fog etc).

All preparation and painting shall be carried out strictly in accordance with ISO 12944. Unless otherwise
instructed, all coats in a particular system, shall originate from a single paint manufacturer. The manufacturer’s
instructions on storage, mixing, thinning, shelf life and application method shall be adhered to under all
circumstances. Minimum and maximum time intervals between coats shall be closely followed. Painting shall
not be performed whilst surfaces are wet, damp or hot. Each coat shall be thoroughly dry before the next coat is
applied.

Painting shall not take place at temperatures <3°C when the relative humidity is >80%, or when the metal
surface temperature is <3°C above the ambient dew point. Painting shall not take place outside daylight hours
at exterior locations.

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Damage to paintwork that occurs at any stage of the work, including site welding operations, shall be re-
prepared. This shall be carried out by blast cleaning both the damaged and immediately adjacent areas and re-
coating to the original standard.

Painted surfaces shall have high durability. A minimum life expectancy of ten years to first maintenance is
required for the surface preparation and paint systems selected for the Works.

The method of application shall ensure mechanical and electrical compatibility with the factory applied coating
and any cathodic protection system.

Pipelines and surfaces that are insulated shall be painted underneath the insulation with a paint suitable for the
operating temperature of the pipe surface.

The Contractor shall provide a full paint and coatings schedule to demonstrate the adequacy of the provision.
The colours of the primer, intermediate and finishing coats of paint shall be easily distinguishable from each
other. The final colours and identification systems for the equipment shall be generally in accordance with
accepted industry practice and shall be subject to the approval of the Owner.

For the gas turbine, the painting system of all external surfaces of the enclosure will be done per GE standard
painting specification.

6.14. Galvanising

All galvanising shall be carried out by the hot dip process and shall conform to the appropriate current codes
and standards and in particular ISO 1461 which refers to the depth of coating and allowances associated with
minor repair work. All surface defects in the steel including cracks, surface laminations, lumps and folds shall be
removed prior to galvanising. All drilling cutting, welding, forming and final fabrications of unit members and
assemblies shall be completed before the structures are galvanised. The surface of the steelwork to be
galvanised shall be free from welding slag, paint, oil, grease and similar contaminants.

On removal from the galvanising bath the resultant coating shall be smooth, continuous free from gross surface
imperfections such as bare spots, lumps, blisters and inclusions of flux, ash or dross.

Small areas of galvanised coating that become damaged shall be restored. This shall be done by either:
· Wire brushing beyond the damaged area and applying two coats of zinc rich paint, or
· Wire brushing beyond the damaged area and applying a low melting point zinc alloy repair rod, which is
heated to 300°C.

For the gas turbine, galvanising will be per GE standard painting specification.

6.15. Corrosion and Weather Protection

Materials shall be selected to minimise the potential for corrosion under their service conditions and take
account of the environmental/atmospheric conditions at the site.

Where dissimilar metals are in contact or close proximity and corrosion may occur through electrolytic action or
differences in electric potential, protection shall be afforded by electroplating, suitable gaskets, cathodic
protection or other means.

Chromium plated parts shall not be used in any damp or corrosive atmosphere.

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All surfaces shall be adequately protected in transit, and any damage shall be renovated immediately on off-
loading and on completion of erection.

Materials subject to corrosion, including all exterior equipment surfaces and structural steelwork, shall be
protected with suitable coatings systems in accordance with the Contractor’s standards, with a durability range
of more than 15 years to first major maintenance. The preparation of surfaces and painting shall be suitable for
the operating environment.

After all machining, forming and welding has been completed, all steelwork surfaces shall be thoroughly cleaned
prior to any painting.

The colours of the primer, intermediate and finishing coats of paint shall be easily distinguishable from each
other. The final colours and identification systems for the equipment shall be generally in accordance with
accepted industry practice and agreed with the Owner.

6.16. Equipment Protection

Prior to shipment, all bright and non-coated metal parts are to be coated with approved protective compound to
provide full protection for both the period of shipment and the period of storage at the plant site.

Preservative coatings used on components shall be suitable for the conditions normally expected during
shipping, storage and throughout the erection period.

Each type of preservative used shall be identified as to quality, life expectancy and type. Toxic and hazardous-
type preservatives shall not be allowed

All electrical and/or electronic parts and delicate mechanical parts subject to damage from moisture shall be
packed in hermetically sealed metal containers, in plastic envelopes, or in other acceptable containers within
their respective cases.

6.17. Shipping Requirements

The Contractor shall prepare, pack and load all materials and equipment for shipment in such a manner that
they are protected from damage during unloading and shipment. Export packing, if any, shall be provided for all
overseas shipment.

Items subject to storage at the plant site shall be suitably protected for the conditions prevailing at the facility
site.

Spare parts, special tools and consumables shall be packed separately and shall be delivered adequately and
properly packed for warehouse storage.

6.18. Prohibited Materials

The Works shall not incorporate any materials which are forbidden, not permitted, banned or considered
“dangerous” in accordance to the applicable National Regulations or World Bank Guidelines. For example,
Contractor shall not use materials such as, but not limited to, the following:
· Asbestos or asbestos-containing materials;
· Naturally occurring aggregates for use in reinforced concrete and/or naturally occurring aggregates for use
in concrete which do not comply with the appropriate Standards;

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· Cast iron for any oil service;

· Polychlorinated biphenyls (pcbs);
· Askarels;
· Isocyanates;
· CFC’s or other ozone depleting substances except (with the Owner’s consent in writing) in applications
where their use cannot reasonably be avoided, and is generally accepted for the specific application;
· Carcinogenic materials;
· Toxic inhalation hazard chemicals except (with Owner’s consent in writing) in applications where their use
cannot reasonably be avoided, and is generally accepted for the specific application ;
· And lead base paints;
· Cadmium plated nuts and bolts;
· Any other materials generally known in the construction industry at the time of use to be deleterious to
health if used or incorporated in such projects the Works.

6.19. Isolation, Locks and Keys

All equipment including valves, switchgear, cubicles and hand switches as appropriate shall be suitable for
being padlocked.

For each process valve which is normally closed, the Contractor shall supply a chain (or equivalent) and
padlock. 3 keys shall be supplied for each padlock. 4 sets of master keys shall be provided.

Key cabinets shall be provided and installed in the PTW office.

Valves shall be capable of being padlocked in either the open or closed position.

The Owner’s Permit to Work maintenance procedures require that padlocks are able to be to be fitted to all
Works isolation points. The auxiliary power supplies systems, associated switchgear and other potentially
hazardous plant shall include a comprehensive interlocking scheme to ensure safety of personnel and to ensure
that the maintenance of the equipment can only take place when the equipment is in a safe state. In addition to
the requisite operational interlocking, the equipment shall be designed to incorporate a system of isolation and
locking such that when an authorized person isolates the equipment he can lock off and make safe. Each
device which has the capability of manual isolation for maintenance purposes shall be provided with means of
locking out with a padlocking system.

Unique keys shall be provided for the padlocks used in the permit to work system.

6.20. Chemicals

Chemical storage areas and facilities shall be sized to store not less than one month’s supply of chemicals
assuming the Facility operates continuously at full load.

All tanks containing liquids other than water shall be situated within an impermeable bund sized to contain 110%
of the relevant tank contents. Where two or more tanks are within a single bund, the bund shall have the
capacity of 110% of the largest tank, or 25% of the total tank capacity, which ever is greater. There shall be no
drains from these bunds and no penetration in the walls of these bunds.

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Spillages shall drain to a blind sump to be removed by manually started pumps suitable for discharging the fluid
to local drain or to a road tanker for off site disposal. Any sumps that are designed to contain a chemical spillage
such as caustic soda or hydrochloric acid should be provided with high level alarms, to warn of potential
incidents. Each sump shall be equipped with two pumps.

All such storage facilities shall comply with Statutory Requirements and relevant Codes and Standards,
including ANSI/ ISEA Z358.1-2014. Eyewashes and emergency showers using potable water shall be provided
wherever chemicals are to be handled, stored or processed. Safety showers and eye-washes shall be supplied
from gravity tanks at sufficient elevation in the event that the water supply pressure is low at the time of need.
These facilities shall be provided with a permanent make-up connection from the potable water system. The
pipework to these facilities shall be protected from solar gain. Operation of an eye-wash or safety shower shall
be alarmed in the central control room. Low level in the head tank shall also be alarmed.

The flooring in areas where chemicals or oils (fuel, lubricating or otherwise) are in use, handled or stored shall
be suitably prepared/coated to protection them in the event of a spill. Where any supporting slab or platform
may be subject to contamination by any corrosive agent or wetness due to liquid spillage, the Contractor shall
provide appropriate surface protection by means of chemical resisting coating/tiles or anti-slip coating/tiles, to be
approved by the Owner.

Road tanker unloading areas shall be lowered relative to the surrounding areas and shall be designed to contain
spills and direct drainage from these areas to appropriate neutralisation drainage system.

Carbon dioxide (CO2) storage if required may be provided either by replaceable manifold cylinder packs
(MCPs), or by at least one liquid storage vessel complete with vaporizers. CO2 storage vessels shall be
designed in accordance with ASME Section VIII Division 1 or equivalent.

6.21. General Mechanical Requirements

For the gas turbine, the OEM’s standard approach shall be considered acceptable.
6.21.1. Pressure Vessels

Pressure vessels shall be designed, fabricated, tested, and installed in accordance with the relevant, Owner
approved code. They shall include the following:
· Process, vent, and drain connections for start-up, operation, and maintenance;
· Where required for maintenance or cleaning access, a minimum of one manhole and one air ventilation
opening;
· Safety and relief valves in accordance with the applicable codes;
· ASME (or equivalent) stamp.
6.21.2. Tanks

Tanks greater than 5m tall shall be provided with an appropriate stairway for access to the roof and to facilitate
access to all instrumentation and for maintenance access. The roof shall have perimeter handrails.

The treads of the stairway shall be of the open grid type. The stairway shall terminate on roof level on a landing
suitably hand-railed for safety.

For tanks less than 5m tall a ladder with safety cage may be provided instead of a stairway.

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Each tank shall have at least two access manholes with davit arm manhole covers on the side of the tanks of an
appropriate size and easily accessible height for inspection of the tanks interior.

An appropriate level of instrumentation/signalling shall be provided on each tank and relayed to the DCS/CCR.

There shall be at least one spare discharge point complete with a blanked off valve on each tank.

Where applications require two tanks, it shall be possible to fill or take from either or both tanks at the same
time. It shall also be possible to pump and drain the contents of one tank into the other.

Tanks containing water shall be either made of corrosion resistant material (stainless steel) or internally coated.
6.21.3. Pumps

Pumps shall be capable of operating continuously over their full operating range, including during cold and
warm start-ups, without overheating, cavitation, excessive noise or vibration, surging or instability when
operating alone or in parallel with other pumps. Pumps shall be selected for maximum efficiency at the design
condition and shall have a head/flow curve that rises steadily from run out to shut off.

Mechanical sealing systems shall be used on all pumps.

Pumps shall be designed to be able to supply the maximum continuous rated flow condition when system
electricity frequencies are between ± 4% of rated frequency.

Margins on all pumps above 15 kW hydraulic power shall be subject to review by the Owner.

All pump bearing housings shall have surfaces suitable for the fitting of portable vibration sensing transducers
for measuring in X, Y and Z directions.

Unless specified otherwise, centrifugal pumps shall be designed, manufactured in accordance with the relevant
ISO code.

Pumps shall be tested and reported to ISO 9906. The major pumps (boiler feed pumps, condensate extraction
pumps and cooling pumps) shall be specified as Class 1 with zero negative tolerance, and all other pumps to
Class 2.

Pumps in pre-engineered package (gas turbine - steam turbine - generator with its auxiliaries) may be
manufactured to the manufacturer’s standard practice.

All leakages shall be collected and directed to suitable drain/collection system.

6.21.4. Piping

6.21.4.1. Piping general

The design, manufacture, installation and testing of piping systems shall be in accordance with approved codes,
such as ASME B31.1 - Power Piping or approved equivalent.

Piping shall be selected from a restricted range of standard industry pipe sizes and non-standard sizes shall not
be utilized.

The design and installation of pipe systems shall be such that the pipes are adequately supported and have
sufficient means of venting and draining. All pipelines shall be provided with vent and drain connections at all

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high and low points respectively, and as required for suitable operation. All piping systems shall be designed to
permit complete drainage when a particular unit or system is shutdown. The pipework shall be arranged with
adequate slope to drainage points. Consideration shall be given to the location of outlets from drains and vents.
Process drains and vents shall be furnished with valves and in general shall be run to closed tundishes. All
natural gas vents shall have flame arresters.

Vents required for start-up and normal operation shall exhaust through silencers to assure the noise limits as
specified within the environmental impact assessment and the permit are not exceeded during all phases of
power station start-up, operation, and shut down.

The design shall provide adequate pipe anchoring and support and pipework shall have sufficient means of
venting and draining. The failure of one pipe support shall not lead to an overloading of adjacent supports.

The supports shall be such that pipes and fittings can expand/contract freely, and any pipe, valve or fitting can
be freely removed without disturbing the remainder of the pipework system. All support attachments for high
pressure steam and other pipes subject to high temperature conditions shall be of the same material as the pipe
and fitted direct to the pipe itself.

Supports shall not be welded to the bottom flange of a beam eccentric from the beam centreline, unless the
beam is appropriately fitted with stiffeners either side of the connection, and calculations presented to
demonstrate their suitability.

The minimum corrosion allowance for carbon steel shall be appropriately selected for the service.

During transport and construction, pipe ends shall be protected from external damage and sealed against
ingress of dirt.

All welding shall comply with the appropriate codes and standards. The Contractor shall submit welding
procedures for the Owner’s review. All welders shall be qualified to the appropriate codes and standards.
Welded joints shall be subjected to non-destructive testing (NDT) before commissioning. The NDT procedures
shall be submitted to the Owner for review prior to testing.

6.21.4.2. Piping and Materials

Materials for the various process and service applications shall be selected as most appropriate for the service.

FRP piping shall be designed manufactured, installed and tested in accordance with ISO 14692.

The Contractor shall provide a material selection diagram for review by Owner detailing material selections by
service and including corrosion allowances.

The Contractor shall develop a pipe specification for submission to the Owner. The specifications shall cover the
service, pressure-temperature rating, valves, fittings, flanges, miscellaneous connections, welding, gaskets and
bolting, pipe material hydro pressure test value, insulation, and cladding.

During the design phase, the Contractor shall supply to the Owner schedules of the piping systems. The
schedules shall state, for each piping system, the design code, 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.

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6.21.4.3. Piping Design

Pipework sizing shall be based on pressure drop calculations to suit equipment requirements, available fluid
pressures and to minimise pumping costs. Pipework and equipment shall be sized for the maximum transient
flow rates that can occur in the pipeline. The minimum difference between the normal and maximum transient
flow for design purposes shall be 15%.

In any one system or piping service all piping and fittings shall be of the same material or similar analysis.

Gravity load cases shall include the hydro test load.

The layout and design of piping systems and their connection to Plant, equipment and structures shall be such
that adequate provision is made for seismic deformations. Piping supported from different structures shall be
provided with adequate flexibility to accommodate the maximum calculated out of phase differential deflections
between each structure at the level of support while maintaining code compliance. Seismic loads on both
horizontal axes of the pipe shall be considered.

6.21.4.4. Stress and Flexibility Analysis

There shall be sufficient allowance for thermal expansion and displacement to prevent excessive stresses,
forces, moments or deflections taking place. Particular attention should be given to the steam pipework,
especially in regard to the locations of expansion loops and anchors. The thermal expansion of the pipework
shall be carefully analysed and appropriate pipe routings and location of the supporting equipment shall
selected to prevent the pipe from causing excessive forces and moments to the anchoring points

Piping systems subject to thermal or other movement and/or stress shall be analysed. The pipeline stress
analysis shall extend up to an anchor point or other fixed point in the system as agreed with the Owner. The
forces and moments transmitted by the pipelines to the connected equipment shall not exceed the maximum
permissible values allowed by the supplier of these components.

Piping systems of the following criteria and condition shall be computer analysed for code compliance and/or to
check nozzle loads on key equipment:
· Complete HP/CRH/HRH/IP/LP steam systems including turbine bypass systems and all interstage
pipework and drains,
· Relief valve pipework, including complete relief valve and pipework to atmosphere
· Relief valve pipework
· Condensate and feedwater systems: suction, discharge and feedwater pipework
· Desuperheating water systems
· Main cooling water pipework, including stress analysis for nozzle loads on the main cooling water pumps
and the connections to the condenser, to include consideration of the maximum pressure setermined by
the surge analysis.
· Nozzle loads on the STG, BFPs, CEPs, gas compressors, condenser, main cooling water pumps
· Any other pipes 150mm NB and larger with design temperature greater than 200°C.

During the detail design stage, the Owner will review the Contractor’s line list (with pipe sizes and design
conditions) and determine whether additional systems need to be included the scope of such analysis.

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All computer analysis shall be carried out using AutoPIPE or Owner approved alternative pipe stress software.

The Contractor shall submit the results of the pipework stress analysis for the Owner’s review. The calculations
shall be based on the maximum operating pressures, temperatures and weights. The positions of supports or
hangers and springs used in the piping system shall be established by calculation. The Contractor will take into
account the worst case operating conditions.

One paper copy (signed by the reviewer) and two soft (Electronic) copies of all stress analysis models and
results shall be provided to the Owner as part of the As-Built documentation.

6.21.4.5. Design Velocity

Unless otherwise agreed by the Owner, velocities used in designing pipework systems shall not exceed the
following:

Fluid Velocity
High pressure steam (Main steam) 65 m/s
Bypass steam 100 m/s
Intermediate pressure steam 55 m/s
Process steam 55 m/s
Extraction steam superheated 55 m/s
Extraction steam saturated 40 m/s
Condensate discharge 3.5 m/s
Condensate suction 1.0 m/s
Feed water discharge 4.5 m/s
Feed water suction 3 m/s
CW through the condenser 2.8 m/s
CW pipes 2.8 m/s
Cooling water 3 m/s
Instrument air 20.0 m/s

The Contractor may propose alternative velocities to those specified above. In each case, the Contractor shall
demonstrate that the velocity is appropriate for the given application and the Owner shall consider each such
proposal on a case by case basis.

6.21.4.6. Piping Layout

Pipe routing and piping arrangements shall keep aisles, access ways and equipment maintenance areas open,
clear and accessible. Pipe system layout shall be arranged such that equipment and sections of pipework can
be removed without major disturbance to adjacent pipework.

For piping sizes 50 mm NB and greater, long radius elbows shall be the preferred design practice. Mitre joints
shall not be used, except where required on large fabricated circulating water pipes.

Butt-welded elbows shall be used for all steam and boiler water lines in cyclic service. Socket welded elbows
may be used for steam and water lines up to 50mm where these are not in cyclic service. In horizontal
pipework, eccentric reducer fittings shall be used as appropriate to maintain grades for venting and draining.

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6.21.4.7. Piping Systems

6.21.4.8. High Pressure Steam, Feedwater, Drain and Blowdown Pipework

High pressure and high temperature pipework shall be of seamless steel construction. Piping for high pressure
services shall be truly cylindrical, uniform in section. High pressure high temperature steam piping shall be solid
drawn chromium molybdenum alloy steel tubing. Carbon steel may be used for high pressure, low temperature
reheat piping. High pressure feed piping shall be of solid drawn carbon steel tubing. Expansion bends or loops
shall be provided where required.

Pipe to pipe joints shall be welded butt joints without the use of internal backing rings. Piping up to 50mm may
be socket welded, except for high cyclic service which shall be butt welded.

Pipe to pipe joints shall be welded butt joints without the use of internal backing rings. Carbon steel up to 50mm
and lower Class 400 as well as alloyed and stainless steel up to 15mm may be socket welded.

All other valves and fittings shall be butt welded into the pipelines except where otherwise approved. Pressure
pipework for instrumentation for high-pressure services shall not be less than 13 mm nominal bore.
Compression couplings may be used only for high-pressure joints at connections to instruments

6.21.4.9. Low Pressure Steam, Water, Drain, Air, Oil and Gas Pipework

Unless otherwise specified, all piping for low-pressure steam, water, drain, air, oil and gas services shall in
accordance with design requirements and applicable international standards.

Compressed air piping for general services shall be of stainless steel or galvanized heavy-duty seamless steel
tubing. Instrument air piping shall be 304 stainless steel or higher grade.

Joints for low pressure steam, water, drain and air services for pipes and valves of 75 mm nominal bore and
above, shall be by means of butt welded or flanged joints, unless otherwise specified or approved. Flanges shall
be square to the pipe.

Steel pipes less than 75mm nominal bore may, in approved locations, use heavy gauge welded sleeve or
socket type fittings or with screwed couplings. All galvanized pipes shall have flanged joints unless otherwise
approved.

All polyethylene pipework joints shall be made using automatic type welding machines with displayed jointing
cycle times and countdown facilities. A demountable type of flanged joint shall be provided at connections to
valves and at such other points in the piping system as necessary to facilitate dismantling for maintenance
purposes. Screwed joints shall not be used for polyethylene piping.

Flanges shall be kept to a minimum on all piping systems that contain corrosive substances.
Joints for oil services shall be flanged or butt-welded. Flanges shall have a secondary containment to catch
leaks and allow for leak detection.

6.21.5. Valves

The Contractor shall provide new, good quality and non-leaking valves and check-valves. Leak tests of valves
shall be undertaken by the Contractor and its Subcontractors. Test results shall be made available to the
Owner.

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All valves required for the regular operation and maintenance of the plant shall be readily accessible from
permanent platforms.

Suitable lifting points shall be provided on heavy valves or valve components to facilitate lifting for maintenance.

Isolating valves shall be capable of being locked in both the open and closed positions for the purposes of plant
isolation. The Contractor shall provide the necessary devices and locks, which shall not incorporate small loose
components.

Valves shall be arranged so that the handwheel moves in a clockwise direction to close the valve. The face of
each handwheel shall be clearly marked with words “open” and “close” and shall be provided with an arrow to
indicate direction for opening and closing. Valves shall not be fitted with the stems below the horizontal. An
indicator shall be fitted to each valve and each extended spindle to clearly show the position of the valve.

Hand wheels and gear reducers shall be sized to permit operation of valves without using hand wheel spanners
with the full pressure differential and with the force applied to the handwheel not exceeding 250 N. All valves
300 mm and above shall be provided with gear reducers.

Parts, particularly seats and discs, which are subject to wear, corrosion or other deterioration which require
adjustment, inspection or repair, shall be accessible and capable of reasonably convenient removal when
required. All valve internals shall preferably be capable of being removed with the valve body in position.

Valves in steam or high pressure water service shall have half-HF facing (i.e. for seats), and those in high
pressure water or superheated steam service shall have full-HF facing (i.e. both seats and discs) with a
hardness differential of 50 Brinnell.

Where desirable to protect valve rising spindles against ingress of dirt, or where the position of the valve may
create a hazard to operators when the spindle is extended, suitable covers shall be provided.

Isolation valves for high pressure system (ASME Class 600 and above) shall be arranged in tandem.

Two valves in series shall also be provided for sample lines.

All test points and pressure gauge connections shall be provided with double isolating valves.

All isolating shall be capable of being operated from floor level. Where valves are located in pits or enclosures
deemed to be confined spaces, extended operating spindles or similar devices shall be provided. . All valves
which are required to open or close during normal operation of the plant, including start up and shut down shall
be equipped with an actuator.

All power operated valves shall have position indication in the DCS. The hand operating and motor operating
mechanism shall be interlocked in such a way that the hand operating mechanism shall be disconnected before
the motor can be started.

In the case of all welded-in valves, the stub ends of the valves shall project from the valve body a sufficient
length to ensure that the welding process will not affect the valve seats.

Cast bodies shall be used valves with a nominal bore larger than 50NB (2 inch). Forged bodies shall be used
valves with a nominal bore 50NB (2 inch) or less.

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Valves shall be fitted with permanent identification plates showing the valve function, number and direction of
closure. Each valve shall be permanently marked with the code designation of valve, body material,
manufacturer’s serial number, nominal bore and the nominal pressure/test pressure and temperature.

The noise from all valves shall comply at all times with the noise limits described in Section 5.

6.21.5.1. Valve Materials

Valve materials and type shall be suitable for the application for the design life of the plant. The Contractor shall
provide the type, size, application and details of the materials used in all valves on the Works to the Owner for
review. Where requested by the Owner the Contractor shall furnish supporting information and reference plant
details in support of the valve selection.

Materials for steam and feedwater service shall be selected appropriate for the specific application. Generally,
for low temperature (below 420 °C) and/or low pressure (900# rating or less) service mild steel cast or forged
gates can be used with 13Cr trim.

6.21.5.2. Drain and Vent Valves

For oil service only ball valves shall be used. Typically, for boiler venting service a reduced-bore gate (master)
followed by a globe (martyr) arrangement is used. For boiler drains a full-bore gate (master) followed by a
metal-seated ball (martyr) arrangement is often used, with bodies in F11.

All valves of NB 300 and larger shall be equipped with casing drain valves.

All material shall be resistant to all chemicals commonly used for acid pickling of the piping system.

Double isolation valves shall be provided on vents and drains of systems as follows:

· the maximum operating pressure-temperature rating is ASME class 600 or above,

· for hazardous services - such as fuel gas

· as noted elsewhere in these Owner’s Requirements.

Exceptions to this are as follows:

· Steam turbine drains and gas turbine gas vents shall be operated automatically with pneumatic
actuators or valves. There will no isolation valves provided for these services in order to protect the
turbines from maloperation and for safety.

To drain the compressed air lines of condensed water and moisture suitable traps of the thermostatic or thermo-
dynamic types shall be installed.

6.21.5.3. Valves for Steam, Feedwater and Other High Pressure Services.

All valves intended for main steam, feed, drain, or any other services subject to high pressure and temperature
shall be of approved make and shall have cast or forged steel bodies with covers and glands of approved
construction.

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 Owner’s Requirements

The design of the high pressure valves shall be such that the selection and thickness of material will be suitable
for high pressures and temperatures. Full details of the design and material used in high pressure valves shall
be submitted for approval as early as possible.

In the case of small size high pressure valves, where screwed covers are unavoidable, seal welding or some
strong form of locking device shall be fitted to secure the cover to the body of the valve.

All high pressure steam and feed isolating valves of 125mm bore in the throat and over shall be provided with
integral steam by-passes. Isolating valves shall be parallel slide, unless otherwise agreed by the Owner.

Approved means shall be provided to relive excessive pressure or vacuum between the discs of high pressure
parallel slide or gate valves.

Where springs are used for keeping the valve discs apart the springs shall be of approved material.

Double isolation valves shall be included on all high pressure steam and feedwater systems.

All steam drain valves shall be of approved type and shall be designed to prevent erosion of the valve seats
when the valves are operated partially opened. Two valves in series shall be provided for operational drains and
vents.

6.21.5.4. Safety and Relief Valves

All pressure vessles and sections of piping which can be subjected to pressure beyond the design value, shall
be provided with pressure safety or relief valves, where the set pressure and design capacity is in accordance
with the boiler, pressure vessel or piping design standard.

Valves shall have been certified as acceptable by relevant codes and standards for the service and duty
intended. Each safety and relief valve shall be supplied with a test certificate issued by the approving authority.

Valves shall be equipped with lifting levers. Test gags shall be furnished for hydrostatic testing. Valves shall be
factory set for pressure – sealing tags shall be applied in the factory, and any subsequent adjustment shall only
be carried out by an appropriately qualified technician. Site “setting” shall be carried out in the presence of the
Owner or his representative(s).

6.21.5.5. Pressure Reducing and Control Valves

All pressure reducing and control valves shall be stable, quiet and free from vibration in operation when
pressure reducing any flow up to the maximum flow, and shall be suitable for continuous use at the operating
temperature.

Inlet/outlet isolating and bypass valves adequate for full flow shall be provided for each control valve.

At full load and under normal operating conditions, control valves shall be 70-80% open. The shutoff class
specified for any control valve shall be appropriate to the service. All actuated control valves shall “fail safe”
from either loss of power or loss of air.

Manufacturer’s shop test certificates shall be furnished for the hydrotest of control and pressure reducing valve
bodies and for the leakage rates across control valve seats. Valve characteristic curves shall be provided for
each type and size of valve.

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6.21.5.6. Power Operated Valves

Any actuated valves required to be in use during an emergency shutdown shall be provided with a handwheel.
This shall be automatically de-coupled when the valve is being power operated.

A mechanical valve position indicator, valve mounted, where it can be easily read from the local operating
position.

If required for DCS logic control, actuated valves shall have position limit switches mounted, for OPEN and/or
CLOSED, as required. The switches shall be preferably mounted in the positioner or in a separate switch box.
The switches will preferably be of the proximity type.

All actuated valves shall “fail safe” from either loss of power or loss of air.

All modulating valve actuators shall include a 4-20 mA valve position transmitter for remote position indication.

6.21.5.7. Motor Operation

Motor operated valve actuators shall be provided with integral contactors, motor thermal cut-out and anti-
condensation heaters. Actuators shall include an integral, dedicated field cable termination compartment
separate from the actuator electrical equipment. This field termination compartment shall be dust and water
resistant to at least IP65.

Motor operated valves shall be fitted with both hand and motor operating gears. Where a bypass valve is
provided and this by-pass has to be operated each time the main valve is operated then this also shall be
arranged with both hand and motor operating gears interlocked to ensure that the bypass valve is opened
before the main valve.

All power operated valves shall have position indication in the CCR.

The hand operating and motor operating mechanism shall be interlocked in such a way that the hand operating
mechanism must be disconnected before the motor can be started. Valves shall be provided with seating
control, and for small valves, a slip clutch or other torque limiting device shall be incorporated in the motor drive.
6.21.6. Filters and Strainers

Filters and/or strainers shall be installed to protect critical system components. All filters and strainers shall be
installed in accessible positions to allow easy cleaning and removal. Isolating valves shall be installed adjacent
to each filter / strainer. Drain valves and vent valves shall be fitted to each filter / strainer body, and shall drain to
a safe tundish for observation of the discharge.

Differential pressure indication across filters and strainers shall be relayed to the DCS.
6.21.7. Steam Traps

Piping arrangements shall be set up to minimise the requirements for steam traps.

Each trap assembly shall have isolation valves and a manual bypass to permit online maintenance of the trap
assembly. Thermodynamic traps shall have replaceable seats. Where steam traps discharge into a header,
means shall be provided to confirm the correct operation of the trap assemblies without shutting down the
balance of the drain system.

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6.21.8. Protection of Moving Parts

All rotating equipment shall have appropriate guards fitted. Guards shall be readily removable during
maintenance. Guards shall be capable of supporting loads of 1kN without deformation.

All nip points on conveyors and other moving plant shall be guarded.

All moving parts where accessible to personnel shall be protected and suitably guarded. All guards shall
facilitate easy removal for equipment maintenance.

Where spillage may occur requiring manual cleaning the design of guarding shall allow access for cleaning, but
prevent the cleaner coming in contact with the moving parts. In these areas cleaning is to be possible without
removing guards.
6.21.9. Thermal Insulation

The Contractor shall supply and install all thermal insulation, cladding and accessory material necessary for
energy conservation, personnel protection and anti-sweat protection on all equipment items, ducts and piping
systems.

For pre-engineered equipment – eg the gas turbine, steam turbine, generator – the OEM’s standard insulation
system shall be acceptable.

Surfaces to be insulated shall be cleaned of dirt, scale, rust, grease or moisture before any insulation is applied.
Insulation materials shall be kept dry and shall not be applied when wet.

Surfaces shall be insulated so that the temperature of the outside of the cladding or protection does not exceed
60°C when the ambient temperature is 35°C and assuming a wind speed of no more than 0.25m/s and the
surface in question is not in direct sunlight.

In areas not requiring insulation for heat conservation, where the surface is accessible to plant personnel and is
within 2 metres of any floor or access way and where insulation is impractical, then, as an alternative to
insulation, stand-off protection may be provided.

The insulation shall be fireproof and waterproof and shall be compatible with the surface to which it is applied.
Suitably positioned drainage holes shall be provided along the underside of metal cladding. The insulation shall
maintain its properties for the plant lifetime, and shall be applied according to good and acceptable insulation
practice for the particular service and temperature involved.

The material used shall withstand the specified temperatures without deterioration shrinkage, change in form or
pulverization. Insulation fitted to stainless steel shall be chloride free.

Unless agreed otherwise with the Owner, insulation materials shall be calcium-silicate in the form of flat or
curved blocks for equipment and in the form of half-cylindrical or curved segments for piping. The materials shall
meet the requirements of ASTM-C533, Type I or equivalent. The use of preformed insulation materials shall be
maximized when fabricating covers on valves, fittings, flanges, vessels, etc. The Contractor shall ensure a
satisfactory fit on all piping and tube sizes to accommodate thermal expansion. It shall be applied such that it
does not corrode the material of apparatus and piping, resists vibrations and shaking and does not deform or
pulverize nor drop from equipment and piping.

For piping of 50NB (two inch) diameter or smaller and less than 350°C, the Contractor may use rock wool as
insulation material.

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 Owner’s Requirements

Where regular inspection of the equipment is required, the insulation and/or protection shall be readily
removable and reassembled. Where access across pipework or insulation is required, the insulation shall be
protected by checker-plating or other suitable protection.

Access doors shall be insulated to a similar degree as casings or enclosures. The insulation of doors shall be
removable and replaceable so that access can be gained without causing damage to nearby insulation.

Insulation of large flat or curved surfaces such as turbine casings shall be by means of blankets or preformed
slabs retained by pins and wired into position as necessary. The insulation for piping systems shall generally be
of the moulded pre-formed type. For piping of greater than DN200 (> NB 8”), the Contractor may use blanket
type insulation.

Piping insulation shall allow for radial expansion and contraction of the pipe, and shall permit the pipe to move
longitudinally. It shall accommodate all normal movements of the piping due to changing thermal conditions
without opening up the joints between sections of insulation.

All piping shall have adequate insulation support rings and/or attachments to support insulation.

All insulation shall be covered with aluminium jacketing strapped with stainless steel strapping. Aluminium
cladding used over piping insulation shall have a minimum cladding thickness of 0.4 mm for 250mm piping and
less, and 0.6 mm for piping greater than 250mm.

All lagging adjacent to hot surfaces shall be capable of withstanding the maximum surface temperature
obtainable in service without deterioration or breakdown of the material.

The Contractor shall coordinate with the Owner and shall provide at locations as instructed plugs in the
insulation to allow subsequent implementation by the Owner of an NDT inspection program incorporating
ultrasonic thickness testing of pipe wall thickness. The plugs shall allow ready removal to enable inspection and
shall ensure that moisture does not enter the insulation when closed.

Cladding shall be adequately supported to prevent sagging or excessive deflection. In the case of exterior
surfaces, it shall be designed to resist wind loadings. Due allowance shall be made in the design and fixing of
the cladding for thermal expansion of the lagged surface. Where necessary, expansion joints shall be provided
in insulating materials. All joints in cladding shall be waterproof.

Cladding shall be protected in areas where it is subject to mechanical damage or being stepped upon.

Insulation and lagging over all flanges and valves shall be in two halves to facilitate maintenance and shall be
easily removable and replaceable without disturbing the surrounding insulation. The separate portion of the
lagging shall extend sufficiently far along the pipe to allow the joint bolts and nuts to be withdrawn (for flanged
joints) or the preparation of the pipe end for welding (for welded joints) without disturbing the insulation on the
pipe. The joint or valve shall be insulated independently of the pipe by preformed blocks or blanket type material
of thickness at least equal to that of the adjacent pipe insulation.

The casing over flanges shall have a drain hole to indicate the presence of a leak. Valves shall be insulated up
to and including the bonnet but not the bonnet joints.

Insulation shall be continuous through floors, walls, pipe supports, anchors, guides and hangers. The insulation
shall be sealed at all interruptions due to hangers etc. and the cladding shall be flashed and sealed to make it
weather tight.

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 Owner’s Requirements

Outdoor clad flat horizontal surfaces shall be cambered to shed water. Cladding shall be designed to prevent
ingress of water and dirt. For indoor or covered applications removable insulation blankets are preferred for
flanges, valves, strainers and in-line instruments.

Equipment nameplates mounted on brackets, extending from the body shall be framed in with the insulation so
as to leave them exposed for ready identification.

Unless otherwise agreed by the Owner, insulation shall be installed only after the completion of any hydrostatic
testing of the pipework system or equipment has been completed.

AM039100-300-SPE-0001, Rev J Page 108