Professional Documents
Culture Documents
Development Board
Tender Documents
Part B
Technical Requirements
Volume 1 of 2
1
B0 General Specification
0.2.2.3.1 General
0.2.2.3.2 Rainfall
0.2.2.3.4 Earthquake
0.2.2.3.5 Wind
0.2.3 Layout
0.2.4 Configuration
0.2.8 Fuel
2
0.2.9 Waste and waste water
0.3.1 General
0.3.3.1 General
0.3.3.2 Mechanical
0.3.3.4 Civil
0.3.5 Documentation
0.3.5.1 Documentation with Tender
0.3.8.3 Consumables
0.3.10 Options
0.3.10.1 Option: Later realization of Power Unit 3
0.4 Interfaces
0.4.1 Limits of supply
3
0.4.2 Interfaces to existing facilities on site
0.4.3 Metering
0.6.6 Vibration
0.6.7 Standardization of makes
0.6.8 Accessibility
0.6.9 Signs
0.6.14 Materials
4
0.6.16.2.6 Cleaning at site
0.6.16.6 Insulation
0.6.17.1 Standards
5
0.6.17.9 Requirements for local cubicles and local
housings for e.g. switchgear, control,
measurement and signaling equipment
0.6.17.14.4 DC motors
0.6.17.14.5 Painting
0.6.18.5 Tests
6
0.6. 18.6.5 Analyses measurements
0.6.18.6. 12 Actuators
0.7.1 General
0.7.1.1 Workshop manufacturing and pre-assembly
0.7.2.3.1 Welding
7
0.7.2.4 Mechanical equipment
8
Table of Contents of the Tender Documents, Part B
• Section B2: Steam Turbine Plant with Condensate and Steam System
• Section B3: Coal Handling System
• Section B4: Air and Flue Gas System
• Section B5: Ash Handling System
• Section B6: Water Storage and Treatment Systems
• Section B7: Auxiliary Systems
9
General Specification
10
B0. General Specification
0.1 Subject of Specification
This section forms an integral part of the Tender Documents issued by the
Bangladesh Power Development Board, Dhaka.
0.2 General Auxiliary Systems
All the auxiliary systems needed for the trouble-free operation of the unit
have to be designed accordingly.
This list is not limited to the systems below, but the contractor has to
supply, erect and commission all the general auxiliaries necessary for the
operation of the unit at M.C.R:
The Plant shall be coal fired and equipped with reheater and all auxiliary
and ancillary systems.
The Contractor shall cover all works for the Engineering, procurement,
construction and commissioning of the whole Plant on a turnkey basis.
11
The equipment of the Plant shall be designed in accordance with the re-
quirements contained in the Tender Documents and as illustrated on the
Tender Drawings attached.
The site is located about 1 km north of the coal mine mouth under construc-
tion.
The only large industrial area nearby is this coal mine including its
residential complexes.
12
The Maddhapara Hard Rock Mining Project, a separate large scale indus-
trial project is located 12 km east of the site.
The closest airport to site is Saidpur. It takes about 1 hour by car from site
to the airport. The airport is in operation now.
The bottom ash from the boiler and the fly ash from boiler &electrical
precipitator shall be dumped in a pond on site. These ashes shall be
transported wet and during the dry time of the year the ash shall be wetened
by water. The water leaving the pond shall be treated in such a way that it will
be suitable for irrigation or for pumping away to the nearby river Tillay.
Loads probably more than 150 t will need to be transported for the Power
Plant. A scheme that the Contractor of the Power Plant may consider
most feasible would be to transport the equipment by river upto nearest
possible location and then to transport by rail or road.
The Contractor shall fix up the transportation possibilities in detail for the
tender.
13
0.2.2.3 Meteorological condition
0.2.2.3.1 General
0.2.2.3.2 Rainfall
Rainfall from May through September contributes over 85% of the annual
total. However, rainfall intensives tend to be high and concentrated in a
comparatively small number of heavy storms, even when monthly rainfall
figures are relatively low. The monthly precipitation data are as follows (in
mm):
Average in Average in Peak Maximum
Dinajpur Rangpur at one day per month
January 11 6
February 13 15
March 16 27
April 70 110
May 241 307 85 307
June 297 499 140 700
July 592 660 142 640
August 442 430 132 442
September 307 412 431 890
October 144 120 104 242
November 7 7
December 16 17
Annual 2,008 2,812
Note: Above mentioned data are very old, probably in the period of 1981- 1988
14
0.2.2.3.3 Temperature and humidity
Dinajpur Rangpur
0.2.2.3.4 Wind
15
Monthly average prevailing wind speed (knots and direction/1knot = 0.514 m/s)
Rangpur (1979-1988)
YEAR JAN FED MAR APL MAY JUN JUL AUG SEP OCT NOV
SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD
1979 3 N S N 6 NNW 5 S 3 S 5 SE 4 SE 5 SE 5 S 3 N 3 N 3
1980 4 W 4 NE 4 E 3 E 4 E 4 SE 4 SE 4 SE 3 S 4 NE 3 NE 2
1981 4 NE 3 S S W 5 NE 3 E 3 S n.a. n.a. n.a. n.a. n.a. n.a. 3 W 4 NE 4
1982 4 W 5 W S W 4 E 4 E 4 E 4 SE 5 SE 3 NE 4 NE 4 NE 4
19&3 4 NE 4 W 6 W 7 W 4 E 4 SE 4 SE 3 SE 4 E 4 NE 4 NE 3
1984 4 NE 4 W S S 4 E 4 E 5 E 5 S 6 SE 5 S 5 S 5 NE 5
1985 5 NE 4 NE 6 E 5 E 6 E 5 SE 5 SE 6 SE 5 SE 4 E 5 NE 4
1986 5 NNE S w 7 W 6 E 5 E 5 E 5 E 5 SE 1 E 5 NE 5 E 4
1987 4 NE 4 NE S NE 6 E 5 SE 4 E 5 SE 5 SE 4 E 4 E 4 NE 4
1988 4 NE 5 E 4 E 6 E 6 E 7 E 4 SE 5 SE 4 S 5 NE 5 NE 4
16
Monthly average prevailing wind speed (knots and direction/1 knot = 0.514 m/s)
YEAR JAN FEU MAR APR' MA\' IUN JUL AUG SEP ocr NO\'
SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD DIR SPD
1981 6 NW 7 NW 8 W 8 NE 7 NE 6 NE 6 NE 6 NE 3 E 2 W 2 N 5
1982 3 NW 4 W 3 W 3 E 3 E 3 E 2 SE 3 E 2 E 2 NE 2 W 2
1983 2 NW 3 W 4 W 5 E 3 E 2 E 2 S 3 SE 3 E 3 E 2 NE 2
1984 2 W 4 W 4 W 3 E 3 E 3 E 2 E 3 E 2 SE 2 E 2 NE 2
1985 3 W 3 W 5 W 3 E 3 E 2 E 2 E 3 E 2 E 3 E 2 NE 2
1986 2 W 3 W 5 W 3 E 3 E 3 E 3 E 2 SE 2 E 2 E 2 E 2
1987 2 W 3 W 3 E 3 E 2 E 2 E 3 E 4 E 2 E 2 E 2 NE 2
1988 2 W 2 W 4 W 3 E 2 E 3 E 2 S 2 S 2 S 2 NE 3 NE 2
17
0.2.2.3.5 Earthquake
General
Bangladesh is historically less affected by earthquakes. During the last some one
hundred years widespread damages were caused by only the Great Earthquake
of 1897 which had its epicentral tract in the Shillong plateau. Two other major
earthquakes, the Bengal Earthquake of 1885 and Srimangal Earthquake of 1918
caused severe damages only in limited areas surrounding their epicenters. The
present geological information does not indicate existence of seismically active
faults within the country. However, north and east of Bangladesh, there are areas
of high seismic activity in India and Myanmar and earthquakes originating in
these areas affect adjacent regions of Bangladesh.
Seismic zoning map
The main aim of the code for earthquake resistant design of structures is to
ensure that structures are able to respond to shocks of moderate intensities
without structural damage. This code is meant only for normal buildings with
height no more than 200 ft. In case of taller building, a dynamic analysis must be
performed, with the ground acceleration inputs appropriate for the probable
maximum intensity for particular zone. According to this code, the shear force at
the base of a building is given by the following formula:
v = Z.I.K.C.S. W
Where Z : Basic horizontal seismic coefficient (0.06 for Zone II)
I : Importance factor
(1.5 for important facilities, 1.0 for others).
K : Structural system factor
(varies 0.67 - 1.33 according to structural systems).
C : Structure flexibility factor
(varies 0.20 - 1.0 according to the fundamental
time period of a building)
S : Soil foundation factor
(varies 1.0 - 1.5 according to the combination of soil
type and foundation type)
w : Design vertical load
18
0.2.2.3.6 Flood water level condition
The elevation of the site area is geodetically higher than the other parts of
Bangladesh. Therefore, the flood damage is "less" than that of the other regions.
According to the resident in the vicinity of the site area, the maximum flood level
in 1988 was less than one meter above the ground level of that time.
Accordingly, during construction of unit no. 1 & 2 the Plant area was filled approx.
2 m high from that ground level to protect the Plant facilities from the flood. For
the flood protection, the railway is situated on an embankment which is 1.5 m to
2.0 higher than the ground level.
Therefore major earthfilling is not required. However if ground level of any area of
the proposed plant is found lower, it shall have to be filled up to the level of
existing plant. Underground piping and cabling shall be installed in waterproof
ducts which shall be equipped with lighting and fire alarms and which shall be
accessible for the maintenance staff.
Geological conditions
The stratigraphical sequence has been divided on purely litho logical grounds
into the following groups:
Dasement (Pre-Cambrian)
The outline of Madhupur Clay and Dupi Tila Formation are as follow:
a) Madhupur clay
The Madhupur Clay formation was found across the entire site beneath a thin soil
horizon. It varies in thickness between 3 and 15 m, but is generally 10-12 m in
thickness. Lithologically, the fonnation comprises series of firm and stiff silty clays
interlaminated and interbedded with silts and siIty sands. The silt and sand
horizons increase in frequency to the base of the formation. The geotechnical
and hydrogeological characteristics of Madhupur clay are summarized as follows:
19
Shear strength of Madhupur clay
Dupi Tila formation is divided into two groups, the upper and the lower.
The upper Dupi Tila formation is dominated by sands between 94 m and 120 m
in thickness. The lower Dupi Tila formation, which is dominated by clays, is
located In the southern part of the coal deposit area and not present in the power
Plant site.
The upper Dupi Tila formation, with the average thickness of 107 m is divisible
into two main units:
The upper unit: average 65 m in thickness, of micaceous gray sands and gravels
with occasional bands of silt and clay. The lower unit; approximately 40 m in
thickness, of orangebrown, slightly micaceous sandstone, generally finer than the
upper unit with more frequent thin beds of slit and clay.
• These tests were carried out on undisturbed samples of cohesive materials such as silt or
clayey silt of the Upper Dupi Tila formation.
20
Permeability
No permeability test has been carried out for this formation. However, the
permeability of this formation is considered larger than that of Madhupur Clay,
judging from its soil composition.
pH: 7.2
Topographic conditions
The project area in Dinajpur district, between Phulbari and Parbatipur is situated
in the deltaic plain of the Jamuna and Padma Rivers. It is flat and its altitude is
about 30 m above mean sea level, which is relatively higher than the other areas
of Bangladesh.
0.2.3 Layouts
The plant area shall be developed upto existing plant level (if required). The ash
pond shall be lowered below the natural ground for about 3 m and shall be
provided with bud walls up to + 5 m above the natural ground. The park area
shall remain at about natural ground level with the exception of the outfall canal.
0.2.4 Configuration
One coal fired boiler with turbine generators represent the core components of
the Plant.
The design lifetime of the Plant shall exceed 200,000 operating hours.
21
Redundancy concept
0.2.5.3 Civil
The area of the Power Station for protection against flooding is considered to be
22
filled up to the existing plant level (if required) to protect the Power Plant against
the flood.
The coal storage area shall be paved. drained and partly covered. The drain shall
be discharged to the ash pond. The ash pond shall be excavated. fertile soil to be
stored aside and the pond shall be lined with clay. The ash pond overflow shall
be treated to meet the relevant standards and shall lead via outfall canal to the
Tillay river. Try ash storage shall be considered as an option.
The ash pond and the park shall be separated from each other and the Plant by
fences and gates.
All the equipment and the facilities shall be suitable for safe and economical
continuous and also for short-time operation under the extreme ambient air.
water and coal conditions specified.
The design of the Plant shall be based on the following operation and dispatching
requirements:
a) The power unit shall be capable of following the daily and seasonal demand
profile of the electrical network.
b) The power generation shall be fully dispatch able within the technical limits
of the Plant to be specified by the Tenderer, but at least between 40% and
100% of the net power output of the Plant without supporting fire.
c) Full compliance with the conditions of the admissible air pollution is required
within 40 - 100% of power unit's power range.
a) Atmospheric quality
There are no industrial activities to pollute air within a radius of 10 km from the
planned Power Station site (except existing 2 x 125 MW coal fired units). Though
there are effects of automobile, etc. emission and smoke generated by burning
after harvesting and from houses, the air pollutant concentration is expected to
be at a very low level.
b) Water quality
As prospective raw water sources, Coal mine discharge water (for normal use)
and wells (during emergency case to meet at least 50% of total requirement) are
considered. Water quality is given in Annex.
23
c) Soil quality
The study team collected the soil (in the year 1998) from the site for analysis
and the results are as follows:
The standard values are given in Annexes. The standard values for effluent are also
given in Annexes.
24
0.2.8 Fuel
0.2.8.1 Characteristic of coal
These data should be compared with new data which will be analyzed by the coal
mine and examined by the personnel of the Power Plant. After having further
investigation on the Barapukuria coal, the coal analysis data for the planning of the
boilers at the Owner/Owner's Representativeing stages should be finalized.
At the time being the proximate analysis (average characteristics of whole seam) is
as follows:
Carbon 83.0%
Hydrogen 5.1%
Oxygen 9.4%
Nitrogen 1.7%
Sulfur 0.77%
99.97%
25
0.2.8.2 Ash
At the time being the following ash analysis (oxides in ash dry basis) (mean % of
whole seam) is available:
Si02 54.4%
AI2O) 35.6%
Fe203 2.9%
Ti02 3.2%
Mn304 0.11%
eaO 0.56%
K20 0.66%
Na20 0.06%
MgO 0.18%
P20S 0.46%
SO3 0.13%
Water supply of the Power Plant will be covered by Coal mine discharge water
(for normal use) and deep tube well water (during emergency case to meet at least
50% of total requirement). To cope with the water requirements of Power Plant
consumers it is necessary to install water treatment and storage facilities. The
design of the storage facilities shall consider especially start-up and routine
maintenance periods in the Power Plant and water treatment plant.
The waste water from the ash pond shall be discharged to the Tillay river. The
water which will be discharged to the Tillay river shall be treated also. This water
shall be suitable to be used in the park for fountains as well as for irrigation
purposes.
26
0.3 Supply and Services
0.3.2 General
The scope of this Tender Specification covers all supplies and services required
for meeting the purpose of the complete Plant, even if these are not expressively
mentioned in the following.
The works include the following main components, where the detailed scope of
supply shall be seen in the corresponding sections as listed below:
All services shall be performed by the Contractor to effect the required permits to
commence the works and operate the Plant, including but not limited to:
27
All fees required due to a split-up into multiple applications shall be covered by
the Contractor.
0.3.3.1 General
• material and personnel costs (e.g. for testing authority staff, BPDB and if
necessary also Owner/Owner's Representative's staff) for tests and in-
spections which are mandated by legislation
• material costs for site inspections
• declaration of conformity with Bangladesh requirements and markings for
all machines
• Owner/Owner's Representativeing design of complete supplied equipment
including interface coordination
• all as-built documents (on data carriers; data formats as requested by the
Owner/Owner' s Representative)
• quality control plan and safety plan
• complete documentation as set out in the tender specification
• operating and maintenance manual in summary form (8 copies),
O&M manual
• detailed operating and maintenance instructions (8 copies)
• a maintenance program including a well proven maintenance management
system for track keeping of all maintenance for all systems and equipment
of the Plant.
0.3.3.2 Mechanical
28
• all temporary pipework as required during connection measures
• check of required existing structures, plant components and systems and
their rehabilitation where they lie within the scope of supply, or definition of
required measures in good time if they lie outside of the scope of supply
• all support structures, hangers etc.
• all base frames, mounting plates, grouted in parts, rag bolts, covers, etc.
• all required steel parts embedded in concrete
• all couplings and coupling guards for electric motors and other drives
• all lifting equipment and hoists (for repair work where loads exceed 50 kg)
(cranes, hoists, monorails, etc.), electrically operated if lifting or lowering
heights exceed 8 m
• required safety equipment, pressure relief valves, etc.
• all thermal and noise insulation including cladding as well as any other noise
attenuation measures
• stairways, ladders, platforms, galleries and walkways to all plant compo-
nents, including escape routes as necessary
• all necessary steel structures, stairs, ladders on platforms weather protec-
tion
• all required ventilation or air conditioning equipment for safe operation of
mechanical and electrical equipment, to be supplied
• all necessary corrosion protection measures for plant components and
equipment stored or mounted on site up to the time of reliability test run
• complete primer and top coatings conforming to color code, clarified with
the Owner/Owner's Representative/Owner/Owner's Representative
• noise abatements measures
• all corrosion protection and electric trace heating for outdoor installations
(e.g. gas ducts, etc.)
• complete labeling of all plant components according to the Owner/Owner's
Representatives system and in plain language (English and Bangla) and
Power Plant Classification System Coding (PPCS)
• all fire protection measures
• all lubrication systems
• initial lubricant filling and sufficient lubricants for commissioning and reliability
test run, minimization of lubricant types by screening and coordination with
the Owner/Owner's Representative, up to Provisional Taking Over of the
relevant Unit
• provision of all connections and temporary pipe work for steam purging of the
live steam line
• flushing of all other lines including disposal of the effluents; protection with
29
wood and/or plastic at all instrumentation and appendages to be installed
during construction
• all standard accessories and auxiliary equipment which normally form part of
the scope of supplies
• all tests, inspections and works acceptances as well as all certificates and
reports of these
• exchange of filter elements following reliability test run up to Provisional
Taking Over of the relevant Unit
• valve trims for purging and subsequent exchange
• removal of any unused material from site
• scaffolding for all work aboveground level
• insurances.
In general, the Power Plant shall be started up, operated and switched down
from the DCS.
The electrical instrumentation and control plant mainly, but not limited to, shall
consist of:
0.3.3.4 Civil
• Soil investigations
30
• all necessary surveying works
• preparation of site, demolition works, removal of underground obstacles, if
any
• site fill
• earthworks, drainage, excavation and refilling works
• roads and pavement
• concrete and reinforced concrete works, masonry and earthing
• water proofing works for pressing and non-pressing water
• fire protection during construction
• roofing (non asbestos)
• plumbing
• facade works/glazing works; non asbestos
• non-load bearing walls/installation partitions/dry construction works
• metalwork and blacksmith work/raised flooring/doors and gates/sheet
metalwork
• flooring work
• fire protection with plumbing; fire protector
• corrosion protection
• crane way works
• air conditioning systems
• potable water, service water and waste water, sewage water, storm water
(permanent and during construction), etc.
• housekeeping during construction.(at least once a week total)
• staff facilities during construction
• Owner/Owner's Representatives office
• transport of all dumping material to dump locations (at least once a week
total)
• interpretation of soil bearing test
• temporary fencing of construction site
• permanent wall and fencing with security road
31
• disposal of packing and transportation material
• customs clearance
• crane or hoisting facilities at seaport, railway, road and site
• transportation to site
• unloading at site
• transportation to the place of installation.
0.3.5 Documentation
0.3.5.1 Documentation with Tender
General
32
• lists of spare parts for warranty period, lists of spare parts for LTSA
period
• spare part storage and supply policy
• mobilization and demobilization schedule for construction equipment
• method of transportation and unloading heavy cargo
Mechanical
Generator
Boiler
• tentative start-up diagrams for cold start, warm start and hot start
• material diagram showing material, dimensions, highest exhaust gas
temperature and highest steam temperature, design material temperature
and maximum admissible material temperature and design pressure for
components of the steam/water system
• change of exhaust gas temperatures over load
• variation of steam temperatures over the heating surfaces, stating ma-
terials employed
Electrical system
• control system architecture showing all components provided for this Power
34
Plant in their structural arrangement
• description of philosophy of the DCS with reference to
• availability
• redundancy concept
• description of burner management and boiler protection system including
information about redundancy concept .
• list of all subcontractors
• reference list for the DCS with indication of plant type, system architecture
and size of the system
• list of package system (black boxes)
Civil
• architectural outline drawings for all buildings and building structures showing
the arrangement of the complete plans, inclusive of all levels and sections
• site plan of the complete plant showing all buildings, building elements, roads,
landscaping etc .
• schematic design of building
Maintenance
For boiler with accessories, steam turbine, generator and the total scope of supply
maintenance and overhaul charts should be submitted. Both major and minor plant
outages for inspection and/ or routine maintenance should be shown on the chart,
together with the nature of the work to be undertaken and the expected duration of
the outage. This information should also include all the auxiliary plant to be supplied
under the Contract.
Only the most important documents are listed below. These documents shall be
submitted sufficiently in advance for approval before award of relevant order, so
that corrections and amendments desired by the Owner/Owner's Representative
as well as resubmission of the documents will not result in any delays with
respect to the guaranteed time table. The Owner/Owner's Representative
reserves the right to request from the Contractor additional drawings, documents,
etc. as may be required for proper understanding and definition of the design and
Owner/Owner's Representativeing of the Plant.
General
35
• erection and installation progress reports (to be updated every month)
• list of subcontractors/manufacturers for approval before purchasing
• proposed inspection and testing programs for approval
• detailed program for commissioning for approval
• testing documents/report of results of all tests for approval
• training program for approval
• operating and maintenance manual with description and instructions for all
equipment and facilities (first issue 3 months before start of commissioning
and second issue before trial run (2 weeks) - OMM for approval
• as-built-documentation including drawings of all equipment
• declaration of conformance with Bangladesh regulations
• spare part lists for approval
36
• sectional and detail drawings of all components
• for all lifting operations (repair, maintenance, etc.) a lifting plan has to be
submitted by the Contractor
• limits of coal and fuel oil properties
37
required)
• arrangement drawings of all electrical equipment
• line plans of fire alarm system if applicable
• arrangement drawings showing exact location of fire alarm devices if
applicable
• power and lighting installation plans
• earthing and lightning protection plans and calculations
• general arrangement drawings of the required cable trays, cable laying plans
• dimensioned drawings and erection drawings for generator, transformers,
switchgear, control panels, etc., including frontal and plan views
• dimensioned drawings of generator auxiliary equipment
• dimensioned drawings of switching cubicles, generator and star point
cubicles, voltage regulation cubicles, excitation cubicles etc., including
equipment configurations
• calculation of mechanical stresses of switchgear rooms due to arcing faults
• short circuit calculation and determination of protection relay settings for
generator protection and auxiliary electrical supplies under consideration
of protection of the entire system .
• overall protection and metering diagrams for the whole protection equipment
• generator charts and exciter characteristics
Contractor will use Construction Power from the existing 33 kV substation. All
arrangements shall have to be done by Contractor.
• list of subcontractors
• list of the overall- I&C equipment
• list of spar parts
• list of "black box" systems with indication of control systems to be used
• schedule of workshop tests
• manufacturer documents (manual, descriptions, etc.) for all I&C components
• manuals for third party computer software
• set of all relevant standard specifications to which the equipment is
manufactured
• list of instruments including code, measuring range, alarm and limit values,
reference drawings
• instrument location plans
38
• instrument hook-up drawings
• list of control valves including operating and design data, materials, makes,
types and reference drawings .
• calculations for control valves, orifices, nozzles, etc.
• Owner/Owner's Representativeing drawings of control valves (including
actuators), control dampers (including actuators), orifices, nozzles, venturi
nozzles
• diagram of control system architecture showing all components provided for
this Power Plant in their structural arrangement
• lists of I/O point assignment
• list of alarms including settings
• program listings for all application programs
• logic diagrams
• description for all functional group controls
• description for all closed loop circuits
• description for all safety and protection circuits
• instrument loop diagrams
• typical cabling diagram showing all cable connections in a typical manner
• cable list including cable coding
• cable routing plans
• interior arrangement drawings of all cubicles
• wiring and terminal diagrams for the entire I&C equipment
• arrangement drawings of central and local control/electronic rooms
• mimic diagrams for control panels and desks
• detailed dimensions of panels, desks and cubicles
• list of recorders
• graphic displays for monitors of options.
• general site plan of the entire site showing all buildings and installations,
traffic routes and landscaping etc.
• architectural arrangement drawings, design layouts and itemized drawings
(plans and sections) to scale 1: 1 00 of all buildings and plants
• views of all sides of all buildings, scale 1: 100
• architectural drawings of each floor (plants, sections) including all necessary
detail drawings, scale 1 :50
• arrangement drawings of the external plants of the site as a whole (existing,
planned) with all supply and disposal facilities, roads and vehicle access and
maneuvering areas, sewers, channels and culverts etc.
39
• detailed constructive description of the single building with regard to the
structural design (structural systems, foundations etc.
• detailed specification of the buildings including information on materials and
qualities for execution
• sectional elevations and roof plan
• floating floors/systems
• underground services and ducts with equipment appertaining to the services
• layout of roads
• principal details and sections for traffic areas, especially for ramps and
retaining walls
• layouts for external works showing plants and fencing etc.
• diagrams for ventilations
• diagrams for supply systems of all buildings
• schematic details for plumbing
• structural drawings pertaining to outlet and inlet water channels and tie-in to
existing channels
• foundations and other underground concrete works for the transformer area
• civil drawings of roads and if applicable for up rated bridge over cooling water
outlet channel.
40
• Handbook of the computer program -
• language for managerial activities
41
4
• Maintenance assembly and adjustment
drawings - before provisional
taking over
at provisional
• As-built drawings - taking over
Unless agreed otherwise, six (6) hard copies and three (3) sets of electronic copies
of all documents are to be submitted in English language for approval.
There shall be no installation and/or any commissioning activity without the relevant
documentation approved by the Owner/Owner's Representative.
Diagrammatic symbols complying with IEC 27, 34, 37 and 117 are to be used for
selling out the circuit and terminal layout.
In addition, the Contractor shall train the Owner's fire fighting personnel on the
premises/training centre of the subcontractor for the fire fighting equipment.
The contract price shall include the following expense for twenty one (21)
persons delegated by the Owner for total 100 person month:
• the cost of return air tickets (economy class) from Bangladesh to the country
where the plant/fire fighting training centre is located
• the cost of local transportation during the entire period
• the cost of full board accommodation
• the cost of special insurance as may be required
• daily allowance at the rate of one hundred (100) US$.
43
0.3.8 Spare parts, tools, appliances, and consumable
0.3.8.1 Spare parts
All items shown in these schedules shall form part of the contract price and the
Owner/Owner's Representative may order all or any of the parts at his discretion
and adjust the contract price accordingly.
All spare parts required for testing of the Plant according to "Inspection and
Testing" and for all action before Provisional Taking Over Certificate form part of
the principal scope of supply and are not to be included in the spare parts list.
They shall be included in the scope of the relevant machinery without pricing, it
means for the time of commissioning, the trial operation and provisional take-
over.
All spare parts required for warranty period (24 months) shall be supplied by the
Contractor.
Major items of spare parts must be priced individually but minor items can be
grouped together. The spare part shall be offered on separate price sheets.
Each item shall be labeled in BangIa and English as well as with PPCS coding
system and be separately packed against damage and sealed to prevent
deterioration from corrosion in a dry weatherproof building.
The spare parts shall be placed in bins, racks, drawers, shelves, cabinets, etc. to
be provided by the Contractor.
The Contractor shall not use any of the spare parts without written permission
from the Owner/Owner's Representative. The Contractor shall deliver the spare
parts for a 24-h-MCR-operation period of five (05) years LTSA. The stores shall
be suitable for these conditions.
The following tools and appliances shall be supplied under this Contract for use
by the Owner/Owner's Representative: ..
a) two sets of special tools and gauges required for the maintenance c1f the Plant
b) one set of special lifting and handling appliances required for the
44
maintenance of the Plant.
Each tool or appliance is to be clearly marked with its size and/or purpose.
The tools and appliances supplied shall not be used for erection purposes by the
Contractor and shall be handed over in brand new condition.
The exception to this is the special lifting gear which may be used provided that
when it is handed over to the Owner/Owner's Representative it has not been
subjected to more than normal wear and is still fully suitable for its intended use.
Each set of tools and appliances under category (a) shall be suitably arranged in
fitted boxes of mild steel construction, the number of boxes being determined in
relation to the layout of the plant and equipment in question. If the weight of any
box and its contents should be such that it cannot conveniently be carried, it shall
be supported on steerable rubber-tyred wheels.
Each cabinet and box shall be painted, fitted with a lock and clearly marked in
white letters with the name of the item of equipment for which the tools and
appliances contained are intended.
Suitable storage racks shall be provided for all portable lifting tackle in this
contract.
Suitable lifting lugs, ears or ring bolts, or tapped holes for lifting rings shall be
provided on all equipment items where the weight exceeds 15 kg.
All lifting tackle shall be stamped with a unique identification number and safe
working load. A test certificate from an approved Authority shall be supplied for
each item of lifting tackle.
The Contractor shall provide a schedule of all lifting tackle and tools and
appliances being supplied, for the approval of the Owner/Owner's
Representative.
The Contractor shall provide all runway beams, trolleys, lifting blocks, special
slings etc. necessary for the safe and efficient handling and maintenance of the
works. Particular attention shall be paid to high level equipment such as
deaerator. Electrically operated hoists and runway trolleys shall be provided for
all lifts in excess of 2.5 tons.
The tools and appliances with the appropriate storage racks, cabinets and boxes
shall be handed over to the Owner/Owner's Representative at the time of taking
over.
Where the Contract includes site erection, any special tools or appliances
required solely for erection shall be provided by the Contractor for his own use
and shall remain the property of the Contractor.
0.3.8.3 Consumables
All lubricants proposed for the Plant operation shall be suitable for all operating
45
and environmental conditions that will be met on site.
All oils and greases shall where possible be readily available in the country of
installation.
The number of oils and greases shall be kept to a minimum. For each type and
grade of lubricant recommended the Contractor shall list at least three equivalent
lubricants manufactured by alternative companies.
The Contractor shall supply the first fill of lubricants for the Plant, and shall
provide at the provisional Taking Over sufficient lubricants and greases
necessary for the efficient operation and maintenance of the Plant at full load 24
hours per day for a period of 24 months (Warranty period).
The Contractor shall also supply lubricants and greases necessary for the
efficient operation and maintenance of the Plant at full load 24 hours per day for
05 years LTSA period after final take over.
The contract includes the provision of all chemicals, reagents, resins, and other
consumables required for testing, commissioning and setting to work of each
section of the Works.
The Contractor shall provide all chemicals, and other consumables required for
the efficient operation and maintenance of the plant at full load 24 hours per day
for a period of 24 months for each section of the works from the date of the
provisional Taking Over.
The Contractor shall deliver to site sufficient quantities of consumables in his supply
to allow for running of the Works prior to the issue of the Temporary Taking Over
Certificate. The delivery of the remainder of the consumables shall be programmed
to suit the operational requirements and space availability within the various stores.
The Contractor shall also provide all chemicals, and other consumables required
for the efficient operation and maintenance of the plant at full load 24 hours per
day for 05 years LTSA period after final take over.
Deleted
0.3.10 Options
Deleted
46
0.4 Interfaces
The interfaces for the Plant shall be as follows; all mentioned equipment,
connections, connection materials, counter flanges, shut-off valves, safety valves
are included in the scope of supply:
• fuel Interface with the coal conveyor of existing
2x125 MW plant.
One separate coal conveyor belt with 02
nos. of coal crusher unit from the upstream
of existing coal crusher unit upto new coal
yard shall have to be installed by modifying
coal conveyor system.
Another coal conveyor belt shall have to be
installed from new coal yard to old coal
yard.
One coal processing Plant (Sorter machine)
shall have to be installed at the down
stream of Weighing scale of Coal mine by
modifying coal conveyor system.
• 230 kV switchyard Interface with BPDB existing substation.
Auxiliaries:
• auxiliary switchgear busbars (400 V, DC
system and safe AC system) for future
extension by the required number of
feeders
• terminal cubicles of status and protection
signals for extension and interfacing of
signals of future diameter extensions
• instrumentation and Interface with 230 kV public grid:
control For SCADA data exchange V24/28
interface at switchyard and (control room).
For protection and telephony at terminal
racks within 230 kV switchyard control
building
• communication PABX cubicle within Power Plant control
systems building
• raw water, potable Coal mine discharge water will be the
industrial, cooling source of raw water, potable industrial,
water cooling water. Proper chemical treatment is
required. Deep well water will be used as
backup. Deep wells having capacity 50% of
47
required quantity shall have to be installed.
Interface with Coal mine discharge water
and interconnection with existing deep well
system are required.
0.4.3 Metering
The accuracy and signal interface requirements for metering devices shall be
according to the Metering Code (which will be submitted by the Owner/Owner's
Representative during contract execution).
CCTV shall be interfaced to the Power Plant's fire alarm system. CCTV shall be
provided with standard interfaces like RS-485/RS-232/ V-14/V-11.
48
0.5 Formsheets (Data Sheets)
Guarantees B0/FG-1 to 14
49
BPDB. Barapukuria Power Plant 250 MW Bidder/Contractor
Section B0: General Specification
Declaration by Bidder
Declaration by Bidder
for
BPDB. Barapukurla Power Plant
It is hereby confirmed that this Bid complies in full with
the Tender Document. Deviations are listed in detail in
the appended data sheet B0/FA. Should this Bid be
successful, beside the offered and agreed deviations
all of the conditions and stipulations of the Invitation
for Bid for 250 MW Barapukuria Coal Fired Power
Station Project will be accepted.
Bidder: ____________________________
__________________________
Stamp and Signature of Bidder:
B0/F-1
50
BPDB, Barapukuria Power Plant 250 MW Bidder/Contractor
'.
B0/FA-1
51
BPDB, Barapukuria Power Plant 250 MW Bidder/Contractor
Section B0: General. Specification
Design Data - List of Major Equipment and Service
Unit Data
Suppliers
• Steam generator
• Steam turbine
• Construction
• Maintenance
• Civil Contractor -
• Compressor Station
• Emergency diesel
B0/FD-1
52
Guarantee Schedule
Net Heat Rate: kJ/ kWh at 100% Load at 75% Load at 50% Load
Net heat rate based on net calorific value of fuel at (H100% ) (H75%) (H50%)
0
site condition (35 C, 1.013 bar, 98% RH)
Definition of “Net Power Output” and “Net Heat Rate” are mentioned in General condition,
Tender Document Part A.
B0/FG-1
53
BPDB, Barapukuria Power Plant 250 MW Minimum Requirements
General Guarantees
B0/FG-2
54
BPDB, Barapukuria Power Plant 250 MW Minimum Requirements
Constant steam temperature turndown range for the %of MCR 60 -100
superheater
Constant steam temperature turndown range for the
% of MCR 70 -100
reheater
B0/FG-3
55
BPDB, Barapukuria Power Plant 250 MW Minimum Requirements
Section B0: General Specification
Guarantees, to be completed by the Bidder Unit Data
Guarantee Conditions
Fuel coal net calorific value (LHV) kJ/kg 23,500
Fuel coal Gross calorific value (HHV) kJ/kg 25,560
Ambient air temperature (dry bulb) °C 26
Relative humidity % 70
Power factor - 0.85
Maximum temperature rise in generator windings
-
according to IEC 34.1, Class B
Correction curves for deviations in operating -
conditions, drwg. Nos
Electrostatic precipitator efficiency on the
% 99.5
basis of the specified coal
Condition A: Maximum Continuous Rating
Live steam flow kg/s
Live steam pressure at boiler outlet bar
Live steam temperature at boiler outlet °C
Reheat steam temperature at boiler outlet °C
Cooling water flow kg/s
Cooling water temperature at cooling tower outlet °C
Gross output (at generator termional) MW
Gross specific heat consumption (qgrA) kJ/kWh
Swallowing capacity at steam turbine kg/s
(100% live steam pressure)
Condition B: 75% Load Operation
Live steam flow kg/s
Live steam pressure at boiler outlet bar
Live steam temperature at boiler outlet °C
Reheat steam temperature at boiler outlet °C
Gross output (at generator termional) MW
Gross specific heat consumption (qgrA) kJ/kWh
B0/FG-4
56
BPDB, Barapukuria Power Plant 250 MW Minimum Requirements
Section B0: General Specification
Guarantees, to be completed by the Bidder Unit Data
B0/FG-5
57
BPDB, Barapukuria Power Plant 250 MW Minimum Requirements
Drop in steam turbine condenser vacuum at closed air mbar/min less than 1.5
suction I mbar/min valves at pure condensing operation
Boiler running time between inspections
Emissions
At all loads and operating conditions of the steam generator
with coal" firing following emission limits shall not be
exceeded, measured In the chimney:
58
BPDB, Barapukuria Power Plant 250 MW Minimum Requirements
• general h 20,000
• refractory h 8,000
• general h 16,000
Load changes
%of
•load range 50 - 90% ±6
MCR/min
%of
• load range 30 - 100% ±4
MCR/min
• capacity %MCR 35
B0/FG-8
59
BPDB, Barapukuria Power Plant 250 MW Minimum Requirements
Section B0: General Specification
Guarantees Unit Data
Rejection
Further to the stipulations stated in other parts of
the Tender Documents the Owner/Owner's
Representative reserves the right to reject in the
following:
Auxiliary consumption % 10
Starting and loading time % 30
Live steam and reheat steam temperature deviation K 8
Effective vibration velocity mm/s 2.5
B0/FG-9
60
BPDB, Barapukuria Power Plant 250 MW Bidder/Contractor
Section B0: General Specification
Design Data and Guarantees for I&C Equipment Unit Data
For closed loop control systems the quality of control shall be such
that for the load changes specified, not only shall control parameter
overshoot values not exceed the amount specified below but also
that all such overshoot values shall return to the set value in a
sinusoidal manner at a rate of not more than 35% in wave
amplitude for each successive half cycle, giving steady state
conditions after 3 cycles of overshoot.
Definition:
Load variation means change in fuel feed with a maximum rate of
change of 10% live-steam flow per minute. limited to 3 minutes within
the possible load range of the boiler.
Overshoots
a) Live-steam temperature:
constant load K ±4
61
BPDB, Barapukuria Power Plant 250 MW Bidder/Contractor
Section B0: General Specification
Design Data and Guarantees for I&C Equipment Unit Data
c) Reheat steam temperature:
• constant load K ±4
• load variation K ±10
d) Boiler drum level:
• constant load mm ±25
• load variation mm ± 50
e) Boiler furnace pressure:
• constant load mbar ±3
• load variation mbar ±8
f) Combustion oxygen content:
• constant load %O2 ±0.4
load variation %O2 ± 1.0
g) load variation Steam pressure and steam temperature reducing
station HP bypass control
• constant load bar/oC ±1.5/±5
o
• load variation bar/ C ± 3/ ± 10
Under all operating conditions, the noise level of control valves dB(A) 85
shall not exceed measured at one meter distance.
To make sure that the permissible noise level is under no
circumstances exceeded, the requirements in respect of the
pipeline and insulation design to be fulfilled by the piping an
insulation contractor shall be specified by the Contractor with the
tender.
Other control and monitoring systems
The Contractor shall guarantee that the equipment provided is
within the tolerances stated in the specification. The Contractor
shall also guarantee that the equipment carries out in a safe and
efficient manner the task for which it is provided.
The quoted values data shall be guaranteed.
Testing procedures
All components supplied shall be tested in accordance with the
requirements and the individual guarantees and the general
performance of the installation shall be demonstrated at the tests
during erection and the acceptance and performance tests.
B0/FG-11
62
BPDB, Barapukuria Power Plant 250 MW Bidder/Contractor
Section B0: General Specification
Design Data and Guarantees for I&C Equipment Unit Data
Acceptance tests serve to provide evidence of the warranted
performance
63
BPDB, Barapukuria Power Plant 250 MW Bidder/Contractor
Section BO: General Specification
Design Data and Guarantees for I&C Equipment Unit Data
If the main performance data are not fulfilled during the accep-
tance tests, the Contractor shall be obliged as a first measure
to improve the supplied control equipment by suitable control
Owner/Owner's Representativeing measures making full use
of all theoretical and equipment Owner/Owner's
Representativeing possibilities e.g. by
If, after final optimization, the quality of the closed loop control
does not meet the requirements the Contractor shall be
obliged to take the actual transient functions at the plant and to
compute the theoretical possible quality of the control loops
based on the actual data.
Should the plant fail to meet the above guarantees after due
account has been taken of the above specified tolerances, the
plant will be made available to the Contractor so as to allow
the Contractor to make good the plant by modifying or
replacing defective or wrongly designed parts.
If, even after remedial measures have been carried out, the
required guaranteed values are not achieved, then the
client shall be entitled to reject the complete plant or parts
thereof.
B0/FG-13
64
BPDB, Barapukuria Power Plant 250 MW Bidder/ Contractor
Section B0: General Specification
Guarantees Data- Water Storage and Treatment Systems Unit Data
(to be completed by the Bidder)
B0/FG-14
65
BPDB, Barapukuria Power Plant 250 MW Bidder/ Contractor
Section B0: General Specification
Days after
Time Schedule effective Date
Date
Anticipated time schedule
B0/FZ-1
66
Table of Contents
0. xxx
0.1 XXX
0.2 XXX
0.3 XXX
0.4 XXX
0.5 XXX
0.6 General Technical Requirements
67
0.6.16.7 Vessels, tanks, heat exchanger
0.6.17 Electrical equipment and works
0.6.17.1 Standards
0.6.17.2 Standard voltages
0.6.17.3 Climatic conditions
0.6.17.4 Inductive interferences
0.6.17.5 Color code system for switchgear, for local switching
measurement-control-signaling cabinets and for mimic
diagrams
0.6.17.6 Protection class for electrical operational equipment
and control and monitoring equipment
0.6.17.7 Protective measures
0.6.17.8 Auxiliary equipment
0.6.17.9 Requirements for local cubicles and local housings for
e.g. switchgear, control, measurement and signaling
equipment
0.6.17.10 Local control points and level control cabinets
0.6.17.11 Terminal boxes and terminal cabinets
0.6.17 .12 Explosion proof equipment
0.6.17 .13 Keys and key cabinets
0.6.17. I 4 Electric motors
0.6.17.14.1 High voltage motors
0.6.17 .14.2 Low voltage AC motors
0.6.17 .14.3 Actuator drives
0.6.17.14.4 DC motors
0.6.17.14.5 Painting
0.6.17 .14.6 Protection against explosion hazards
0.6.17.14.7 Frequency converters
0.6.17 .14.8 Tests
0.6.17 .14.9 Motor list
0.6.17 .15 Labels
0.6.18 Instrumentation and control
0.6.18.1 Measuring units
0.6.18.2 Sizes of indicators, recorders, etc.
0.6.18.3 Protection and safety interlocks
0.6.18.4 Special local conditions
0.6.18.5 Tests
0.6.18.6 Field equipment
0.6.18.6.1 Measuring systems/transmitters
0.6.18.6.2 Flow measurements
0.6.18.6.3 Temperature measurements
0.6.18.6.4 Pressure measurements
0.6. 18.6.5 Analyses measurements
0.6. 18.6.6 Level measurements
0.6. 18.6.7 Electrical measurements
0.6. 18.6.8 Position measurements
0.6. 18.6.9 Contact devices
0.6.18.6.10 Vibration measurements.
0.6.18.6.11 Control valves
0.6.18.6. 12 Actuators
68
0.6.18.6.13. Local instrumentation
0.6.18.7 Racks, junction boxes
0.6.18.8 Transmitter racks and piping
0.6.18.9 Programmable logic controller
0.6.18.10 Control cubicles
69
0.6 General Technical Requirements
Any changes on the design of any part, of the Plant, which may become necessary
after signing of the Contract have to be submitted by the Contractor in writing to the
Owner/Owner's representative for approval, being sufficiently substantiated and
justified.
The Plant shall be brand new and clean, and designed, manufactured and arranged
so that it will have a functional design and a pleasant appearance. All parts of the
Plant shall be arranged in such a manner as to facilitate surveillance by the operator
and to ease maintenance, operation and control.
The parts of the Plant shall be designed and arranged so that they can be easily
inspected, cleaned, erected and dismantled without necessitating large scale
dismantling of other parts of the plant. They shall be designed, I1lClnufactured and
put into operation in accordance with the latest recognized rules of workmanship,
modern engineering practice and with good standards of prudence applicable to the
international electricity generation industry which would have been expected to
accomplish the desired result at the lowest reasonable cost consistent with reliability,
safety and expedition.
The regulations, standards and guidelines listed in the Specification as well as all
applicable laws and governmental decrees, regulations, orders, etc. shall be
observed in the design, calculation, manufacture, erection, installation, testing,
commissioning and start-up of all parts of the Plant.
The following shall be considered in the design and engineering of the Plant
facilities:
• All parts of the Plant shall be suitable in every respect for continuous operation at
maximum output as well as part loads and expected transient operating
conditions peculiar to the site and shall be able to safely withstand the stresses
arising from the operating conditions without any reduction in its planned life
which shall be at least equal to 200,000 operating hours.
• The Contractor shall familiarize himself with the conditions on site and in the
country, especially with respect to transportation of heavy loads and flood.
70
components (such as pipelines, tanks, etc.) shall be performed automatically or
manually from the control room.
• All live, moving and rotating parts shall be provided with appropriate effective
protection in order to avoid danger to the operating staff. All metal parts shall be
electrically grounded.
• All equipment shall be designed to ensure start-up from any condition, i.e. from
cold, warm or hot condition without necessitating special or preparatory
measures.
The work must be performed according to the most recent relevant codes,
standards, accident prevention regulations and legal regulations.
All materials and equipment supplied and all work carried out as well as calculation
sheets, drawings, quality and Class of goods, methods of inspection, specific design
features of equipment and parts and acceptances of partial plants shall comply in
every respect with the following technical standards, codes and regulations .
• Statutory safety regulations for equipment items (e.g. for noise preventions).
If this standard once is approved, the Contractor has to follow up. No standard mix
will be all owed.
Before starting his works, the Contractor shall deliver those standards in English
language, which will be used on site to the Owner/Owner's representative and
the Engineer.
71
0.6.3 Plant and equipment identification (e.g. Power Plant Coding System KKS)
The Contractor shall apply a plant identification system showing the name and number
of each item of plant and its respective arrangement drawing number and add any
additional items necessary to fully identify the plant. The identification and numbering of
equipment, systems, items, etc. of supply, as well as of all documents and drawings
shall be in accordance with the IDENTlFICA TION system
(KraftwerksJiennzeichnungssystem = Power Plant Coding System PPCS) or equal. The
IDENTIFICATION system is available from
VGB-Kraftwerkstechnik GmbH,
VerIag technisch-wissenschaftlicher Schriften Klinkestrasse 27
- 31,45136 Essen, Germany.
The Contractor shall work with this or any equivalent system that the works me going on
smoothly.
There is to be only one description for anyone item of plant and this must be used
consistently for plant, electrical and instrumentation designations throughout.
The Contractor shall supply all labels, nameplates, instruction and warning plates
necessary for the identification and safe operation of the plant, and all inscriptions shall
be in the English/Bangla languages.
All labels, nameplates, instruction and warning plates shall be securely fixed to items of
plant and equipment with stainless steel rivets, plated self tapping screws or other
approved means. The use of adhesives will not be permitted.
Nameplates for plant and equipment identification and record purposes shall be
manufactured from stainless steel or aluminum with a mat or satin finish, and
engraved with black lettering of a size which is legible from the working position.
All equipment within panels and desks shall be individually identified by satin or mat
finish stainless steel or aluminum labels, or laminated plastic labels where
approved.
Each circuit breaker panel, electrical control panel, relay panel, etc. shall have a
circuit designation label on the front as well as on the rear panels engraved with
black lettering in accordance with the circuit designation system. Circuit
designations must be precise and convey complete information. There should be no
doubt whatsoever for the operation as to which area of the plant a particular feeder
is supplying with power. Labels such as interconnector 1, feeder 2 are not
acceptable. Corridor type panels shall in addition have circuit designation labels
within the panels.
Pipe work systems shall be identified with a color identification systems in conformity
with the colors according to the chosen standards, with colors af the nameplates
and, if necessary by color bands and with identification numbering and plain
language. The direction of flow shall be shown.
72
Each valve shall be fitted with a stainless steel or aluminum name plate indicating
the valve service and reference number in accordance with the IDENTIFICATION
system.
Where possible valve nameplates shall be circular and fitted under the hand wheel
captive nut. They have to be of such a diameter that there is no danger for persons
operating the valve or that they do not prevent lock-off of this valve; on check valves
and small valves the Contractor may provide rectangular nameplates fitted to
brackets on the valve or attached to a wall or steelwork in a convenient position
adjacent to the valve.
Each crate or package is to contain a packing list in a waterproof envelope. All items
of material arc to be clearly marked for easy identification against the packing list.
All cases, packages, etc. are to be clearly marked on the outside to indicate the total
weight, where the weight is bearing and the correct position of the slings and arc to
bear all identification mark relating them to the appropriate shipping documents.
All stencil marks on the outside of cases are either to be made in waterproof material
or protected by shellac or varnish to prevent obliteration in transit.
This specification shall be used for the corrosion protection of steel structures,
components, pipings and equipment in general which are installed in confined
areas (indoors) or outdoors.
Surface preparation, as well as protective coatings and coating systems are based
on this specification in order to assure that structural parts of different suppliers will
get a corrosion protection of similar and high quality .
The manufacturer's materials and equipment used, the methods of application and
the quality of work shall at nil times be subject to the inspection and approval of the
Owner/Owner's representntive or his representative.
73
• tight blasting agents
• corrosion protection, hot dip batch galvanizing of single parts, requirements and
testing
• corrosion protection of structural steel work through protective coatings and
topcoats
• preparation of steel substrates before application of paints and associated
products
• paints and varnishes - corrosion protection of steel structures by protective paint
systems
• color card
• Swedish standard or equivalent for steel surface preparation steel structure
painting council.
• oil
• grease
• paint residues
• splatters
• mill scale
• welding splashes and
• Welding slag.
The preparation of substrates shall be carried out on the basis of the specifications
according to proposed standards.
Steel work protected by shop primer after arrival on site must be c1eancd of salt,
sand, oil, etc. before the first coat of paint is applied on site. Shop primer damaged
during transport must be rectified by blast-cleaning and coating before application of
the site coats.
Transport and erection damages, as well as damages which result out of additional
welding have to be repaired as soon as possible. The damaged areas have to be
derusted with rotating or steel brushes, abrasive wheels, abrasive blasting according
to the chosen standards.
74
Cleaning of prime and intermediate coats (if required)
To prevent contamination by mineral oil products, areas with prime and intermediate
coat have to be treated with suitable cleaning agent. Cleaning has to be done free of
residues, e.g. with alkaline detergents and thorough washing done with fresh water.
Rusty spots have to be removed according to required purity. Metallic areas which
are provided with temporary corrosion protection have to be cleaned. No oxidation
products shall remain on the surface. Furthermore it has to be taken care that on hot
components no destructive nor reaction products will be released when heating
which could injure insulation.
Application procedure
When using the provided coating material, strict adherence to all application
instructions given in product data of coating. manufacturer is necessary. To obtain
the maximum performance, technical data as well as application instructions for the
individual coating material have to be strictly followed.
For a multi-layer coating system each layer has to have a different color shade in
order to clearly identify number of coats applied.
The last finish coat has to be applied in the specified color shade, to be agreed by
the Owner/Owner's representative.
The interval between applying the different coats has to follow according to supplier's
precautions. Each layer has to be cleaned and released from spray dust before the
next layer will be applied. Prior to applying a further layer, the last one has to be
repaired. All coatings have to be applied without retarding.
When applying coating systems by roller, rollers have to be of kind and quality
which make an appropriate application possible.
Number and performance of the control areas have to be done in accordance with
the chosen standards and have to be documented in writing.
No application may take place neither when the relative humidity will not be within
the given limit nor in case of fog, dust, rain, snow or hail or when it can be assumed
75
that such conditions of poor weather within 2 hours after application can arise.
Temperature of the coated parts has always to be above 5°C and 3 K above dew
point.
Welding seams mounted at site have to be taped with an adhesive tape of about 30-50
mm after surface preparation (blasting or manual derusting) and prior to application in
the manufacturing plant and to be coated with stripping coat.
Chequered plates, nap plates, etc. have not to be covered with adhesive tape, but have
to be coated with stripping coat in a dry film thickness of at least 150 µm.
Edging lines on steel structure have to be taped prior to application and after blasting
in sufficient width or have to be protected with varnish before application. Thickness
of prime coat may be 50 µm max.
Galvanizing
Galvanizing work shall conform in all respects to the chosen standards and shall be
performed by the hot dip process unless otherwise specified.
It is essential that details of steel members and assemblies which arc to be hot-dip
galvanized should be designed to suit the requirements of the process. They should
be in accordance with the chosen standards.
Vent holes and drain holes shall be provided to avoid high internal pressures and air
locks during immersion and to ensure that molten zinc is not retained in pockets
during withdrawal.
The minimum average coating weight shall be as specified in the chosen standards.
Structural steel items shall be first grit-blasted (Sa 2 1/2) or pickled in a bath, and the
minimum average coating weight on steel sections 5 mm thick and over shall be
900 g/m2, on steel sections 2 - 5 mm thick 600 g/m2 .
Galvanized contact surfaces to be joined by high-tensile friction-grip bolts shall be
roughened before assembly so that the required slip factor is achieved. Care shall
76
be taken to ensure that the roughening is confined to the area of the mating faces.
Protected slings must be used for off-loading and erection. Galvanized work which is to
be stored at the works or on site shall be stacked so as to provide adequate ventilation
of all surfaces to avoid wet storage staining (white rust).
Small areas of the galvanized coating damaged in any way shall be restored by:
• cleaning the area of any weld slag and thorough wire brushing to give a clean surface
• the application of two coats of zinc-rich paint, or the application of a low melting point
zinc alloy repair rod or powder to the damaged area, which is heated to 300°C.
77
Coating Systems
vessels, tanks
2
OUTDOOR Intermediate 1-2 Epoxy High Solid 160 160
Finish 1 2-Comp.Polyurethane 50 50
290
Piping, tanks, etc. up to 120 SA 2.5 Primer 1 Zinc-Epoxy 50 50
3 INDOOR and OUTDOOR,
Insulated .
up to 120 SA2.5 Primer 1 Zinc-Epoxy 80 80
Pumps, motors, other equipment
Finish 1 2-Comp.Polyurethane 50 50
240
up to 120 SA 2.5 Primer 1 Zinc-Epoxy 80 80
Pumps, motors, other equipment
5 Finish 2 Epoxy High Solid 50 100
INDOOR 180
78
Coating Systems
6 OUTDOOR
Insulated
Stacks < 120 SA 2.5 Primer I Zinc Ethysilicate 75 75
OUTDOOR
7
<200 Finish 2 Silicone Acrylic 50 100
175
Steel surfaces 200 - 450 SA 2.5 Primer I Zinc Ethysilicate 75 75
Un insulated
8
Finish 2 Silicone Aluminium 25 50
125
Mechanical
cleaning from
contaminants When Finish
and zinc salts Coat is
by means of required, such
9 Galvanized surfaces up to 120 I Epoxy High Solid 125 125
washing or as sea climate
steam or with chloride
sweep- jetting exposure
blasting with
fme sand
Steel surfaces permanently in Medium Prime and
Glassflake reinforced
10 contact with water temp.oC SA 2.5 Finish 1 500 500
High Solid Epoxy.
up to 60 Coat in One
Additional 1 x Finish Coat 2-Comp. Polyurethane, 50 µm, when exposed to UV and colour retention is required or when exposed to weathering.
79
0.6.6 Vibration
All equipment performing similar functions shall be of the same type and
manufacture, to limit the stock of spare parts required and maintains uniformity of
plant and equipment to be installed.
0.6.8 Accessibility
The Contractor shall supply and erect sufficiently large safe platforms, galleries,
stairways and access ways necessary for providing safe and easy access to all the
plant items for operation and maintenance. The Contractor shall ensure that the
whole of the access ways is of W1iform design and pattern throughout the works.
Ladders are only to be provided as an extra means of escape. No dead ends are
allowed, especially where the escape way may be blocked by fire/steam, etc.
The design of all stairways, access ways etc. shall conform to the requirements of
Section 0.6.11.
0.6.9 Signs
General
Safety colors, safety symbols and safety signs must comply in construction,
geometrical form, color and meaning with the chosen standards.
Signs for plant identification during the erection period are subject to the
Owner/Owner's Representative approval.
The positions for the signs must be chosen so that they are within the field of vision
of the persons to whom they apply. The signs should be permanently attached.
80
Temporarily dangerous areas (e.g. construction sites, assembly areas) may also be
marked by movable signs. The safety signs must be mounted or installed in such a
manner that there is no possibility of misunderstanding.
Information signs
In the choice of information signs in situations not covered by the chosen standards
the possibility of using pictograms should be considered. Pictograms are particularly
suitable for the identification of rooms, areas and buildings in the non-technical areas
of the plant, sanitary and amenities buildings, etc.
Emergency signs
Mandatory signs
Signs indicating obligatory actions must be provided installed wherever certain action
is necessary, e.g. do not obstruct the entrance; keep right, etc.
Signs should also indicate when the wearing of protective clothing and equipment is
necessary and obligatory, e.g., protective goggles, protective clothing, helmets, head
guards, breathing equipment, ear muffs, etc.
Warning signs
Warning signs should refer to the existence or possible existence of danger, e.g.,
flammable substances, explosive substances, corrosive or noxious substances,
suspended loads, general danger, width height restriction, steps, risk of trapping,
slipping, falling, etc.
The Contract shall be conducted in the Systems International Units (SI) system of
units in accordance with the provisions of ISO 31 and ISO 1000.
81
Quantity Name of Unit Symbol
Length Millimeter mm
Mass Kilogram kg
Time Second s
Temperature Degree Celsius °C
Temperature Difference Kelvin K
Electric Current Ampere A
Luminous Intensity Candela cd
Area Square meter m2
Volume Cubic meter m3
Liter I
Force Newton N
Pressure (absolute) Bar bar
Kilopascal kPa
Pressure below 1 bar Millibar mbar
Stress Newton per square millimeter N/mm2
Velocity Meter per second mls
Rotational speed Revolutions per minute rpm
Flow Cubic meter per day m3/d
Cubic meter per hour m3/h
Kilogram per hour kg/h
Liter per second L/s
metric ton per hour t/h
For gaseous substance: standard Nm3/h
cubic meter per hour (referred to
O°C and 1013 mbar)
Density Kilogram per cubic meter kg/m3
Kilogram per standard cubic Kg/Nm3
meter
Torque, moment of force Newton meter Nm
Momcnt of inertia (mr2) Kilogram square meter kgm2
Work, energy or heat Joule J
Heat capacity, entropy Joule per Kelvin J/K
82
Quantity Name of Unit Symbol
Kinematics' viscosity Meter squared per second m2/s
Surface tension Newton per meter N/m
Concentration Parts per million ppm
Electrical conductivity Micro Siemens per meter at 25°C µS/m
Frequency Hertz Hz
Electric charge Coulomb C
Electric potential Volt V
Electric field strength Volt per meter Vim
Electric capacitance Farad F
Electric resistance Ohm n
Conductance Siemens S
Magnetic flux Weber Wb
Magnetic flux density Tesla T
Magnetic field strength Ampere per meter A/m
Luminous flux Lumen lm
Illuminance Lux Ix
Thermal resistivity Kelvin meter per Watt Km/W
Energy Kilowatt hour kWh
For the thermodynamic properties of steam and water the latest edition of the
"VDI- Wasserdampftafeln" (= Water Steam Tabular) shall be used which is based
on the formulations published by the International Formulation Committee (IFC)
under the title "The 1967 IFC Formulation, for Industrial Use".
The Contractor shall supply all platforms, galleries and stairways necessary for
providing safe and proper access to the plant for operation and efficient
maintenance. The Contractor shall ensure that the type of flooring, stair treads and
handrails conform to a uniform pattern throughout the whole Project.
The loads for the design of platforms, galleries etc. shall be in accordance with the
section 'Design Loads' of the special civil part of these specifications.
All platforms, galleries, stairways and hand railing shall be of galvanized ,i steel
unless otherwise specified.
All aspects of platforms, stairways, ladders and other access ways shall comply
with the requirements of applicable 'standards.
83
nature, handling and storage of all fuel oils, gases and chemicals etc., and provide
plant, equipment, buildings and other services accordingly, including all facilities to
ensure the safety of the operating and maintenance personnel.
The Contractor shall provide drawings to define all the hazardous zones taking
account of all sources of hazards under normal and abnormal operating conditions,
(regardless of whether or not these areas are specifically listed in the
specification).The zoning philosophy shall be subject to the approval of the
Owner/Owner's representative.
In particular, equipment directly concerned with plant which may give rise to a
hazardous situation shall be designed to requirements with electrical connection
safety barriers or intrinsically safe equipment. Where required by the Engineer,
certification shall be provided to confirm the suitability of the equipment and
devices.
The Contractor shall be responsible for ensuring that all electrical equipment
installed in any hazardous zone is designed and tested to suit the relevant zone
classification and shall be to the approval of the Employer. Cables shall not be laid
in trenches etc with fuel pipe work.
• Pipeline insulation and the in-fills of cable and pipeline wall penetrations are to
be of non-combustible material.
• All pipelines or vessels with internal temperatures of more than 180°C shall be
so arranged as to avoid any contact with flammable liquids if fuel or lube oil
lines should leak. Sufficient physical separation shall be ensured.
• Particular care should be taken to eliminate any risk of hot pipeline insulating
material becoming impregnated with flammable liquids in the case of fuel or
lube oil line leakage. The insulation is to be covered in its entirety, with an oil
resistant sheet, over which the cladding is to be fitted.
• Cable and pipeline ducts must be so arranged and sealed as to avoid all risk of
flooding with fuel oil, lube oil or any other flammable liquid. In addition to
sealing the cable and pipeline ducts, the cable basements must be completely
scaled against leakage from above as well, in order to preclude the ingress of
lube oil or other flammable liquids.
• Covered floor ducts must be easily accessible for inspection and cleaning.
• All parts of plant and equipment are to be arranged so that no corners or pits
that would be difficult to inspect and clean and in which flammable matter could
collect are formed.
• Fuel preheating temperatures should be limited to a margin of at least 10K
below the fuel flash point.
• Lubricating oil lines in the turbine-generator lube oil system arc not to be
connected with compression-type joints but rather with welded or screwed-type
points.
84
• Non-combustible materials which do not release noxious or toxic fumes must
be used for wall and ceiling paneling, for floor covering, and for cubicles and
cabinets.
• Corners likely to collect dust respectively-coal powder shall be prevented.
All major equipment shall be arranged to facilitate safe isolation frol11 all
hazards for maintenance purposes. In addition all valves must be capable of
being locked either in the open or closed position by means of a chain and
padlock.
0.6.14 Materials
All materials shall be brand new and of the best quality for use in the conditions
and the variations in temperature and pressure that will be encountered in
service without undue distortion or deterioration or the setting up of undue
strains in any part that might affect the efficiency and reliability of the plant.
All materials shall correspond either to the approved standards and the
respective code number or to exact analysis data, and full information
concerning properties and applied heat, chemical and mechanical treatment
shall be submitted for Owner/Owner's Representant's spot check.
Unless the materials meet these codes and standards, they shall be subject to
the Owner/Owner's representative's spot check.
85
0.6.15 Pre-service cleaning and protection of plant equipment
This clause covers mechanical and pre-service cleaning and protection of the
plant items and equipment at the Manufacturer's workshop and at site that are
not subsequently to be painted.
Cleaning of fabricated component items shall be carried out after fabrication and
final heat treatment or welding at manufacturers' works or at site, as appropriate.
In the event of the surfaces not being cleaned to the Employer's or Engineer's
satisfaction, such parts of the cleaning procedures or agreed alternatives as are
deemed necessary to overcome the deficiencies shall be carried out at the
Contractor's sole expense.
Austenitic stainless steels, copper and aluminum alloys, cast iron, bimetallic and
metallic/plastic items, and components fabricated by spot welding or riveting shall
not be chemically cleaned. All weld areas shall be suitably stress-relieved before
chemical cleaning
Further, the Contractor shall submit at the. same time the basic draft of the
cleaning procedure and of the treatment of wastes.
Not less than six months prior to the commencement of any site cleaning, the
Contractor has to submit programs covering all procedures, lists of chemicals,
calculations which quote the velocities, temperatures handpipework forces and
movements imposed during site cleaning.
Besides this, the Contractor shall take over all responsibility for the treatment and
disposal of wastes according to the local law and to the satisfaction of the
Owner/Owner's representative.
The date at which cleaning of plant equipment will be carried out at site shall be
notified to the Owner/Owner's representative at least 20 days in advance.
The Contractor shall take all necessary precautions to ensure that the internal
surf.1ces of all plant are kept clean and free from injurious matter during erection.
86
When all plant has been erected and lagged or at such other time as may be
agreed with the Owner/Owner's representative for sub-assemblies, the
installation shall undergo a procedure for site cleaning proposed by the
Contractor and subject to the approval of the Employer.
General
All pumps shall be designed for continuous operation unless otherwise specified.
Lifting lugs and eyes and other special tackle shall be provided as necessary to
permit easy handling of the pump and its components.
All pumps shall be designed to withstand a test pressure of 1.5 times the
maximum possible pump shutoff pressure under maximum suction pressure
conditions. If a pump can operate at sub-atmospheric suction conditions, the
entire pump shall be designed for full vacuum.
All pump shafts shall be of ample size to transmit the maximum possible output
from the prime mover. The pump shaft and coupling are to be so dimensioned
that the maximum permissible torque of the shaft is higher than the maximum
transmissible torque of the coupling. Directly coupled pumps shall be used
preferably.
Renewable wear rings shall be fitted to the casing and impeller where
economically justified.
All pumps and accessories in contact with the pumped fluid shall be constructed
of materials specifically designed for the conditions and nature of the pumped
fluid, and be resistant to erosion and corrosion.
Product water flushing lines are to be supplied for each pump handling seawater
to avoid corrosion if the pump is out of operation for extended periods.
The pump casing shall preferably be split for ease of maintenance and be
87
designed such that the impeller and shaft are capable of being withdrawn from
the casing without disturbing any of the main paperwork. and valves carrying the
pumped fluid. In general, all horizontal pumps with draw-outrotors are to be fitted
with a coupling to facilitate disassembly without removing the motor. Pull-out
design of the shaft shall be applied to vertical wet pit and dry pit pumps as well.
Each .horizontal pump shall be mounted with its drive on a common base plate of
rigid construction. Vertical pumps are to be provided with foundation frames. In
case of submersible pumps suitable frames shall be provided in the pump sump.
It shall however be possible love these pumps without entering the sump.
Pumps must be carefully set to ensure that the net positive suction head
available under all operating conditions will be adequate for the type of pump
employed. The NPSH values are to be referred to the least favorable operating
conditions -lowest atmospheric pressure, lowest level of water <W the suction side
of the pump, and highest temperature of the pumped fluid. An adequate safety
margin of normally greater than 1 m to the max. NPSI-1 required shall be
provided.
Pumps shall operate smoothly throughout the speed range up to their operating
speeds. The first coupled critical speed must be at least 20% higher than the
maximum operating speed. The determination of the shaft diameter and the
distance between two consecutive bearings must include a sufficiently large
safety margin to satisfy this condition.
Where necessary, the pumps are to be fitted with devices to ensure a minimum
throughput.
Bearings
For large pumps the bearings shall be of automatic oil lubricated sleeve type,
unless otherwise specified. Bearings on vertical shaft pumps shall be so spaced
to prevent shaft whipping or vibration under any mode of operation.
All bearing oil wells shall be fitted with visual oil level indicators. Non pressure-oil
lubricated bearings shall be equipped with constant level oilers.
Pumps characteristics
When several pumps arc installed for the same service, they shall be suitable for
unrestricted parallel operation.
The pump flow/head characteristics shall be such that within the operation range
the head will continuously increase with decreasing flow, maximum head (shut
off head) being at least 10% higher than the duty point head.
88
Unless otherwise specified all pumps shall be capable of operating at 110% of
the rated capacity at the rated delivery head. Maximum size impellers shall not
be quoted for. By installation of a new impeller a head increase of 5% minimum
shall be possible. The performance of the drive motor is to be determined
according to the above mentioned technical requirements and to the
requirements as specified in the electrical part.
Fittings
All pumps shall be installed with isolating valves, a non-return valve and suction
and discharge pressure gauges unless otherwise stated. Accessible couplings
shall be supplied with removable type guards.
All positive displacement pumps shall be fitted with a discharge relief valve
capable of passing the maximum pump delivery flow.
Venting valves shall be fitted to all pumps at suitable points on the pump casing
unless the pump is self-venting, due to the arrangement of the suction and
discharge nozzles. Drainage facilities shall be provided on the pump casing or
adjacent pipe work to facilitate the dismantling of pumps.
All pumps other than submersible pumps shall have temporary strainers fitted in
the suction pipe work during all initial running and commissioning phases.
Permanent strainers shall be provided where specified.
As far as arrangement and number of valves for drains and vents, etc., are
concerned, the stipulation of this article define the minimum requirements.
The intent of this chapter is to describe the general technical requirements and
essential particulars of pipes, valves, fittings, expansion joints, insulation as well
as the complete power piping system furnished, fabricated, shop tested,
delivered, completely erected land installed, clean inside and outside, in first
class condition throughout, hydrostatically field-tested and demonstrated to be in
a condition to operate commercially and continuously in a manner acceptable to
the Owner/Owner/Owner's representative up to maximum operating conditions.
As far as arrangement and number of valves for drains and vents, etc., are
concerned, the stipulation of this article defines the minimum requirements.
89
0.6.16.2.1Standards and general conditions
Piping and valves shall comply with currently approved applicable codes,
specifications and standards (latest revisions), such as DIN, American standards
(A.S.A., ASTM, ASME, A WW A), Japanese standards and shall conform with
the Contract specification.
All piping materials, bypasses, open blows, welding joints, flanges, bolting
materials, gaskets, piping supports, turn buckle red hangers, spring hangers,
guides, sway braces, vibration dampers, trays, brackets, anchors, rollers,
expansion bends, operating platforms and supports of all types as well as
miscellaneous structural steel and other items required to support the piping in a
proper manner, shall be included in all piping systems.
Pockets in pipelines shall be avoided wherever possible and all lines are to be
provided with fittings, valves and/or traps arranged in such a way that the pipes
may be completely drained when desired.
Welding wires and electrodes material for welded connection of pipe systems
shall be according to relevant standards or codes of the appertaining
For all piping systems, separate list of pipes and list of valves. shall be
submitted by the Contractor.
The Owner requires entirely and continuously-welded connections for all high
pressure temperature service including welding' of pipes to the valves or other
equipment. Other piping systems shall comprise all welded connections or
bolting of pipe to the valves or equipment. The use of odd or short pieces of
pipe in making up long runs is prohibited.
All pipe bends shall be made preferably to radii not less than five times nominal
pipe diameter unless otherwise specified; they shall be true to angle and radius
and maintain a true circular cross-section of the pipe without buckling or undue
stretching of the pipe wall.
The Contractor shall machine completely all welded ends on piping, bends and
fittings to make all welds sophisticated both in shop and field. Welding joint
design shall avoid all sharp comers.
90
0.6.16.2.3 Expansion and flexibility
Piping systems shall be calculated, supported, guided and anchored in such a
way as to preclude excessive thrust or stress due to the combination of leading
from internal pressure, thermal expansion and weight. The Contractor shall be
responsible for computing expanding movements and combined stress on and
weights of all major pipelines and for providing suitable supports and restraints
to assure compliance with the latest rules of the available standards. Reactions
at equipment connections shall be within the limits specified by the
manufacturers respective equipment.
Pipe supports and anchors shall generally be situated at those points in the
building where provisions has been made to sustain the loads imposed. The
cutting of floor or roof beams of the reinforcement in slabs shall not be
permitted. Piping attached to a plant item shall be supported in such a way
that the weight of the piping is not carried by and no stress is exerted on the
plant item.
All pipe supports and anchors shall be preferably located at the main grid
lines of the structures and buildings. Where pipe supports and anchors are
required elsewhere, all the secondary beams to direct the load to the main
beams and connecting pipes shall be provided by the Contractor.
Only minor loads shall be permitted to hang to the concrete slabs and subject
to the approval or Owner/Owner's Representative. The supporting
arrangements - inapplicable - shall be capable of supporting the weight or the
piping systems when full of water during, chemical cleaning or hydraulic
testing. The number and position of pipe supports shall be such that the
piping may be free to move, and that lateral loading on the piping system
under working conditions may be minimized.
All supports for high pressure steam and other pipes subjected to high
temperature conditions shall be fastened onto the pipe under consideration of
the operating conditions of the pipe supported. The material influenced by the
temperature conditions shall be of nearly the same quality as the related
pipe.
91
the pipe shall be fixed in a constant position if not otherwise instructed by the
Engineer. The Contractor is responsible for meeting all the requirements for
pipe connections established by the manufacturers of the turbine, the pumps
and other relevant equipment.
After drying, inspection and conservation, wooden plugs, metal or plastic caps
shall be securely fitted to the ends of each pipe to prevent the ingress of dirt
and to protect flanges and pipe ends from damage during transportation and
storage.
During erection, the open ends of any work shall be protected at all times by
suitable temporary covers, which shall be securely fixed.
The Contractor shall make provisions for "blowing-out" procedures of the , main
steam pipe work by steam and shall provide any branches, temporary. pipe
work and supports that may become necessary. Disconnecting and remaking
of points shall be included.
After boiling-out of the boiler and blowing-out of the several pipe systems the
systems have to be passivated. The proposed process shall be fully described
by the Contractor and shall be subject to the Engineer's approval.
On completion of the cleaning processes, an inspection shall be carried out in
the presence of the Engineer, to ascertain the effectiveness of the processes
just completed.
It shall be the Contractor's responsibility to remove from Site all chemicals and
debris accumulated during the chemical cleaning process. Any damage caused
as a result of the process shall be made good by the Contractor at his own
expense, therefore an adequate insurance cover shall be a necessity for such a
contingency.
92
0.6.16.2. Wall boxes and collars.
The wall boxes and floor collars shall be constructed in such a way that, if
necessary, they can be erected after the pipes are in position. Pipes passing
through roof collars shall be provided with approved weather-hoods and cowls
which shall be fixed by the Contractor.
The Contractor shall provide all the necessary wall boxes and sleeves where
pipes pass through walls, floors and roofs, also the necessary supports fot) .
any pipes laid in trenches. Roof collars shall be fitted with high coamings to
prevent rainwater from passing through the holes.
All bolts, nuts, etc. shall conform to an approved Standard. Bolts or studs which
are subjected to high pressure and temperature shall be of approved high
tensile alloy steel with nuts of a suitable, approved material.
All bolts or studs shall be of steel suitably machined, at the shank and under
the bolt head. Washers shall be provided under nuts, and also under bolt
heads, if required.
Dolts, nuts made from high temperature resistant materials and ones installed
in enclosed parts of machines are not concerned of this regulation
The pipe work shall be designed, fabricated, erected, inspected and tested on
the basis of the currently approved applicable standards and codes such as
DIN, American standards (ASA; ASTM; ASME; A WW A), Japanese standards
or equivalent and the additional requirements as set out below.
For the HP Live Steam and Re-heater System high alloy steel, for example
material P91 (XI0CrMO VN b 91) is preferred.
For the main cooling water system GRP is preferred (see article D7).
The maximum flow velocities for the individual media must not bc ex exceeded
at maximum throughput (unless expressly specified in the documents):
Type of pipe work max. velocity
Steam lines:
High-pressure live steam lines (PN > 64) 60 m/s
Intermediate-pressure steam lines (PN
40 m/s
25140)
93
Low-pressure steam lines above 5 bar 35 m/s
Low-pressure steam lines < 5 bar 25 mls
Vacuum lines 80 m/s
Saturated steam Iincs 20 mls
The following standard pipe sizes shall preferably be used for main process
lines:
Nominal
Diameter in mm: 25, 50, 80, 100, 150, 200, 250, 300, 350, 400, etc.
Pipes with a diameter size smaller than 25 mm (one inch) may be used only
for control air, control oil, chemical dosing, scaling water, instrument
connections, sampling pipes and other instrument and analysis lines.
All safety valves shall have a test certificate issued by an approved authority.
94
water and seawater supply systems must be designed according to . the water
hammer calculation.
For live steam lines the design pressure of the boiler shall be taken as the
design pressure of these lines up to the inlet of the turbine main stop valves.
For the piping systems with a nominal pressure specified as PN > 40 as in DIN
2401, or equivalent, the drainage and ventilation facilities shall be fitted with
double valves.
All vents, drains or dump points with more than 10 bar/10000C operating
pressure/temperature shall lead to the flash tanks and into funnels at visible
points with covers.
Guidelines for the design and construction of pipe work and accessories
• Design and construction of all parts of the pipelines and accessories should
correspond to the present state of the art and shall be based on the latest
standards.
• The pipe work and its accessories shall be designed and arranged so that all
parts subject to operation and maintenance can be operated, inspected,.
maintained and replaced without difficulty and with a minimum of effort. All
important parts must be accessible.
• Provisions to allow for isolation and for access must be foreseen on all parts
subject to acceptance resets by the local authorities.
• The nominal bore of gate valves shall be the same as the nominal diameter
of the pipeline in which they are installed.
• None of the forces and moments transmitted by the pipes to connected
machines, apparatus and other components must exceed the maximum
permissible values, given by the manufacturers of these items. Attachments
to turbine foundations shall be carried out only as agreed with the turbine
manufacturer.
• All steam traps shall be provided with a bypass and lines which open to a
funnel.
• As far as expansion joints and other parts of pipe work are concerned it shall
be borne in mind that differential settlement can occur. The reaction forces
and moments of the piping system to be withstood by fixed points~ walls,
foundations and other dvil structures shall be reduced to the utmost
minimum by suitable means (e.g. expansion joints shall be provided where
required).
95
• Since the steam pipes may be filled with water for a short time (e.g. when
flushing or pressure testing), supports shall be dimensioned accordingly. The
load information to be given by the Contractor to the civil designers shall
take account of this requirement.
• The pipe support structures shall be designed to minimize heat transfer.
• The installed pipe work with its supports and other components shall not
obstruct gangways (min. 1000 mm wide), maintenance; escape routes etc.
Overhead piping shall have a minimum vertical clearance of 2.3 meters, in
pump rooms 2.45 meters and 6 meters above roadways.
• Main pipe ways shall be designed to accommodate 20% more lines than is
required for the initial installation. When designing sleeper ways, allow space
for adding 20% additional sleeper width.
• Pipe spools for HP steam, feed water piping and all steel pipes > DN 50
shall be cleaned internally prior to delivery by shot blasting (no sand
blasting) at the workshop with iron particles to SA2 1/2 or by acid cleaning,
and shall be property protected against corrosion.
• Pipe ends and branch connections of underground piping shall be sealed
temporarily during installation if the connecting pipe is not immediately
installed.
• The Contractor shall submit a detailed description of proposed steam
blowing and other cleaning procedures for all pipelines, and no part of this
work shall be started until these procedures have been approved by the
Employer. Temporary silencers shall be provided for this.
• The Owner/Owner's representative reserves the right to require the
Contractor to modify any of his cleaning .procedures if found necessary to
obtain acceptable results.
• The contractor shall furnish, install and dismantle all temporary pipes,
hangers, anchors, etc. required for cleaning all piping system.
• To the extent that hot fluids can accumulate in pipe sections isolated for
maintenance purposes (including control valves with injection water), drains
with hand-operated shut-off valves are to be provided for the safety of the
personnel (block and bleed systems) . Furthermore the Contractor shall
safeguard the piping systems against over-pressurization caused by thermal
expansion of blocked-in fluids by adequate means.
• AH welding shall be carried out according to relevant standards. For quality
reasons as many welds as possible are to be carried out of the workshop.
• Welding ends of all piping must be carefully prepared before welding. The type
of butt welding ends of valves, control devices, orifices, etc. shall be specified by
the Contractor and must be given to the manufacturers of these components in
due time prior to their start of work if necessary/post weld heating treatment. If
there are differences in the wall thickness and/or different materials of piping
and valves with butt-welding ends, the necessary transition pieces must be
provided by the manufacturer of the valves
• Control valves should have flanged connections.
• Socket welds are not permitted for lines above DN 50, for corrosive media
96
lines or for lubricating oil lines.
• After completion of the weld joint, the welder must mark with indelible
crayon his identity number and the last two digits of the year in which the
work was completed on the pipes. The Contractor shall keep a record of
welders.
• The Contractor shall provide suitable thimbles and flashing where pipelines
pass through floors and walls. Floor thimbles shall be installed to provide 90
mm projection above the finished floor surface.
• A flexibility analysis must be performed for all piping systems DN > 80 with
an operating temperature > 120°C.
• The piping stress and flexibility analysis shall be based on the relevant
standards. Recalculation must be taken into consideration as built condition,
actual weight and dimensions.
• Pipe materials, bends and fittings shall be tested in accordance with the
applicable material standards.
Constant support hangers and spring hangers shall be equipped with a means
of locking the springes) against movement during erection, hydrostatic testing
etc. The use of counterweights in substitution for support spring assemblies will
not be permitted.
Support spring hangers shall be of the enclosed spring type, and shall have an
embossed on factory load indication scale showing the hot (operating) and cold
(ambient) positions. Each spring assembly shall incorporate an adjustable
hanger rod coupling to permit load adjustment. All support springs shall be
designed to permit at least ± 10% field load deviation from. the factory
calibrated load.
The supporting force provided by variable support type spring hangers shall not
change by more than 20% between the cold and hot positions, and supports of this
type shall not be used at any point where such a change in supporting force cannot
be safely permitted. Variable support spring hangers shall incorporate springs with
maximum working range Iength in order to reduce the overall length of the
assembly.
97
All pipe hangers and support stands shall be attached to the piping and
structural supports such that they will be vertical when the piping is at operating
condition. So far as practicable, hangers and supports shall be of the same
type and component assembly.
All hangers shall be carefully adjusted. After plant start-up checks shall confirm
that all hangers and supports are in the correct position.
The Contractor shall prepare a complete documentation of a1\ pipe hangers
and supporting elements. These documents shall contain the following
information:
• identification coding number
• loads, forces and moments, and their directions at all supports, hangers at
normal operating conditions, etc.
• magnitude and directions of the movements at the loading points
• measurements of the loading points referred to the axes 'of the buildings
• item No. of the supports, hangers etc. according to the piping group
• material specification for the supporting parts.
All hangers shall be carefully adjusted. After plant start-up checks shall
confirm that all hangers and supports are in the correct position.
The Contractor shall prepare a complete documentation of a1\ pipe hangers
and supporting elements. These documents shall contain the following
information:
• identification coding number
• loads, forces and moments, and their directions at all supports, hangers at
normal operating conditions, etc.
• magnitude and directions of the movements at the loading points
• measurements of the loading points referred to the axes 'of the buildings
• item No. of the supports, hangers etc. according to the piping group
• material specification for the supporting parts.
Trace heating
Trace heating shall be provided for fuel oil pipes and other pipes as required.
Protection of buried pipe work systems (as far as not installable in ducts)
All buried pipe work of steel or cast iron or other materials prone to corrosion
shall be protected from corrosion by catholic protection and a system of tape
wrapping to be applied in the workshop.
The design of the catholic protection system(s) shall be executed by a specialist
and authorized company under consideration of the following:
• impressed current-type catholic protection systems shall be employed; only if
98
the calculated current required is too low may suitable sacrificial anodes be
used for protection,
• coating of a minimum finished thickness of 6.5 mm for bitumen or 2.5 3.5 mm
for plastic coatings (PVC or PE), applied for tape wrapping spirally with an
overlap of 50%, the coated pipeline supplemented by suitable, catholic
protection systems,
• suitable insulating joints arc to be provided where systems arc to be separated
and, as a minimum, locations where there is a change from above-ground to
buried piping,
• the designed catholic protection shall be a completely functioning system in all
respects according to the state of the art and shall also include the appropriate
equipment for measurements .
0.6.16.4.1 Responsibility
Each Contractor must have the necessary facilities available to ensure that the
materials are properly processed and all tests can be carried out.
It must have his own supervisory staff and trained workers for the manufacture.
Each Contractor shall be responsible for the quality of the welding carried out
by his organization and shall conduct tests not only of the welding procedure to
determine its suitability of ensuring welds which will meet the required
specifications and tests, but also of the welders and welding operators to
determine their ability of applying the procedure properly. No production work
shall be undertaken until both the welding procedure and the welders or
welding operators have been qualified.
• instruction for issue and return of welding auxiliary materials their drying and
warming, storage and identification
99
• welding schedule, welding procedure specification
• inspection plan and procedure for testing of weld edges and complete weld
• record of performed welding and repairs by welding, their test results and the
welder or welding operator who made them
The specific data including the test results shall be recorded in a procedure
qualification test record and approved by an internationally recognized authority
and shall not date back for more than 3 years.
The Contractor shall employ his own welding supervisors. The name of the
supervisor shall be made known to the Owner/Owner's Representative.
The Contractor shall only employ welders who have passed a qualification test
as stated in DIN or ASME or an approved standard with equivalent i
requirements.
100
I f not otherwise agreed upon, the tests and certificates shall be valid as per
adopted pressure code.
The procedure of preparation of the test pieces, and the standards to be used
for the examination shall be in accordance with the relevant standards or as
may be agreed upon between the Contractor and the Owner/Owner's
Representative.
101
• welding sequences especially for tank welding and large equipment
• inspection plan and test procedure for testing of weld edges and complete
weld.
Prior to start of welding, the welding schedule and test procedure shall be
available at workshop respective site.
The extent of the weld inspection, the final weld quality and the method of
examination shall be such as stated in
The Contractor shall also establish a procedure whereby welded joints can be
identified as to the welder or welding operator who made them if requested by
the Owner/Owner's representative or as stated in sub-sections of the
Contract.
The Contractor shall prepare written instructions for issue and return of
welding auxiliary materials, their drying and warming if required, their
handling, storage and identification.
All joints shall be prepared according to the relevant standards and to the
welding schedule,
102
Tack welds shall be made by qualified welders only.
In order to cope with the requirements for a surface protection suitable for the
prevailing aggressive environmental conditions and to' avoid corrosion in
crevices, all welded steel works for structures has completely to be seal
welded.
0.6.16.4.5.5 Non-conformities
The Contractor shall issue an instruction sheet for handling of nonconformities.
If heat treatment has already been performed, the repair documents for
approval shall include the heat treatment plan after completion of the repair.
Apparatus and equipment used for heat treatment shall be inspected and
checked for correct operation.
In any case, the welding schedule or welding procedure specification for the
material being welded shall specify the minimum preheating temperature.
Heat treatment prior to and after welding in order to achieve stress relieving
shall be applied as specified in the internationally recognized standards and
Codes.
The Contractor shall issue a heat treatment plan showing the temperature
103
time diagram and a sketch with the temperature-measuring points <Illd
describe the manner of temperature control.
Welding after final stress relieving is basically prohibited. The relevant piece
shall undergo a new stress relieving process if any welding has been
performed afterwards.
0.6.16.4.7 Documentation
0.6.16.5 Valves, Steam traps, condensate drainers, safety valves, control valves
The Contractor shall design and supply all valves and their accessories.
required for the safe, efficient and sound operation and maintenance of the
plant based on the appropriate standards. They shall comply as a minimum
with the design criteria of the relevant piping.
All valves shall be suitable for the media and for the service conditions an~
those performing similar duties shall be interchangeable.
104
In vacuum service and wherever otherwise necessary to prevent the entry of
air, valves shall be provided with suitable sealing facilities. Where applica-
ble, the valves must be suitable for outdoor installation under consideration
of the special climatic and environmental conditions of the site.
Unless otherwise agreed, all valves shall be fitted with the spindle in upright
position.
All valves shall be closed in a clockwise direction when looking at the face
of the hand wheel. The valves shall have rising spindles and non rising
hand wheels. Plastic valve hand wheels will not be accepted.
HP and large size gate valves to be opened under differential pressure shall
be equipped with pressure equalizing valves (globe valves).
All valves (especially including ball valves) shall be fitted with indicators to
determine the valve position. In the case of valves fitted with extended
spindles, indicators shall be fitted both to the extended spindle and to the:
valve spindle.
All globe valves shall be equipped with throttling cones with parabolic
characteristic.
In general, LP safety valves, butterfly valves, ball valves and orifices as well
as all control valves shall be flanged. All valves for steam, feed water and
condensate, HP safety valves (inlet side) shall have welded ends, corre-
sponding to the connected pipes.
Design of valves and materials used must comply with the relevant stan-
dards. They must be chosen in accordance with the requirements to be met
and to corresponding pipe work .
For limiting hand wheel forces, for control and operation purposes it may be
necessary to install gears and drives.
The max hand wheel force of 25 deka Newton must not be exceeded.
All block valves DN 500 arc to be provided with electrical actuators with
manual override. The actuators arc to be operated by local control points
which can be locked.
105
The Contractor shall furnish and install steam traps at each low point. Each
steam trap installation shall include a permanent strainer,. upstream and
downstream globe valves and a globe valve as free drain. Steam traps shall
be supplied with weld ends.
Drain traps shall be provided with inlet and discharge valves, vents and hand-
controlled bypasses and, when discharging into a closed header, shall also
be provided with discharge non-return valves.
Each trap shall be sized to provide ample capacity at the minimum working
differential pressure, and to open the orifice at maximum working differen-
tial pressure.
All gate valves shall be of the fullway gate type and when in full open
position. the bore of the valve shall not be obstructed by any part of the gate.
The internal diameter of all valves at the end adjacent to the pipe work shall
be the same as the internal diameter of the connecting pipe.
All valves shall have bolted gland stuffing boxes. Screwed glands and
bonnets will not be accepted.
Spindle glands shall be of the bridge type. In all cases where applicable,
spindles shall have back-scaling seats to allow renewing of the spindle
glands with the valve open under pressure conditions.
HP gate valves shall be equipped with self scaling lid covers. The self-
scaling lid covers shall be equipped with a safety device at the body with
shut-off valve and interlocking system. This system must be approved by
the authorities.
The valves for live steam, HP feed water and HP injection water shall be
made of forged steel. Forged steel or cast steel shall be used for the remain-
ing systems. Valves made of gray cast iron are not acceptable.
106
c) Relief valves in hydrocarbon service discharging to atmosphere shall
have outlet piping extended not less than 3.6 meters above highest
working level or 4.5 meters above roof of nearest building within a
radius of 12 meters.
d) All relief valves discharging to atmosphere shall have a weephole located at
low point, and for hydrocarbon relief valves a steam dispersal line, operable
from grade.
0.6.16.6 Insulation
Thermal insulation
The thermal insulation shall be designed and installed in accordance with the
chosen standards, considering the following minimum requirements:
All pipes and equipment to be insulated must be indicated on the flow sheet and
technical data sheets with the following code letters:
HI = heat insulation
CI = cold insulation
The mats shall be stable in shape, chemically inert, free of sulfur and alkali,
resistant to water and steam, non-flammable and capable of withstanding
continuous exposure to the pipe design temperature. The mats used for insulation
of stainless steel equipment shall have a chloride content of less than 0.15%. Under
no circumstances may asbestos or asbestos containing materials be used.
The material will have the following physical/chemical properties (± 10%
allowance):
• service temperature up to 6000 C
• density 120 kg/m3
• water adsorption 0.5% weight
• specific heat capacity 0.84 kJ/kg UK
• compressive strength 20 kPa
• conductivity versus temperature
107
Average temperature (OC) Blanket (W/m K)
0 0.034
50 0.040
100 0.048
150 0.058
200 0.070
250 0.083
300 0.100
The manufacturer's name and the material properties shall be labeled on each
package of insulation material.
The insulating mats shall be stitched to galvanized wire mesh using galvanized steel
wire. The mesh size shall be approximately 19 mm.
For special purposes such as for turbines, boilers, etc. spray type insulation or
insulation brickwork (for example calcium silicate) may also be applied. The special
insulation materials shall be stated by the Contractor and their design shall match the
overall design and guarantee the requirements stated in the specifications.
The surface cladtling shall be made of aluminum sheets specified as "99.5% aluminum
grade II24, mill finish surface" in accordance with UNI 9001 or other equivalent
standard, manufactured in sheets with the following minimum thickness:
Tank tops shall be provided with insulation strong enough to support a man's weight.
The sheets shall be secured and connected at the longitudinal scams with at least five
stainless steel self-tapping screws per meter run.
Plain sheets for fiat surfaces shall not exceed 1 meter square and shall be stiffened by
crimping.
At the longitudinal and circumferential joints, the sheets shall overlap by at least 50
mm so as to drain off the liquid and to trap the liquid in the insulation.
Places at which the metal sheets are penetrated for pipe hangers, thermometer
sockets, etc. shall be sealed with funnel-shaped recesses or sheet metal rims.
The seams and penetrations of any sheet metal insulating jacket installed
108
outdoors as well as in the boiler and turbine house in areas with risk of water
spray etc., shall be sealed against penetration of water by means of a suitable
silicon based sealant.
The inside of the aluminum jacket shall be protected against contact corrosion
from the wire mesh of the insulating mats by suitable means (e.g. Kraft paper or
equivalent).
In the case of pipe insulation thicknesses greater than 60 mm, where insulation
blankets are used spacers shall be provided at maximum intervals of 950 nun to
ensure a uniform insulating thickness on all sides and a perfectly circular shape"
of the sheet metal jacket. The sheet metal jacket shall be supported by support
webs (for pipe diameters below 100 nun) and enclosed support rings (for pipe
diameters 100 mm and above). If the enclosed support rings are not provided with
ceramic spacers, the spacers made of steel shall be insulated with one heat
insulation strip in the case of operating temperatures of up to 200°C, and with two
heat insulation strips where the operating temperature exceeds 200°C.
The mats shall be secured in position by suitable means and stitched to one
another by galvanized binding wires of diameter 1.0 mm minimum.
All flanges, valves and fittings shall be provided with two-piece or multi-part caps
made of aluminum sheet of the specified thickness. Each piece or part shall be
double jacketed and the various ports shall be held together by quick release
clamps or lever hooks to facilitate assembly and disassembly.
All caps of the welded-in fittings shall be made longer by approximately twice
the insulation thickness so that the welding seams will be exposed after removal
of the cap.
All manholes shall be provided with heavy duty hinged insulated covers
wherever possible. Such covers shall be secured with easily accessible
clamps.
Tanks and process equipment shall be insulated in the same way as pipes, except
that the insulating material shall not be attached by wire but by using strong
galvanized steel bands.
109
Insulation for personnel protection
Where necessary, drain lines and valves shall be provided with a contact guard of
minimum 30 mm thickness against accidental contact, and this shall be installed in
the same way as the other insulation.
Where insulation is provided for heat conservation it shall reduce the heat loss to
an economic minimum. The maximum heat loss shall be 200 W/m2 at an ambient
temperature acceptable at 30°C and a wind speed of 2 m/s.
For personnel protection all surfaces with a temperature above 50°C and which
are within the reach of personnel shall be provided with protection insulation. The
maximum insulation surface temperature shall be 60°C.
Cold insulation
Pre-fabricated block and sleeves insulating pieces made from polyurethane (or
equal quality).
Pipes and flanges shall be cleaned and given an external protection; coat of paint
to 0.35mm (or equivalent).
Prefabricated pieces shall be fitted tightly to the pipes. A self-adhesive plastic foil
shall be wrapped tightly around the hard foam shells to serve as a steam seal.
The material and thickness of insulation for the various temperature groups of cold
piping shall be as given in the following table:
if required for 125 and larger 40. thick fiber glass or required
condensation rockwool
Materials and thickness of insulation for piping and equipment outside the
building exposed to weather:
The material and thickness of insulation for the various temperature groups of
piping exposed to the weather outside of buildings shall be as specified in this
article, except that the thickness will increase 13 mm in excess of thicknesses
indicated therein.
110
Chilled-water insulation
Cut-outs in the dover sheets for pipe supports shall be sealed with a permanent
plastic putty.
Vessels
All pressure vessels supplied under Contract shall be designed and manu-
factured in accordance with the relevant pressure vessel and welding standards
and codes.
The Contractor is held responsible for the correct design and dimensioning of the
apparatus.
Connections shall be provided for all pipe work, together with connection and
tapping points for instrumentation. Manholes, vents, drains, safety devices and any
platforms necessary for safe operation and easy maintenance have to be included
in design and supply.
If under any operation conditions vacuum can occur in the vessels. they shall be
designed for max. pressure and full (= 100%) vacuum.
The welding factor for all vessels is fixed to v = 1.0. The minimum wall thickness
should not be less than 10 mm, and an appropriate corrosion allowance based
upon the particular material, but not less then 1 mm.
1. manhole (minimum nominal bore 600 mm) for vessels of 1.0 meter diameter
and above
2. handholes (minimum size 200 mm) for vessels below 1.0 meter diameter.
All nozzles shall be provided with flanges and shall be so arranged that practical
pipe connections are possible. The stub length for all stub pipes shall be at least
200 nun, measured from the tank wall to the flange sealing surface. In the case of
insulated vessels, the length shall be chosen so that there will be a clear space of
at least 100 mm between the cover of the insulation and the underside of the
flange. Nozzles of nominal bore DN 50 and less shall be reinforced by two ribs at
different planes.
111
Nozzles below DN 25 are not acceptable.
For insulated vessels, provisions must be made for fixing and supporting the
insulation.
Manhole covers of nominal weight more than 20 kg shall be provided with hinged
arms.
All tank internals must be replaceable through the manhole. Prefabricated vessels
must as a minimum have a coat of primer applied before transport. They shall be
cleaned and internally dry. All openings must be secured closed before transport.
Tanks
Unless otherwise specified, tanks used for the storage of liquid fuels, lubricating
oil, raw water, makeup water, condensate, chemicals, etc. and tanks used for
mixing and agitation shall be of welded construction, manufactured from mild steel
plates of accepted quality and thickness in accordance with the approved relevant
standards.
All welds shall be continuous, including welds around internal slays, stiffeners and
supports (see also Article "Welding" of this Section V).
All large tanks shall have at least two manholes each of 600 mm inner diameter
complete with covers of the bolted type, fitted with a davit for easy handling.
All tank nozzles shall be provided with flanges, if not otherwise specified.
Nozzles shall be provided where necessary for the fitting of instruments, level
controllers and piping.
Arrangements shall be made for the blanking off or removal of all valves or pipe
connections during sand- blasting and painting to prevent the ingress of sand or
other matter. The protective process shall be applied also to any ferrous or non-
ferrous parts mounted inside the tanks.
Heat exchanger I
Only proven products shall be delivered. No cast iron components are permitted.
It must be possible to install and remove the heat exchangers without undue
difficulty. Lifting lugs and eyes and other special tackle shall be provided to permit
easy handling. '.
Tubular heat exchangers or plate and frame type heat exchangers are acceptable.
Where necessary the tubes are to be protected by impact shields. An adequate
number of visual inspection ports is to be provided in critical areas to facilitate
condition monitoring.
112
Unless otherwise specified; all heat exchanger tubes and casings must be
designed to withstand 1.2 times the zero flow pressure of the relevant pump at
cold conditions, or 1.2 times of the maximum positive operating pressure, as
applicable. The minimum design pressure is 6 bar, and the design shall be proof
against full vacuum. The test pressure must be 1.5 times the design pressure.
The heat exchangers shall be designed for the maximum temperature incurred
plus 20 K.
Where any heat exchanger part in contact with liquid can be isolated, and there is
a possibility of being heated from the other side, safety valves are to be provided
for pressure relief.
Pipes from drains, vents and safety valves are to be grouped together, and routed
to easily observable points equipped with covered funnels or to the flash tanks.
The overall design and conception of the heat exchangers and accessories is to be such that
they are suitable for the degree of automation envisaged for the individual system.
0.6.17.1 Standards
113
• IEC 162 Lighting fittings for tubular fluorescent
lamps
• IEC 214 On-load tap changers
• lEC 269 Low voltage fuses with high breaking
capacity
• IEC 287 Calculation of the continuous current rating
of cables
• lEC 292 LV motor starters
The Contractor shall provide the Owner/Owner's representative with four sets
(official, complete, unabridged and in the English language) of all relevant standard
specifications according to which the equipment is manufactured.
• 230/400 V ± 10% for power supplies to small electric power consumers and
motors up to 150 kW, for lighting and domestic power outlets.
• 230 V safe AC system for uninterrupted essential supplies to consumers,
where no break in supplies can be tolerated.
The general arrangement of the particular voltage level for each part of the plant
within the scope of the Contract' arid the connections of the power supply systems
can be seen from the general single line diagram.
All electrical equipment shall be entirely suitable for the use under the prevailing
site conditions (see elsewhere in this document) and be of tropical design with
vermin proofing.
114
0.6.17.4 Inductive interferences
The Owner may operate wireless communication equipment in the station, inside
and outside the housings of all the equipment to be supplied under this Contract.
The Contractor shall ensure that all the supplied equipment proof against any
signals emitted by this wireless communication equipment.
0.6.17.5 Color code system for switchgear, for local switching measurement-control-
signaling cabinets and for mimic diagrams
RAL 7032, pebble-gray shall be applied for all electrical and instrumentation
equipment housings.
Color code for indications, push buttons on control cubicles, panels, desks, etc.
shall be worked out by the Contractor according to the relevant IEC/VDE
regulations to be approved by the Owner/Owner's Representative.
Where the On/ Off function of a push button cannot easily be identified by the
location, this will be indicated by a sign “ON”/ “OFF” or “0”/ “1” or by color code as
se4scribed above.
Switchgear, housings for electrical equipment and electrical equipment itself must be
designed at least to:
115
splashing water and sand, additional sealing, special seawater or acid resistive coating
etc., depending upon the particular site conditions.
General diffusing lights in switchgear rooms and lights for figments in. luminous
ceilings for offices and control room must be designed at least to class IP32. The
lamps for external lighting and halide lights for internal lighting must have protection
class IP54.
In all rooms and areas where the local and operational conditions and
surroundings can lead to the accumulation of gases, vapors, mists or dusts which,
in combination with air, form explosive mixtures, the operational equipment and
installations to be used iri these circumstances must be of ~ explosion-proof
design. All operational equipment must be designed to comply with the class of
protection dictated by the ignitable mixture (e.g. compression-proof casing,
external ventilation, inherent safety, etc.).
In view of the potential dangers of electrical power, the following measures are
required for the protection of life, equipment and materials. Basically, all 'live' parts,
i.e. all parts of electrical, operational equipment at an electrical potential above or
below earth potential when in operation, and with a rated voltage over 42 V, must
be insulated or covered so that they cannot be touched accidentally
116
V, the contact potential shall be according to the values. given in VDE 0141
section 4. (Verein Deutscher Elektroingenieure)
The following rules and regulations are to be observed in carrying out protective
measure and in earthling procedure:
• IEC 79 and 364 including VDE 0100 and 0190 for installations up to 1000 V
All 'live' parts of electrical operational equipment that can be reached by hand must
be protected against direct contact either by means of insulation or through
constructional design, position or arrangement, or by means of special devices. If,
in the case of enclosed switchgear or control cabinets, access is required in the
course of normal operation (e.g. for replacing fuses). protection against direct
contact must still be ensured when the switchgear or control cabinet has been
opened up.
Protective insulation
Connection to neutral
The LV network shall be of the TN type, i.e. the LV neutrals of the 6.6/0.42 kV
auxiliary transformers are earthed directly.
117
The neutral conductor must be earthed in the vicinity of the particular local
distribution transformer, where it serves as the system earth.
The connection of the conductive non-live parts (e.g. consumer enclosures, frames
of electrical apparatus) shall be carried out.
• in the case of conductor cross-sections up to 10 mm2 Cu via a protective
conductor to the neutral conductor
• in the case of conductor cross-sections from 10 mm2 Cu upward direct to the
neutral conductor ...
At least the following measures arc to be taken for all parts that are 'live' when in
operation:
• in general areas:
• in electrical rooms:
118
Protection against contact voltages
Auxiliary switches
Where appropriate, each item of plant shall be equipped with all necessary
auxiliary switches, contactors and mechanism for indication, protection, metering,
control, interlocking, supervisory and other services. All auxiliary switches shall be
wired up to a terminal board on the fixed portion of the plant. whether they are in
use or not in the first instance. .
Auxiliary switches associated with circuit breakers shall have additionally 2 N.O.
and 2 N.C. contacts for spare.
Anti-condensation heaters
Heaters in switchgear/ MCC cubicles. control cubicles. panels. desks. etc., shall be
controlled automatically by adjustable hygrostats (setting range about 50-100%
relative humidity).
119
Heaters shall be connected to a suitable terminal box with main switch and
indicating lamp. They shall be placed in an accessible position. All equipment.
whether fitted with a heater or not. shall be provided with suitable drainage and be
free from pockets in which moisture can collect.
0.6.17.9 Requirements for local cubicles and local housings for e.g.
switchgear, control, measurement and signaling equipment
Steel-clad cubicles and enclosures with fixed, integral switchgear and apparatus
must be provided.
The switchgear cubicles must be partitioned off and incorporate a bus bar system,
the necessary instruments, control switches, switch panels of the individual switch
and apparatus chambers. The main bus bars are to be installed on the rear face,
topside of the switchgear cubicle in a lockable shuttered compartment.
Connections to switching devices, MCB's fuses etc. are to be made from these bus
bars. The lower part of the cubicle will house the terminal 'strips and connecting
blocks, the clamps for the cable terminals and if required parallel connection
copper straps for the connection of more than 2 cables in parallel. An adequate
number of ball studs must be provided within the switchgear cubicle suitable for
earthing the main and distribution bus bars as well as the switchgear itself by
means of portable earthing and short circuiting equipment (to be provided once per
switchgear panel row).
The space in the interior of the cubicles must be divided into a section with 'live'
parts, 'live' switching elements etc. and a section with control and measuring
equipment. The sections arc to be separated by reinforced sheet- steel. .
Care must be taken that in the event of arcing hot gases will not escape to the front
of the cubicles (the operational side).
Ammeters are to be provided on the cubicle front panel for the cubicle feeders and
the supply outlets for motors higher than 55 kW or motors of lower rating, but
particularly important for the process. A single voltmeter with 4-position voltmeter
changeover switch must be provided for measurements of bus bar voltage
between each phase and neutral. Measuring instruments should, in general, be
square in shape.
All cubicles, cabinets, panels, etc. shall be designed for an ambient temperature of
40°C (outside the enclosure) in non-air conditioned areas. Special precautions
shall be taken in the design of electronic devices for protection and control systems
housed in the cubicle in order to allow for these conditions.
Heating elements are to be provided generally in each local cubicle or cabinet and
shall be humidity controlled.
For easy monitoring and a rapid grasp of the operational state, colored mimic
diagrams with the required switch position indicators, apparatus symbols and pilot
lamps must be provided in every case on main process cubicles and switchgear
cubicles. Lamp test facilities for all signed lamps connected shall be provided. All
cubicles shall be provided with the required earthing screws.
120
Plastic-insulated, stranded conductors must be used for wiring within the
switchgear cabinets, which must be numbered at each end with special tabs so
that change by mistake is impossible.
Preferably plug-in type auxiliary relays are to 'be used. Apparatus being sensitive
to impact must be protected against shock and vibration.
On completion of hand-over the cubicles must contain at least 15% of fully fitted
spare terminal capacity and 15% of spare space for the future installation of extra
equipment. It shall be possible to replace indicating lamps on the front panels of
cubicle feeders and motor-supply outlets with<?ut isolating the equipment
concerned. Further-more the control system must be designed in such a way that
lamps operate at less than their rated voltage in order to avoid their being
overheated.
Incoming and outgoing cables have to be fixed by suitable metallic cubic glands.
General
Any electrical consumer unit, which is not controlled automatically or from the
central control room, is to be fitted with a suitable local control cabinet. The
local control cabinets arc to be installed in the immediate vicinity of the motor
drive to be controlled.
Pump motors, which are level controlled locally, will be given an automatic and
manual control. The respective level control cabinets arc to be fitted in the
immediate vicinity of the pump motors, gauge glasses or level monitoring
instruments.
Local control points are to be provided for all MV motors and important LV
motors.
Construction requirements
In general local control cabinets and level control cabinets with plastic casings
or cast aluminum housings, resistant to impact, sand, light and seawater,
mounted on walls or hot-dip galvanized supporting constructions, are to be
provided. Hot-dip galvanized casings will be acceptable.
The cabinets must be equipped with the necessary mini circuit breakers, fuses,
auxiliary relays, power contactors, terminal blocks and cable attachment
components.
The stipulation of clause "Requirements. for local cubicles and local housing for
e.g. switch gear, control, measuring and signaling equipment" shall be applied
too.
121
In hazardous areas, the necessary explosion proof control cabinets and level
control equipment must be provided in accordance with IEC 79 and VDE
0165/170/171.
The local control points are to be equipped as the minimum requirement with:
• ON button
• OFF button
• Running lamp
• FAULT LAMP
• TRIP HEALTHY indication
• Lamp test.
When two motors are installed, serving as operation and stand-by lIlIil, then in
addition to a double set of the above items, the following equipment has to he
installed as the minimum requiem:
Level controls
In the case of pump motors controlled by levels, in addition to thc level control
in each case the MANUAL - AUTOMATIC selector switch and the necessary
local points are to be fitted. Control of individual pump motors must be effected
as follows as the minimum requirement:
When two pump motors are installed for the same purpose the control is to
be effected as follows, as a minimum requirement:
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0.6.17.11 Terminal boxes and terminal cabinets
Terminal boxes and cabinets must at least have class of protection IP 54 and
must be equipped with the necessary terminal strips, cable glands and fittings
components for the connection of the cables ..
The necessary earthing terminals are to be provided for the earthing of the
boxes and cabinets.
According to the kind of fuels and gases used, the danger of explosions in
hazardous locations may be caused by ordinary electrical equipment.
Therefore, the installation in such locations shall generally be kept to a
minimum with said equipment designed or installed in compliance with the
latest issue of lEC Recommendation 79 and the appropriate Articles of the
American National Electrical Code (NEC) or the German VDE Standards
0165,0170,0171.
and
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(2) where inflammable volatile liquids or gases are handled, processed, or
used, but where concentrations are not normally hazardous, because liquids
or gases are handled in close~ systems,
All parts which may ignite a hazardous atmosphere shall have an enclosure
of sufficient strength to withstand the maximum pressure caused by ignition
of the most inflammable mixture of the gas involved. All necessary joints of
such enclosure shall be provided with long fits (minimum 25 mm) and close
clearances (equal or smaller 0.6 mm) to cool the escaping flame and to
prevent flame propagation to the outside atmosphere.
• Oil Immersion:
• Increased Safety:
• Intrinsic Safety:
All explosion proof equipment shall be of approved 'design and must have
undergone type tests according to the appropriate standards. The selection of
such equipment with reference to design features and allocation to hazardous
groups shall be subject to approval by the Owner/Owner's Representative.
Key interlocked switches shall be provided with a Yale or other approved lock
124
for locking in the neutral position. A similar lock shall be provided for each
selector switch for Locking the switch in any of its positions.
Approved means shall be provided for locking the cubicle doors, live terminal
shutters, etc.
The locks or padlocks shall be coordinated for the different applications and
shall be supplied with three keys. A key cabinet at the end of each board shall
be provided for storing the keys of that board. All eyes shall have six master
keys to open any lock or padlock/supplied.
Each key shall have one identification label fixed above the key hanging
hook inside the cabinet.
The cabinet door keys shall be similar and shall be six in number.
General
All motors shall be of approved manufacture and shall comply with the
requirements of this Contract. They shall be complete with terminal boxes,
cable glands and, where specified, with heaters and monitoring instruments.
Motors of the same type must be fully interchangeable and shall comply as far
as applicable with IEC motor standard dimensions. All AC motors shall be of
the squirrel cage type provided with either deep slots or double squirrel cages.
All motors shall preferably be from the same manufacturer. The general
construction shall be stiff and rigid, no light metal alloy casings will be accepted
for motors above the size of 10 kW. All precautions shall be taken to avoid any
type of corrosion.
All motors shall be fitted with approved types of lifting hooks or eye bolts as
suitable.
Rating
The rating of each motor shall be adequate to meet the requirements of its
associated plant. The service factor, being the ratio of the installed motor
output to the required power at the shaft of the driven machine at its
expected maximum power demand, shall be applied as follows:
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0.6.17.14.1 High voltage motors
Constructive features:
a) Climatic protection provisions for mounting in the open in n humid and hot
climate. Insulation class F. During operation at rated power of the driven
machine, the motor insulation must only be stressed in accordance with the
requirements of class B insulation.
b) Motor parts made of iron internally and externally sandblasted and surface-
protected.
c) Paint finish resistant to chemicals and seawater.
d) Bolts dichromate.
e) All joint faces and gaps sealed.
f) Anti-condensation heating to be switched into operation when the motor feed
circuit is in the ‘off’ position. Heater supply power 'on' indicting -lamps is to
be provided.
g) Special treatment of windings with resin impregnation plus immersion in
varnish.
h) Varnish-insulated laminations.
i) Pressboard material protected by varnishing.
j) Selection of special grade of sealing which are resistant to seawater.
k) Totally enclosed fan cooled type. For motor ratings the cooling air available
at the specific location has to be considered.
l) Condensation outlets to be provided at the lowest point in the housing.
Design and construction of the 1110tors shall comply with IEC 34-1, 34-5 or VDE
0530 and DIN 40050.
Electric features
126
h) In general motors must be capable of running without overheating when
subjected to three consecutive starts within one hour after having run for an
extended period on a voltage of 95% nominal volt-age. Thereby the second
start must be possible immediately after the first start and the third 30
minutes after the second start. In individual cases where operation depends
on signals from pressure switches or other such sources, then a more severe
duty with respect to the frequency of starting cycles per hour shall be
necessary and the design of the motors must be carried out accordingly.
Protective features
i) High voltage motors must be fitted with measuring points for the
determination of slot and bearing temperatures.
Six Pt 100 resistance thermometers (2 per phase, one each utilized for over-
temperature warning, the other for over temperature trip) are to be provided
for slot temperature measurement, and a double thermocouple or resistance
thermometer per bearing must be provided for bearing temperature
measurement.
Other features
Terminal boxes
The main terminal boxes on the high voltage side shall be provided with a pressure
relief joint for the purpose of reducing the danger of an accident as a result of
short-circuits, and shall be fitted with a terminal block suitable for any desired type
of connection .
Terminal boxes shall be totally enclosed and designed, to prevent the ingress of
moisture and dust (minimum IP 55). All joints shall be flanged with gaskets of
neoprene or similar material. The terminal box shall be scaled from the internal air
circuit of the motor.
127
In case lightning arresters for vacuum type switchgear controlled motors are to be
foreseen, they shall be incorporated in the terminal box or in a separate box.
Inside the terminal box an earthing clamp for connection of the cable shield must
be foreseen.
The opened terminal boxes must have provision for local earthing to be carried out.
Bearings
Motors smaller than 2000 kW shall preferably be provided with a constant level
gravity-fed type oil lubrication system with reservoir and oil breather.
Motors with roller bearings must be provided with a lubricator and lubricant supply
regulator fitted with solid brass cages that can be refilled while the machine is
running.
The bearings of the motors. must be free from stray bearing currents.
Where sleeve bearings are being used they shall be of the self forced lubricating
type. If forced lubrication is required it shall be arranged common to both -the
motor and the driven machine and provisions shall be made to ensure lubrication
during start-up and shut-down operations without the necessity to start an auxiliary
lube oil pump. Self-lubricated bearings shall be equipped with an easily accessible
lubrication pot with overflow pipe and oil collecting vessel.
All motors must have the star-point connection brought out separately to terminals.
For all motors with a rating of 2000 kW or above a differential relay for winding
protection shall be provided and installed in the associated switchgear. In that case
the star-point connection shall be brought out separately to terminals.
The differential current transformers are to be designed to class 5P1 0 with a rating
matched to the protection system. The CTs shall be accommodated in the star-
point terminal box.
Coupling
The motor shaft halves of the couplings, finish-bored, balanced. and complete with
keyways are to be drawn on to the motor shaft and balanced out together with the
rotor. A coupling guard will be provided.
Running quality
The running quality must be within the classification of "good" according to the
VDE recommendations (VDl 2056 group D), i.e. the vibration velocity must be less
than or equal to 1.8 mm/s (rms.).
128
Cooling
Air cooling for the motors is the preferred method; where water-cooling is applied,
conditioned, treated water is to be used.
Motors shall have a closed internal cooling air circuit recooled by an external
cooling air circuit drawn, from the opposite side of the driving end. MV motors
installed in the turbine hall shrill be recooled by water taken. from the service water
s)'stem. The air/water coolers shall he arranged in such a way as to give free
access for cleaning purposes without dismantling them or the associated C.W.
pipes.
Motors installed outdoors and directly subjected to sun radiation shall be rated
such as not to overstep the maximum metal temperature of 85°C. Where
necessary such motors shall be provided with fabricated steel sun coverings.
Reverse speed
If reverse running can occur in the case of equipment driven by a motor (e.g.
cooling water pump), the motor must be designed for maximum possible
reverse speed.
Constructive features.
The same features as for high voltage motors shall apply. Anti-condensing
heating shall be provided for motors of 55 kW and above.
Electric features
129
network and with phases in opposition.
The electric features a), b) and c) of high voltage motors also apply here.
Motors starting current must not exceed 7.0 times rated current (referred to
the motor rating and 40°C ambient temp.).
Protective features
Other features
Cable Leads
The cable connecting boxes are to be installed easily accessible on the motor. The
connecting boxes .must be capable of being turned by 900 or 1800 and of being
opened up longitudinally. The connection boxes are to be filled with a terminal
block.
Bearings
The motors are to be provided with roller bearings (i.e. groove ball or cylindrical
roller type). The motors must be free from stray bearing currents.
Cooling
Shafts
Where not otherwise specified, motors must be filled with a free shaft end
All actuators for valves, dampers etc are to be fitted with socket and plug of well-
established make to IEC 309, VDE 0620, CEE 17 or equivalent for the power cable
connection. For the control cable connection separate socket and plug shall be
provided.
130
0.6.17.14.4 DC motors
Brush gear for DC motors shall be designed to ensure constant brush pressure.
Carbon brushes shall be provided which stand at least six months of operation
without replacement. Each brush shall be independently adjustable but shall not
require adjustment" throughout its life.
The brush holder shall not touch the commutator as the brushes wear and current
carrying through the pressure fingers will not be accepted.
A sufficient number of brushes, not less than two per pole, shall be fitted to ensure
that vibrations do not effect the commutation.
The minimum safe wearing depth of commutators shall not be less than 6 mm and
the minimum safe diameter shall be marked on them.
0.6.17.14.5 Painting
All motors, whether for outdoor or indoor installation, shall receive a coating of
paint which is resistant to sea water and corrosion.
All internal and external steel parts of the motors must be sand-blasted and
impregnated. Following this, a paint finish resistant to chemicals and seawater
must be applied. The' bolts used must be chromated at least.
General
On the basis of the requirements of the driven equipment, the Contractor will
design, supply, install and commission a complete, fully operative, variable-
speed converter drive (frequency converter and motor, for motors up to 400
kW, for motors 400 kW and above in addition to the converter a converter
transformer wiII be provided) .
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Technical requirements
Maintenance work and cable connections must always be possible from the
front of the converter cubicles.
The terminals on the input and output sides are to be rated. such that parallel
cables can be connected.
For motors with a rating lip to 400 kW the frequency converter shall be
designed in at least a six-pulse circuit on both the line and motor sides.
For motors with a rating above 400 kW the converter should be designed in a
12 pulse circuit supplied via converter transformer.
In the case of a current converter, the line rectifier is to take the form of a
line-commutated, fully controllable three-phase bridge. A self commutated,
fully controllable three-phase bridge is to be provided for the inverter on the
load side.
In the case of a voltage converter, the line rectifier is to take the form of a
fully controllable three-phase bridge. A self com mutated three-phase bridge
with turn-off thyristor branches is to be provided for the inverter on the load
side.
The line rectifiers are to be designed for a braking current which is at least
85% of the motor rated current.
If the voltage reduction or the power failure lasts for a long time, the drive must
132
remain switched off; in this case, it must subsequently only be possible to
switch it on again either manually or by means of the higher order control.
The converters arc to be designed for 10% more than the maximum power
output required by the system. The purpose of regulating the converter is to
ensure that the indirect current and voltage remain within the permissible limits
during all control processes. This should apply both when the motor is started
up and when the speed is adjusted during operation.
The reactors in the DC link should smooth the DC current and limit the current
rise in the event of a malfunction.
Flow monitors (not air vanes) are to be used to monitor the fans. Positive
control is to be provided for fan drives with a master drive.
Converter transformers
The transformers are to take the form of cast-resin transformers and arc to be
installed in protective casings made of sheet steel, cooling method AN, type of
protection at least IP 21.
The connections on the high-voltage side have to be carried out using cables.
Bus bar connections with short-circuit protection arc to be provided to the
current converters on the 100\'-voltage side.
133
.winding after shut-off periods. The protection against voltage surges and short
circuits, the noise levels and the freedom from partial discharges up to twice
the rated voltage will be verified by means of type tests.
The equipment types are to be agreed with the client in the event of an order
being placed.
All the lines belonging to the protection and monitoring systems are to be
applied to a transfer terminal strip as individual signal lines.
Controls
a) local/remote converter control (key-operated switch)
b) "on" and "off' converter controls
c) set point adjuster (speed)
d) incoming master switch, "on-off'
e) all the controls necessary for internal converter settings and adjustments,
as specified by the manufacturer
134
dance with the manufacturer's standards, though at least:
• over temperature
• line voltage monitoring
• line under voltage
• over current
• control voltage monitoring
• converter protection
• fan monitoring
• incoming air temperature
• motor feeder interruption
• motor feeder short circuit
• earth fault
• motor blocked
• other faults
Account must be taken of the following types of remote control and indica-
tion in the control room, and suitable interposing relays, transducers and
switchgears are to be provided in the cubicle:
All event signals and check back signals must be made available on the
terminal strip as floating change-over contacts
System perturbation
The motor list will be issued by the Contractor shall include all aggregates
driven by electrical -motors (except final control elements as control valves,
dampers, etc.) and shall contain at least the following technical data:
135
• design speed of driven machine
• kind of operation (continuous, intermittent, for start-up only)
• type of motor construction, cooling, and protection
• actual service factor
• electrical design data e.g. nameplate rating, rated voltage, rated speed,
rated current, power factor, efficiency, ratio of starting to rated current, ratio
of pull-out to rated torque
• other electrical data e.g. starting time at maximum opposing torque,
frequency of permissible starts (for motors above 10 kW only)
• driving end and non driving end bearings: manufacturer, type and type
number, size.
0.6.17.14.9 Tests
Each motor shall be factory tested and shall undergo a test at site. The
following tests shall be performed under full responsibility of the Contractor:
Workshop tests
Tests at site
0.6.17.15 Labels
General
The proposed material of the labels, the size, the exact label inscriptions as well as
proposals for the arrangement of the labels shall be submitted to the Engineer for
approval. Where applicable, Bengali designations shall appear above or to the
136
right of the English designation. The Bengali translations and writings shall ,be
readable Bengali and samples shall be submitted beforehand for approval.
Labels written in English shall be provided for all instruments, relays, control
switches, push buttons, indication lights, breakers, etc. In case of instruments,
instrument switches and control switches, where the function is indicated on the
dial plate or the switch escutcheon plate, no label is required. The label shall be
fixed close to the instrument in such a way that easy identification is possible.
Fixing on the dial glass of instruments will not be accepted. The wording shall
conform to the wording used in engineering documents and shall be submitted for
approval to the Owner/Engineer.
All equipment inside cubicles, panels, boxes etc., shall be properly labeled with
their item number. This number shall be the same as indicated in the pertaining
documents (wiring diagrams, equipment list, etc.).
Each separate construction unit (cubicle, panel desk, box, etc.) shall be provided
with top mounted labels made of anodized aluminum with black inscriptions giving
the overall designation in Bengali and in English.
Warning labels
Warning labels shall be made of synthetic resin with letters engraved in Bengali
and English.
For indoor circuit breakers, starters, etc., transparent plastic material with suitably
contrasting colors and engraved lettering shall be provided.
L V switchgear shall have yellow labels with 5 cm black letters reading "MAINS
400 VOLTS" .
MV switchgear and transformers shall have red labels with 7.5 cm white fetters
reading "DANGER 400 V or 6600 VOLTS".
137
Labels for conduits, etc.
The cable identification numbers shall comply with those of the cable schedule.
All cables in cable pits and at entry to building blocks shall be labeled utilizing
the aforementioned type of label.
Nameplates
138
• A,kA for currents
• V,kV for voltage
• MW, kW for active power
• MVAr, kVAr for reactive power
• Wh, kWh for active energy
• V Arh, kVArh for reactive energy
The control switches, adjusters, etc., on the panels and desks shall harmo-
nize with the above mentioned indicator sizes.
0.6.18.3 Protection and safety interlocks
To protect individual units or parts of the power plant, interlocks are to be
formed in accordance with process criteria, which can be either active or
passive depending on their functions.
139
plant before they reach a critical operating condition or shall start certain
units (e.g. stand-by) in order to avoid a critical operating condition. In
addition, such dangerous conditions must be immediately indicated to the
operating personnel by means of an alarm.
Active and passive interlocks must not be capable of being switched off
operationally from the central control room. All protections have to work fully
automatically and independent of the operator and always have to be
effective for all procedures (manual, partial automatic, fully automatic).
After a stop or close action by protection, the restart of the equipment shall
be possible only after the fault is rectified and the protection signal is reset.
Simple cancellation of protection signal by start command shall not be
possible. The protection action and the operator reset shall be recorded by
the DCS.
0.6.18.4 Special local conditions
Due to the high humidity special measures shall be considered for the
I&C equipment.
0.6.18.5 Tests
140
representatives. Besides. all equipment shall be tested in compliance with
the prevailing lEC standards and recommendations.
Generally 2-wire transmitters shall be used. If for some special purposes (e.g.
analyzers) 230 V AC power supply is required. the output circuit shall be isolated.
As far as possible. all transmitters shall be of the SMART-type. This applies also to
field-mounted temperature transmitters.
Thus. only sensors, transmitters and converters with electrical output shall be
provided. The output signal of transmitters shall be linear and over a wide range
independent of the burden in the output circuit.
Transmitters with accuracy class 0.5 or better must be used. The repeatability shall
be within a range of ± 0.1 % of full span.
The removal of connected devices must not open the transmitter output circuit or
cause malfunction of this circuit. In the case of failure and return of the supply
voltage within a measuring circuit. no false signals endangering the system shall
be issued. All transmitters shall be individually fused.
The components shall quickly respond to any changes of the measured variables.
Measuring errors shall be as low as practicable. Measuring ranges of indicators,
transmitters, etc. shall be selected in such way that the rated value of the variable
covers approximately 75% of the span.
141
into enclosed racks or panels for easy access. Sunshades shall be provided for all
outdoor panels
Individually installed transmitters shall have their own weather proof enclosure of
robust construction "nu be suitable for the proposed environment. All field
equipment terminals shall be wired to a terminal box using screwed connections.
Transmitters shall be provided with all necessary isolating, vent and blow down
valves and facilities shall be provided for the connection of test instruments at the
input and output of each transmitter, to enable calibration to be carried out.
The primary elements of flow meters shall be standard orifices and standard
nozzles unless otherwise specified.
Their design and performance shall be in accordance with the before mentioned
Standards.
The throats of flow metering nozzles and orifices shall properly be protected
against erosion by means of stellite lining or equivalent means. In case of Reynold
numbers below 100,000 quadrant nozzles or double tapered orifices shall be
provided.
Isolating valves shall be provided at the tapping points of the orifices/ nozzles. In
the case of steam flow measurements condensing vessels (steam traps) shall be
provided between the tapping point and the isolating valve.
In case of flow measurements for fluids with pressures higher than 25 bar double
shut-off tapping valves shall be installed. The design and arrangement of tapping
point, piping and valves should be according to VDI/VDE rules 3512 Bl.1 or
equivalent standards.
The material and dimensions of the piping shall conform to those laid down for the
piping concerned. The welds shall be executed in such a manner as to avoid
turbulence them can affect measurement.
In order to achieve exact installation, the vendor supplying the orifice plate or
nozzle for high pressure pipes shall install the orifice plate or nozzle in its own
works in a section of pipe of about 3.5 times the pipe diameter (1.0 x Nil in the
outlet, 2.5 x Nil in the inlet). For orifice plates or nozzles installed in pipes with a
nominal bore smaller than 80 mm, complete meter runs shall be supplied.
Orifice plates and nozzles shall be manufactured of ANSI 316 Stainless Steel
unless specified otherwise.
Orifice plates shall be sized for a d/D ratio not less than 0.20 and not greater than
142
0.70. Higher other than lower d/D ratio are preferred to minimi7.c line restrictions.
All sizing calculations shall be submitted to the Engineer for approval.
Tags on orifice plates shall be stamped with the basic design information (i.e. flow
rate, pressure and temperature of the passing fluid, the orifice diameter and the
pressure differential generated).
Venturi tubes shall only be considered when operating economy requires low
permanent pressure losses.
Steam, gas and air flow measurements at measuring points with variable
temperature and/or pressure should be provided with automatic correction of
flow signal.
All flow transmitters shall begin to measure correctly at a rate of flow of at least
5% of the measuring range. The error limit shall be limited to ± I % f~ a rate of
flow higher than 10%. The error of the primary elements is not included in this
accuracy.
The root extraction of flow measurements shall be effected electrically within
the transmitters.
For the measurement of fuel oil flow, turbine type meters or positive
displacement meters shall be used.
Magnetic and ultrasonic flow meters may be used under special circumstances
but prior to their" use agreement must be obtained from the Engineer.
When the requirements of the Standards cannot be fully complied within some
cases, then, as an exception, an uninterrupted pipe run of at least lOx Diameter
143
(D) length should be provided, with 8 D located upstream, and 2 D downstream
from the measuring point. The said exception is subject to special approval by
the Engineer.
The temperature sensors shall be selected in such a way, that only a small
number of different spare inserts is required.
For all pipe work a minimum immersion depth of 55 mm in the internal pipeline
cross-section and a minimum distance of 15 mm from the opposite pipe wall
must be provided. If the diameter of the pipeline does not allow the
thermometer to be inserted perpendicular to the pipe axis while still maintaining
the above mentioned measurements another solution must be found in
cooperation with the Engineer.
When determining the lengths of the insertion and connecting tubes the
insulation thickness is 10 be taken into consideration.
Pressure gauges shall be shock and vibration proof (preferably by filling with
glycerin). They shall be made as far as possible of stainless steel. Pressure
gauges for steam and gas shall have safety properties according to DIN 16006
or equivalent.
Over ranging the measured pressure shall not deteriorate the pressure gauge
nor affect its calibration. The pressure gauges shall be equipped with a radial
connecting stud, to allow the mounting on a gauge holder.
145
transmitters shall group wise be combined on racks or in cubicles (in open
area). In case of flowing substances, the tapping point shall be selected in
regions of undisturbed flow.
The design and arrangement of tapping points, piping and valves shall be
according to VDI/VDE rules 3512 Bl 3 or equivalent standards.
For gas measurements the pressure sensor shall be arranged above the
tapping point; if this arrangement is impossible condensate craps and blow
down valves shall be installed.
For liquid measurements the pressure sensor shall be arranged below the
tapping point, gas traps and blow-off valves shall be mounted if this is
impossible.
Open blow down/drain connections shall not be arranged within panels and
local equipment. Instead it shall be led to a drain external to the panel.
All valves shall be installed so that they are accessible for maintenance
from a floor or permanent structure landing.
The blow-off valves must be separated from the valve block, if test connec-
tions are required.
146
0.6.18.6.5 Analyses measurements
Conductivity electrodes, pH-electrodes, and other sensors for analysis may only
be built directly into pipes if the medium pressure is below 25 bar. In all other
cases sampling devices shall be provided.
Sampling devices and analyzers for steam and water shall be centralized by
groups on sampling racks. These devices shall simultaneously serve for local
supervision and manual sample taking as well.
Furthermore, these sampling devices shall operate in a way that first cooling and
then throttling of the medium takes place.
The sampling system shall include but not be limited to all' probes, valves, filters,
coolers, drainage facilities, flow regulators, flow meters, piping and pumps as
necessary, to give the analyzer a representative and suitably conditioned
sample.
For convenient manual sample taking the sampling devices shall be equipped
with funnels with inherent screens to locate the sample bottles upon.
The sample racks shall be situated in such a way as to obtain minimum length of
the tubes from the sample tapping points to the racks. These tubes shall be of
nickel or equivalent material.
147
0.6.18.6.5.2 Analysis of exhaust gas
The analysis of 02, CO, NOx, SOx and dust in the exhaust gas shall be
performed for each unit by appropriate analyzers of proven type.
The reliability and response time of the 02-analyzer shall be of the quality'
required for closed-loop control. A zirconium oxide measuring cell shall be
used. Maintenance shall not be more than once a week.
Analyzers provided shall. have auto-calibration for zero and span as well as
self-diagnostic functions.
In order to keep the sampling lays to acceptable limits the analyzers shall be
located close to their sample take-off point, so that easy access to the sample
take-off point and to the analyzers shall be provided for maintenance.
The exhaust gas sampling lines shall be heated to prevent condensation and
shall not form a siphon in the case where condensate may be collected
during heater failure. Condensate drainage facilities shall be provided the
analyzers.
Generally, the analyzers and the sampling probe equipment shall be mounted
in an air-conditioned room or container.
Power failure and system failures of analyzers shall be monitored in the DCS
by a group alarm.
Adequate measures shall be taken to eliminate dirt from the sampled gas
before it reaches the analyzer. Besides; effective measures shall be taken to
avoid-sulfuric corrosion within the samplers/or analyzers. .
The analyzers shall be a type which does not continuously consume refer-
ence gases (like hydrogen).
148
indication time constant: 20 sec. per 90% of full deflection
The remote measurements for the liquid level in the boiler drums and banks
with a steam cushion of pressure above atmosphere shall be of the hydro-
static principle by means of a differential pressure transmitter.
Where detection of discrete levels is required, the simple float operated switch
should be used, however each switch shall have snap action with limited
hysteresis to prevent contact bounce caused by small fluctuations in level.
Switches used for level detection shall provide facilities for testing the
mechanical and electrical operation of the switch without its removal from the
process. Isolation by means or shut-off valve will be allowable during testing.
POI' measurement of large storage tanks, the load indication and transmitting
mechanism shall be located at the base of the tank.
For measurements where a reference leg of process fluid is used. the design
of the system shall ensure that the reference leg is fully maintained at its
prescribed height during all conditions of process level change and changes in
process conditions and the density of the reference leg docs not vary from that
of the process fluid due to. temperature changes or other reasons.
Local level indicators of big tanks shall be equipped with a scale length of full
height of the tank. Locally mounted water level indicators shall be of bicolor
149
type equipped with electric illumination, working in such a way that the water
level is clearly readable as a column over the complete measuring range.
Level indicators showing the level only as a point will not be accepted.
The indicating range of local level indicators shall cover all switching points of
level switches mounted on the tank or similar as a minimum requirement.
On all forms of measurement all parts of the switch, transmitter, etc. in contact
with the process fluid shall be made of material compatible with the process
fluid, Stainless steel shall normally be used for all corrosive duties
All indicating instruments shall comply with IEC-51 and shall have a Class Index
between 1.0 and 5.0 depending upon scale length. They shall be of approved
type, make and size and flush mounted with square bezels and square or
rectangular faces. The cases of instrument and meters shall be dust and
moisture proof and suitable for use in a tropical climate.
Where ammeters are provided for indication of motor currents they shall be
supplied with overload scales indicating the six times full load current.
The dials of such ammeters shall include a red line to indicate the full load
current of the motor.
Instrument pointers shall be of low parallax type and means shall be provided for
zero adjustments without dismantling. They shall be as arranged that the normal
working indication is between 50 and 75% of full-scale deflection.
All integrating meters shall be flush mounted and shall comply with the relevant
parts of IEC-521 for MWh meters, with dial type registers. Approved test terminal
blocks of the three-phase type shall be provided
The meters shall be able to record min. 10000 hours and shall be suitable for
unsymmetrically loaded phases.
For generator circuits all export only and import only MWh meters shall have
maximum demand indicators of class 0.5. They shall be fitted with inductive
transmitters to operate MWh electronic summators with maximum demand
indicators. All maximum demand indicators shall have a 30 minutes resetting
period.
All other meters for acceptance testing shall be not less than class 1.0.
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the primaries of their corresponding instrument transformers.
The scales of all direct current instruments and of all alternating current indicating
watt meters shall be arranged so that the instruments will read 10% of the full
scale reading below zero and this part of the scale shall be marked in red.
Watt meters and Var meters shall include the limits for inductive and capacitive
power factor.
When more than one measured value will be indicated on the same instrument,
the measuring point selector switch will be provided next to the instrument and
will be engraved with a legend of the measuring points.
0.6.18.6.7.2 Transducers
General
All transducers shall be provided with a nameplate, indelibly marked with the
following information:
• name of manufacturer
• manufacturer's type reference
• serial number
• rate input voltage and current, as appropriate
• DC output current
• overall ratio (e.g. Watts/mA).
The type of transducers selected shall be suitable for use in digital instru-
mentation schemes and the outputs of all transducers shall have a linear
relationship with the measured quantity. Transducers shall be self-powered,
where possible, or powered from the RTU battery power supply.
Each current input shall be capable of carrying 200% rated current continuously
and shall withstand 10 times rated current for 5 seconds without damage. The
output shall be accurate up to 120% rated output. In addition, transducer inputs
shall withstand 30 times rated input current on each range for 3 seconds without
damage.
Transducers shall withstand for one hour, without damage, a short circuit on the
output terminals when the input circuits arc carrying rated voltage and current.
The error in transducer output shall be not more than ± 0.5% of full rated output
over as great a part of the output range as possible. For all inputs, the output
error shall not exceed ± 0.2% due to ± 10% voltage variation in the
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voltage circuit input nor exceed ± 0.5% due to a ± 10% change in the input
frequency.
The root-mean square ripple current shall not exceed 5% of the maximum signal
current and shall preferably be much less.
The response time to reach and remain above 80% of the final steady value for a
step change in input from zero to a value equal to full rated output shall not
exceed 1 second.
Power transducers
The transducer output shall be 0 to 10 mA for single direction power flow, and -
10 to 0 to + 10 mA for reversible flow, respectively~ representing 0 to 1.2 amps
input current at nominal rated input voltage. The polarity of transducers for
measurement of both forward and reverse power flow shall be such that power
flow into the busbar is positive.
The burden imposed on the primary circuit current and voltage transformers at
full rated input shall not exceed 2 VA and 12 VA respectively.
The additional burden imposed on the primary circuit current transformer at full
rated input when the dc output is open circuited shall not exceed 2 VA, and the
transducer's steady output voltage shall not exceed 25 volts.
Voltage transducers
The phase angle voltage transducer shall have an inverted linear output of 10 to
0 mA representing an input range of 0 to 240% of rated input voltage.
The burden imposed on the primary circuit voltage transformer at nominal input
shall not exceed 5 VA.
Current transducers
The nominal input current rating shall be 1 amp. The effective range of the
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transducer shall be 0 to 120% of the rated input current and the accuracy shall
be ± 0.5% at full rated output.
Frequency transducers
Summators
The transducer shall have an output range of 0-10 mA representing tap position
1 to maximum tap position. Tap 1 should be at 1 mA and maximum tap at 9 mA.
Due account shall be taken of tap change transfer taps positions which do not
affect voltage output.
For the continuous remote position indication of valves, dampers etc. also
transmitters with impressed output signal of 4-20 mA shall be employed.
Therefore, electronic position transmitters shall be used.
Where binary signals cannot be derived from an analog value. binary transmitters
e.g. temperature switches, pressure switches etc. may be used. Indicators with
integrated limit switches are allowed within package units. Preferably limit
switches shall be of the proximity type.
All switches shall be of robust design and reliable performance. The switches
shall have an adjustable switching hysteresis.
The set point and the dead band (reset point) of each switch shall be adjustable
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from inside the case, over the full range specified. The set point and reset point
shall be indicated 011 the adjusting mechanism.
The switches shall be housed in robust, dust and moisture proof cases having
glanded cable entries and shall be suitable for the ambient conditions local to the
equipment, on which they are mounted.
Contact devices for interlocking systems shall be separate, i.e. contact devices
serving commonly for interlocking and other purposes will not he 'accepted.
The vibration monitoring system shall be reliable, accurate, easy to maintain, and
suitable for use in such ambient conditions appertaining to the intended plant
installation.
The following criteria shall be used as a guideline for rotating machinery, in order
to ascertain the monitoring points, principles of what signal shall be measured,
what is displayed, and what mechanical conditions entail alarm and/or trip status:
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• Facilities shall be provided for the calibration of the instrumentation system.
0.6.18.6.11.1 General
General requirements for control valves are contained in Clause B06 and further
details are given below.
Control valves shall be standardized wherever possible and shall be sized for
optimum control. The sizing calculations shall include CV, noise and cavitation
calculations.
Valves bodies shall in all cases match the piping pressure and temperature
rating specifications as a minimum and the operating point on the valve
characteristic, i.e. lift/throughput curve should be within the 60-70% operating
range.
For normal service duties valve bodies shall be of carbon steel with and
connections flanged raised face, unless process conditions dictate or otherwise
specified. Flange type connections shall in all cases match the piping
specifications as a minimum but never Iess than a pressure rating equivalent to
ANSI Class 300 specification. (See ANSI B36. 10 for full details rating
schedules.)
For liquid services with high pressure drop cage-guided control valves shall be
provided having the plug supported at the critical area.
For severely erosive service the fluid impact area inside the valve body shall be
covered by welded stellite.
For high pressure superheated steam service the complete valve body shall be
of Cr 13 Mo 44 or equivalent.
A linear characteristic shall be provided when the pressure drop across the
control valve under all operating conditions is more than 2/3 of the pressure drop
across the valve in the closed position. Unless otherwise approved an equal
percentage characteristic shall he provided for all other cases.
Hardened and/or stellite plug and seal rings shall be used for the following
applications:
• erosive service
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• wet steam service with pressure drop above 5 bar
• general service with pressure drops greater than 5 bar.
For the above applications valves up to and including 38 mm shall have their
plug and scat rings made from solid stellite. For larger sizes, Ihc plug and scat
rings shall be made from stainless steel, ANSI 316 and be completely metal
coated wilh Stellite No.6
Valves shall be provided with teflon asbestos packing and a lubricator assembly.
For services with fluid temperatures above 200°C or below 10°C a normalizing
bonnet shall be provided to keep the packing box at ambient temperature
Bellow seals shall be used on valve stem packing for services with
dangerous/poisonous fluids: Suitable valve stem material shall be provided with
valves used on chlorine services or other services which become acidic when in
contact with a moist atmosphere.
Where very large sizes are involved (on high flows), butterfly type valves shall be
used and it will be “balanced torque" type disc usable to the fully open position.
The overall shaft rating shall be at least 25% above rated pressure as differential
across the closed valve.
Multi-stage valves shall be used on services, e.g. steam and gas, having
very high pressure drops which would result in supersonic velocity inside a
conventional body and shock waves in the piping creating unacceptable
noise levels.
For liquids the exit trim velocity shall not exceed 30m/sec.
For flashing service the exit trim velocity shall not exceed 22.5 m/sec.
For gas and steam the velocity head in line shall be less than 70 psia.
Ball valves shall be used for on-off and throttling services under moderate
operating conditions.
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details and justification shall be submitted to the Engineer for approval.
0.6.18.6.11.7 Installation
The installation shall include for upstream and downstream isolating valves and,
and for critical control valves, a bypass valve for each control valve on all
services. Unless otherwise agreed by the Engineer the bypass valve providing
tight shut-off shall have the same characteristics and construction as the control
main valve. Any exceptions or variations to this requirement shall be subject to
the approval of the Engineer. Where a service is subject to pressure above three
bar g a 25 mm vent valve shall be provided, between the upstream and
downstream isolating valves, in order to relieve the pressure to enable
maintenance to be carried out on the control valve. Control valves shall be
adequately supported in all cases and shall be accessible for maintenance. Local
pressure gauges shall be provided at the upstream and downstream of each
control valve.
0.6.18.6.12 Actuators
0.6.18.6.12.1 General
Unless otherwise specified actuators for modulating valves and dampers shall
either be pneumatic or electrically operated. Self contained scaled hydraulic units
may be considered where high thrusts or high speeds of operation are required
but each application shall be to the approval of the Engineer.
The various types and sizes of actuators shall be rationalized and as far as
possible each type shall be from a common manufacturer to facilitate
interchangeability and spares.
The operation of all actuators, control valves and driven units, shall be so
arranged as to ensure the safety of the "plant" under failure of control or
actuating supplies.
With either action the failure mode shall be suitably monitored and the plant
operator informed by some form of alarm.
Where pneumatic actuators arc used, an internal bias spring shall be used to
obtain motive power 10 reach the safe position in the event supply failure
Where the type of actuator offered does not have the appropriate fail-safe
facilities described above then the valve/damper shall have a second
valve/damper in series or parallel as appropriate, designed to provide the correct
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failure response.
The failure response of all actuators in .the event of the loss of the prime mover
(air pressure, oil pressure, electrical power) shall be indicated on the Piping and
Instrumentation (P&I) diagrams, valve Sc11cdules, etc.
All modulating and regulating actuators shall be filled with position measurement
for CCR indication of actuator position. This requirement applied irrespective of
the operating mechanism, whether electric, pneumatic or hydraulic.
All actuators which are controlled remotely from a panel or from the CCR shall
have independent control units and independent remote/local, auto/man
functions where specified or applicable. It is not permitted to gang several
actuators onto one signal output and independent positioning control shall be
provided for each actuator.
Where control requirements call for split range operation, the computing of the
split range shall be carried out externally from the actuator such that standard
signal inputs to the actuator are maintained.
All actuators shall include a mechanical device to show the true position of the
operating mechanism.
All actuators shall have a hand wheel for direct manual operation. The diameter
of the hand whelp and geared effort shall be such that they are reasonably
operable by one man. A lockable mechanical clutch mechanism shall be
provided to inhibit power control of the actuators when the hand wheel is
operated. The disengagement for hand control shall signal remotely to indicate
that the normal operation of the actuator is inhibited.
All actuators shall be provided with a local control facility. which in general will be
used for test purposes only. Such controls may take the following forms, as
appropriate or specified:
a) Control initiations (i.e. raise, lower, etc.) with lockable local/remote selection
when appropriate either on the actuator, in the direct vicinity of the actuator
or on its associated switchgear.
b) A portable test facility for injecting the appropriate position demand signal
either at the actuator or drive unit (switchgear or power amplifier).
Two classes of actuators are identified; firstly the motorized actuator which shall
cover the isolating actuator type and including actuator type required: for open
loop (binary) control; secondly the modulating actuator which shall cover the
switched types and continuous control type required for closed loop control.
Isolating actuators shall have short time ratings appropriate to duty cycle type S2
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10 min. to IEC 34-1, and n maintenance free interval better than 10,000
open/close cycles.
Unless otherwise specified actuators with integral or separate switch units may
be offered. The contactors may be of the mechanical or static (thyristor) switch
type. If a static switch is offered then the switclll1nit and actuator shall be
supplied by the same manufacturer as a complete system.
These actuators shall be provided for closed loop control functions. Two
principal types are recognized:
• Switched actuators
For each actuator the drive voltage and current or frequency of the AC
power source shall be continuously varied to regulate the rate of
operation. Each shall be capable of slow creep operations as well as
rapid stroke action and the operating torque shall be sensibly
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independent of the speed of operation.
If integrated within the actuator, the actuator and associated power amplifier
unit shall be manufactured as a composite system with a minimum of three
years of proven service reliability. In any case, the actuator and drive limit
shall be rated continuously for the stalled condition and three phase motors.
shall be provided for all actuators with ratings above 250 \watts.
(i) the drive unit shall accept an analogue (4 - 20 mA) actuator position demand
signal or pulsed raise and lower signals if an external position loop is provided
(iv) an override facility for stroking the actuator in either direction for binary
control interventions
(v) monitoring of common fault conditions such as thyristor drive fault, motor
temperature high, AC power supply failure, circuit continuity fault, high torque etc.
(vi) all necessary protection devices to protect the actuator and drive unit against
abnormal operating conditions.
Generally the actuator drive units shall either be integrated in the actuator or be
grouped and mounted within cubicles of appropriate enclosure standard. Unless
otherwise specified the later cubicles shall be located in an electrical switchgear
room to obtain protection from the normal plant environment.
The Engineer's approval shall be required where different types of actuators are
offered to those specified above or where the drive unit and actuator are
selected from different range of manufacture (preferably from two different
manufacturers). Additionally these shall he subject to a type test, approved by
the Engineer, to prove their satisfactory performance under equivalent operation
conditions.
All pneumatic actuators shall be provided with a positioner using a standard 0.2
to 1.0 bar signal.
Pneumatic actuators and drive units shall automatically return to the rest position
upon signal and/or air supply failure unless "process control" or the specification
requirements dictate for "stay put" response.
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Where "lock up" devices are provided on those services requiring the actuator to
remain in the position prevailing immediately before an operating medium failure,
the following two methods of "freezing" are acceptable:
a) The pneumatic system may be locked, but equipment used for this
purpose shall always be installed between a positioner output and an
actuator input.
All pneumatic control equipment, control drives rind control valves, shall be
capable of satisfactory operating on n main air supply pressure of approximately
7 bar g normal down to 5.5 bar g minimum.
On positioners where the output control air is of equal range to that of the input
signal air (e.g. 0.2 to 1.0 bar) they shall be furnished with integral pneumatic
"bypass switch" facilities for applying signal air direct to the actuator.
All positioners and electro pneumatic: converters shall be furnished with three
pressure gauges: air supply, signal input and control air output and an air filter
regulator set. All pneumatic tubing to drives and actuators shall, unless otherwise
agreed to by the Engineer, be in copper which shall be sheathed in PVC.
All on/off (open/close) actuation systems shall be provided with suitable tamper
proof adjustments for actuator stroking time, independent for the open and close
stroke.
All actuators which are in control loops shall be provided with robust precision
position measuring transmitters for CCR indication.
Solenoid valves for controlling the air to/from actuators shall be mounted on n
rigid mounting frame or plate independent from the actuator. It is not permitted to
mount the solenoid valve on' the actuator, unless agreed by the Engineer.
Solenoid valves shall not be merely supported from the air piping connections.
Generally these actuators shall only be used where high thrusts are required
combined with fast operating times and the applications requirements cannot be
met by the standard range of actuators used on the remainder of the contract.
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The units offered shall be or the self contained, fully sealed types which allow
removal of the complete unit to n clean room for any maintenance requirements.
Failure of the internal hydraulic supply shall result in the actuator locking in its
last operating position or stroking to its fail safe position and a suitable alarm
being given to the operator.
All local instruments, necessary for local operation, maintenance and local
supervision have to be delivered.
The scope of supply shall comprise but shall not be limited to:
• pressure indicator on the suction and discharge side of each pump and
compressor
• pressure indicator at each heat exchanger inlet and outlet (except for sample
coolers)
• temperature indicator at each heat exchanger inlet and outlet
• pressure indicator upstream of each safety valve
• temperature indicator at each bearing oil drain
• pressure gauge at each tank or vessel if pressurized
• differential pressure gauge at each important strainer or filler.
• level indicator for each tank or basin
• pressure gauge upstream and downstream of control valves .
• pressure gauges at pneumatic actuators for air supply, signal input and control
air output.
All local indicating instruments and test connections shall be included in the
respective plant equipment as integrated parts. The scope of local indicating
instruments and best connections shall enable the local operator to properly
survey the equipment, and shall also allow to properly carry out all acceptance
and other tests. All Local instruments of main equipment (pumps, motors,
transformers) shall be readable from one side only, accessible for operation and
maintenance.
Instrument racks
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Junction boxes
The connecting lines between the primary elements and the transmitters shall
be installed with an inclination in such a way that no air pockets (e.g. in case
of liquid measurements) or no water locks can occur.
For signal exchange with the main DCS, PLCs shall be compatible with this
system. Depending on the amount of information to be exchanged, parallel or
serial interfacing shall be considered.
If serial interfacing is used, the interface equipment between the PLC and the
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DCS must be capable of communication using an industrial standard protocol. The
transmission baud rate shall be selected dependent on the application (e.g. 19200 baud
or higher). If commands are issued from the DCS to the PLC, the time between
command and PLC signal output shall not be more than 5 seconds. The same
requirement goes for answer back signals from the PLC and updating of displays of
analogue values coming from the PLC on the DCS monitor displays.
As a. minimum requirement, the offered serial link shall have a data integrity checking
and retransmission facility in case of error detection, independent of the DCS or external
system software. Hardware and software failures during data transmission shall be
monitored and alarmed.
The communication link shall be redundant (two cables) but only one traffic controller
shall be provided. In case of failure in the communication, quick manual switch-over to
the standby communication link shall be possible.
The functions realized in the PLC and the method by which they are invoked shall be
represented graphically similar to IEC-1131-3. Additionally, a description of the program
shall be supplied.
Programming devices with keyboard, VDU and printer for ease of programming, effective
on-line monitoring and diagnostic functions, together with the necessary equipment to
write in and to erase EPROMs shall be provided.
The PLCs should be selected from minimum no. manufacturers (preferably two).
PLC hardware and other associated control equipment shall be installed in suitable
control cubicles. Where ambient conditions are suitable, these cubicles shall be set up in
a protected area, near to the secondary system to be controlled. Should this not be
possible, the cubicles shall be set up in local switchgear rooms or in local control rooms.
The protection class shall be IP 54 as stipulated in IEC-529.
The required control elements and displays (annunciation anti status lights, analogue
displays, switches etc.) shall be so configured that as far as possible they can be viewed
from the associated secondary system. Should it be necessary to place the control and
monitoring elements in the field, these shall be installed in separate, robust housings
(protection c1nss IP 65).
In preference LED displays shall be used. Ease of access and operation of the equipment
shall be ensured.
Where appropriate, visual display unit (VDUs) shall be employed for field operation and
monitoring.
All cubicles shall be adequately ventilated in order that the heat generated by the
equipment mounted there shall remain within the specified limits, even in the case of high
ambient temperatures that may occur in the event of failure of the air-conditioning
system.
Locally installed cubicles shall be suitable for the location in which they are situated and
shall provide adequate protection against dust, moisture or mechanical damage for the
equipment mounted therein. Sunshades shall be provided for all cubicle located
outdoors.
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Table of Contents
0 xxx
0.0 xxx
0.1 xxx
0.2 xxx
0.3 xxx
0.4 xxx
0.5 xxx
0.6 xxx
0.7 Inspection and Testing
0.7.1 General
0.7.1.1 Workshop manufacturing and pre-assembly
0.7.1.2 Works inspections
0.7.2 Testing during manufacturing
0.7.2.1 Material tests
0.7.2.2 Tests at site
0.7.2.2.1 General remarks
0.7.2.2.2 Hydraulic tests
0.7.2.2.3 Test runs and functional tests
0.7.2.2.4 Visual inspection, checking of dimensions, test
instruments
0.7.2.3 Manufacturing tests
0.7.2.3.1 Welding
0.7.2.3.2 Pressure testing
0.7.2.3.3 Testing of corrosion protection
0.7.2.4 Mechanical equipment
0.7.2.5 Electrical equipment
0.7.2.6 Control and monitoring equipment
0.7.3 Testing at site during installation
0.7.3.1 Erection Tests
0.7.3.2 Pre-commissioning tests
0.7.3.3 Tests on completion
0.7.4 Reliability Test run
Performance tests
0.7.5
0.8 Abbreviations
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0.7 Inspection and Testing
0.7.1 General
The Contractor shall be responsible for providing all supplies required for carrying
out such tests, except to the fuel used during Reliability Test Run and Performance
Tests.
The overall testing program for the Project shall consist of the following:
Three (3) months after effective date of Contract, the Contractor shall submit to the
Owner/Owner's Representative all relevant test documents, which shall include:
• test program
• test standards
• type of inspection and tests
• tests which are to be witnessed by third parties
• quality control procedure.
Six (6) months prior to the proposed start of commissioning the Contractor shall
submit to the Owner/Owner's Representative:
Six (6) months prior to commissioning the Contractor shall submit to the
166
Owner/Owner's Representative for the performance tests:
• test program
• test standards
• manpower and deployment schedule of' the Contractor for performing the tests
forms of test records and report .
• description of instrumentation to be used, including accuracy, and calibration
test results
• method of data recording
• method and equations/correction curves used for adjustment of recorded data to
the design conditions.
Document files containing material certificates, welding procedures, test report etc.
shall be compiled for each item of plant and shall be suitably identified (including
equipment classification reference) and bound.
All workshop fabricated components and parts of the plant shall, to the fullest
practical extent, be formed, machined, fitted, welded, stress-relieved. X-rayed,
adjusted, tested, cleaned and painted. The equipment shall be preassembled in
the workshop of the Contractor or his sub-contractors to the maximum possible
extent, then dismantled only as far as required for safe and proper shipment, in
order to keep erection work on site to a minimum. Equipment and parts shall be
marked, labeled or otherwise identified to facilitate assembly and erection on site.
Marks and labels shall be fixed in such a manner so that deformation or
obliteration shall not occur during shipment, storage and erection on site.
The equipment shall be designed and fabricated in accordance with the industrial
standards to reach the highest possible grade of reliability and a minimal and easy
maintenance.
167
Owner/Owner's Representative to carry out such tests efficiently.
• safety conditions
• consideration of the applied standards and regulations
• execution of workmanship
• conformity with the present state of modern technology.
Whenever inspections or tests are carried out in the manufacturers' workshop, all
material certificates as well as all other intermediate test certificates, in accordance
with the agreed upon test schedule, shall be made available to the
Owner/Owner/Owner's Representative for inspection. Besides the latest issue of
the related drawings, indicating also the state of approval by the Owner/Owner's
Representative, shall be made available.
The same applies to the final works' inspections or workshop tests when all test
certificates have to be submitted to the Owner/Owner's Representative.
Further, for each kind of test, a "Test and Inspection Manual" has to be prepared
showing all steps of the test procedure as well as the relating standards and
codes.
Test specimens shall be taken from all important forgings, castings, tubing, etc., in
accordance with the relevant standards and codes. Dimensions shall be adequate
for the purpose intended and the test specimen shall accompany the component
through all phases of the heat treatment. Before cutting or otherwise removing the
test specimens, these shall be permanently banded together with the forgings,
castings or components which they represent and, if requested, in the presence of
the Owner/Owner's Representative. Except where expressively otherwise
approved, all test specimens shall be machined to the dimensions specified in the
relevant standards find codes. Steel castings and forgings, in all cases, be
annealed before the test specimens are withdrawn.
Chemical analysis and mechanical properties of the material concerned shall also
be submitted.
All casting components shall be tested for compliance with the relevant standards
and codes and shall be suitable for the purpose for which the castings are to be
used. The chemical analysis and mechanical properties of the material tested shall
be provided by the Contractor. The results obtained from these material tests shall
be in compliance with the values contained in the relevant standards and codes
and with the figures quoted in the relevant sections of the Contract, if any X-ray
examination and ultrasonic examination of circumferential, longitudinal, nozzle
168
welded joints, stiffening rings, etc., shall be carried out by the Contractor in
compliance with the standards under which the relevant equipment will be
designed.
All castings and forging shall be subjected to X-ray and/or ultrasonic tests before
the start of machining procedures, in order to detect defects as early as possible
and to replace in time defective parts, thus avoiding undue delay in the
manufacture and delivery of plant components. After partial machining in the
Contractor's workshop, further tests may be performed. No repair welding
machining of castings and forgings of major components shall be carried out
without prior inspection and confirmation by the Owner/Owner's Representative. In
case of a rejection, written and certified notice must be given to the Owner/Owner's
Representative, indicating also measures undertaken by the Contractor in order to
cope with the requirements 'of the Contract.
Purchase specifications shall clearly state the quality and inspection requirements
and should include, but not be limited to:
Each forging shall be suitably marked with an identification number which shall
transferred throughout all machining stages. The identification number shall be
indicated on all documents relating to the forging.
Repair welding will not be permitted on rotating parts and on other components the
proposal will be subject to approval by the Owner/Owner's Representative.
Rotor forgings
The profile of forgings at the stage of final ultrasonic Inspection should be such as
to minimize the regions where complete coverage is not possible.
The toughness of rim and core (where applicable) material shall be evaluated by
testing charpy V impact specimens over a range of temperatures and thus
determining the 50% fibrosity fracture appearance temperature.
Allowable indication size and material toughness are interdependent design related
criteria and the Contractor must be prepared, if requested by the Owner/Owner's
Representative's Representative, to justify his proposals by reference to fracture
169
mechanics calculations.
Purchase specifications shall clearly state the quality and inspection requirements
and should include:
Non-destructive testing
Repair welding
In the case of excavations which penetrate more than 25 mm or 50% of the wall
thickness or cover more than 10,000 mm2 area the Owner/Owner's
Representative's Representative written approval of the proposed repair must be
obtained.
Checks shall be made on all raw materials to ensure that they comply with the
relevant ASTM Standard.
All deliveries of resin shall be checked for consistency by viscosity and reactivity.
Any resins deviating from the manufacturer's published figures shall not be used.
• Long term hoop strength (type test for pressure pipes only)
In accordance with ASTM D2992 Procedure D with the exception that the test
results shall be extrapolated to determine the stress which the pipe can withstand
for a period of 60 years without failure. The lower 95% confidence limit at 60 years
shall also be calculated.
• Hydraulic test
100% of the pipes shall be subjected to an internal hydraulic pressure test at the
manufacturer's works prior to delivery. The test shall be applied to a pressure
equal to 1.5 times the maximum working pressure stated for each classification
of pipe. The test pressure shall be applied for a minimum period of 5 minutes
171
without signs of leakage.
In addition to the above the first pipe and every thirtieth thereafter of each class
and diameter shall be maintained at test pressure for a minimum of 4 hours
without signs of leakage.
Each pipe and fitting shall be subjected to an internal low pressure air test at the
manufacturer's works prior to delivery. The test pressure shall be an
overpressure of 0.1 bar and this shall be applied for a minimum period of 5
minutes without signs of leakage or distress. Fittings which are of mitred
construction shall be manufactured from pipes which have successfully passed
the tests defined above.
• Dimensions
• Stiffness
A minimum of one pipe for every 30 pipes manufactured shall be tested for
stiffness in accordance with ASTM-D 2412 "Method of Test for External Loading
Properties of Plastic Pipe by Parallel Plate Loading". A minimum of one pipe of
each class and diameter of pipe shall be tested.
The tensile strength properties of a minimum of one pipe for every 100 pipes
manufactured shall be measured in accordance with ASTM-D 638. A minimum
of one pipe of each class and diameter of pipe shall be tested
• Cure
• Loss on ignition
• Joint tests
• Visual inspection
Each pipe and fitting shall be subjected to a complete visual inspection before
shipment in accordance with ASTM-D 2563.
172
• Vacuum test
Vacuum test of pipe shall be carried out for each diameter once at beginning of
production. The vacuum to be applied shall be equivalent to the condition which
occurs during full vacuum. The corresponding derated vacuum for this test shall
be proved by the pipe manufacturer.
In the event of a specimen not fulfilling the minimum requirements for strain
corrosion resistance, all pipes of that class and diameter which have been
manufactured shall be rejected and shall be rep]aced .entirely.
Any pipe or fitting which fails any of the quality control tests which are to be
carried out on each and every pipe or fitting shall be rejected. In the event of
any pipe failing any of the remaining tests outlined above that pipe shall be
rejected and the relevant test shall be carried out on a further ten pipes of that
class and diameter. If anyone of these ten pipes fails than the manufacture of
pipes of that class and diameter shall cease and the Owner/Owner's
Representative reserves the right to reject all the pipes of that class and
diameter
Materials shall be tested for bulk density, specific heat, compressive strength, fire
resistance under pressure, service temperature limit in accordance with VDI 2055
or equivalent standards.
The equipment to be supplied under the Contract shall be tested at Site during
erection and initial operation. These tests shall prove whether the equipment
meets the requirements of the Contract and the safety conditions, whether it has
been executed with satisfactory workmanship and whether the equipment is in
'conformity with the prevailing standards and regulations as well as with the
present state of modern technology.
Waiving of any tests shall not release the Contractor of his responsibility to fully
meet the requirements of the Contract.
Test runs and functional tests shall be carried out on individl1al equipment where
practicable to prove the reliability and the correct functioning of the component and
its compliance with the stipulations of the Contract.
0.7.2.3.1 Welding
A system of positively identifying the work of each welder shall be maintained and
any welder whose work is the subject of multiple rejections shall be required to
undergo a requalification test. Any welder failing the retest may, at the discretion of
the Owner/Owner’s Representative's Representative be disqualified from further
welding on items under this contract.
Copies of temperature charts referenced with load items shall be included in the
test certification supplied for the relevant items.
All welds shall be visually examined and shall be of smooth contour, free from
cracks, undercut and other significant defects. Wherever possible the interior of
tubes etc. shall be examined using a suitable optical device where necessary.
174
Fillet welds shall be checked for size using suitable gauges which shall be
available for use on request by the Owner/Owner's Representative's
Representative during an inspection visit.
175
TABLE Non-Destructive Testing
Design Wall Inside
Type of Steel Type and Extent of non destructive testing Remarks
factor thickness diam
(shell) (mm) (10m) Butt nozzle Fillet
≤ all 10%R - -
>40 all 100% R 10%M 10%M
all > 30 all 100%R 100%M 100%M Test after stress relief
176
Wall
Type of Steel Design factor Inside diam Type and Extent of non destructive testing Remarks
thickness
≤ 100 10%R - -
>0.85 ≤30
> 100 100%R 10%D 10%D
> 30 all 100%R 100%D 100% D
Legend:R = Radiographic examination
U= Ultrasonic examination
M=Magnetic particle examination
O= Dye penetrant examination
Note:
1. Where 10% examinations are shown for pipe work under 100 mm diam bore this shall be the circumference of 10% of the welds by each welder selected at random
with a minimum of one per welder.
2. Where 10% examinations arc shown for vessels or large diameter pipe work this shall be 10% of each weld length and must include all intersections of longitudinal
and circumferential welds.
3. Where partial exam' at ions reveal rejectable defects, adjacent welds or areas of weld shall be examined. In the event of rejectable defects being found welds shall be
subject to 100% examination.
4. Welds in clad materials shall be tested in accordance with the requirements of the base material and the surface of the overlaid welds shall be dye penetrant
tested throughout the length.
177
Non-destructive examination of structural welds
Weld repairs
Hydrostatic testing
All pressure vessels inserts or other parts of such vessels which are subject
to an internal pressure or vacuum during operation shall undergo a
hydraulic or other approved test. Unless otherwise stated in the
specification the test pressure shall be maintained for a sufficient period to
permit complete examination by the inspector.
Particular attention must be paid to the temperature of water used for hydraulic
testing which shall not be less than 20°C. Prior to testing, metal temperatures
shall also not be less than 20°C. Where pressure parts 600 mm in diameter
and above are being tested the hydraulic pressure shall be raised to the test
pressure in stages during which the item shall be examined and all defects
rectified before the full test pressure is reached.
Suitable water shall be used as the test media unless otherwise agreed and
test pressures shall be in accordance with the applicable construction
178
standard but if none is specified then the test pressure shall be 1.5 times
the design pressure but not less than an overpressure of 3.5 bar. Test
pressure of vacuum containment items shall be agreed with the
Owner/Owner's Representative's Representative.
The test pressure shall be maintained for sufficient time to permit complete
visual examination of all surfaces and joints and in no cases less than
specified in the applicable construction standard.
The chloride content of water used for testing austenitic stainless steel
items shall not exceed 30 ppm unless immediate flushing with water of this
quality is done after the test.
Pneumatic testing
Surface coatings
179
Surfaces shall be visually inspected. Uneven surfaces, splits, blisters or
inclusion of foreign matter shall be cause for rejection.
Rotating units
Each rotating unit shall be first statically balanced and then dynamically
balanced (in the case of impellers this shall be done before and after
mounting of the service rotor shaft). A check balance of items that have
undergone over speed test shall also be made.
Pumps
Results for feed pumps shall be assessed with reference to DIN 1944 class
1 (without construction tolerances), and results for other pumps to class II
or III as agreed.
The lubricating oil used in the test shall be of the same brand and grade as
that recommended by the manufacturer for service use.
Steam turbines
The turbines shall be completely assembled with their control, stop and
governing valves on a suitable erection rig at the manufacturer's works and
shall be carefully inspected and measured for manufacture and assembly
tolerances. Functional tests shall be performed on the safety equipment
(running with steam is not requested).
Air compressors
Where size permits cranes and hoists shall be completely assembled at the
manufacturers works and functional tests without load conducted.
181
IEC 298 High-voltage metal-enclosed switcher and control gear
IEC 420 High-voltage alternating current fuse-switch
combinations and fuse-circuit-breaker combinations
Power transformers
Current transformers
Voltage transformers
Generators
IEC 34, VDE 0530, IEEE 115, ISO R1680 and VDI 2056
• Generator test report
Comprehensive test reports for the generators are to be compiled and
submitted by the Contractor, which shall include:
• Description of the test method, equipment used and any limitations of
182
the test plant.
• copies of the oscillographs recorded with appropriate calibration data
• open circuit saturation, short circuit and loss curves for the generator
• a performance chart of the generator (being a diagram of constant
stator and rotor current curves plotted on rectangular axis of MV Ar
and MW load) The recommended loading, stator core end heating
and stability limits shall be shown on the chart.
• calculations of full load temperature rise for the stator, rotor and ex-
citer. Any correction factors used to allow for different voltage current
and cooling conditions shall be justified by reference to published lit-
erature or to previous type tests.
• calculations of the efficiency of the complete generator at 100%, 75%
find 50% load. Any correction factors for losses that could not be
measured at routine tests shall be justified by reference to published
literature or to previous type tests.
• calculations of machine parameters such as transient reactance and
time constant, sub-transient reactance and time constant, short circuit
ratio, synchronous reactance, negative phase sequence reactance,
zero sequence reactance capacitance and also the harmonic analysis
of the neutral current.
• circulation of full load excitation of the machine at rated power factor
lag1i.ing and at unity power factor, excitation V curves .
• Routine tests on generator
• Generator rotor
• ultrasonic examination
• mechanical balance coupled with exciter rotor
• over-speed test coupled with exciter
• Measurement of 50 Hz rotor impedance
• Generator assembled:
• three phase short circuit characteristic test and current balance
check
• dielectric test
• measurement of insulation resistance
• measurement of winding resistance and resistance check of tem-
perature detectors
• open circuit characteristic test and voltage balance, phase
sequence
check
• segregation of mechanical loss and core loss
• segregation of stray load loss
• efficiency calculation
• unbalanced load test for negative-phase sequence and zero se-
183
quence reactance
• shaft voltage measurement
• oscillographing of verified voltage wave form and harmonic (,lIlaly-
SIS
• measurement of vibration
• polarization index
• tan delta measurement of complete winding
• bearing insulation resistance .
• Type tests on generator as far as type test certificates are not avail-
able
• sudden short circuit test at reduced voltage (30%, 50% and 70% of
rated voltage), extrapolated to 100% voltage
• equivalent heat run test consisting of windage and friction heat run,
open circuit heat run at 105% rated voltage, short-circuit beat run at
rated line current, open-circuit heat run at rated line voltage
• measurement of open-circuit direct-axis transient time constant
• noise measurement
• moment of inertia
• measurement of excitation response time
• overall characteristic coupled with generator and A VR cubicle at no
load
• applicable to assembled unit consisting of generator, exciter and
voltage regulator, may be carried out on site
• Routine tests on generator exciter (as far as applicable)
• resistance of windings
• insulation resistance
• high voltage tests
• short-circuit characteristic
• no-load characteristic
MV Motors
IEC 34, ISO R 1680, VDl 2056
• Type tests (each motor type) as far as type test certificates are not
available
• measurement of starting current and torque
• efficiency measurement
• heat run test
• noise measurement
• Routine tests (each motor)
• measurement of winding resistances
184
• no-load short circuit measurement
• dielectric test
• measurement of insulation resistance
• over speed tests
• check of motor vibrations
Capacitors
Telecommunication installations
IEC 215 Safety requirements for radio transmitting equipment
Aerials
IEC 64
VDE 0100 Regulations for the construction of power installations with
rated voltages below 1000 V
VDE 0107 Regulations for setting up electrical installations in ,rooms
for medical purposes .
VDE 612 VDE Specifications for electricity distribution units for use
on construction an building sites at rated voltages up to 380
V AC and rated currents up to 630 A
Protection equipment
Equipment for modular numeric protection systems (e.g. generator, distance, bus
186
bar, protection, etc.) pre-assembled in the relevant standardized boards I cubicles
etc. shall be tested in the manufacturers workshops as far as wiring and proper
function is concerned. Simulated inputs (binary signals, current and voltage inputs
from test power supplies) shall be used.
• synchronizing units
• flow evaluators
Calibration tests
All main closed-loop control systems shall be tested for polarity and func-
tion in accordance with the applicable standards. Control valves shall be
tested in accordance with mechanical functional tests on control valves
and shall be performed with the actuator mounted (open to closed
position and vice- versa). Actuators shall be subject to mechanical and
electrical function tests.
The alarm annunciator and fault printing system shall be tested using
simulated inputs.
DCS system
General
During erection all required erection tests as well as final erection checks
of the mechanical completion of the systems and part there of have to be
performed.
The activities necessary for mechanical completion shall included but not
be limited to following testing:
• visual inspection after unloading at site
• checking of completion of relevant systems
• completion of buildings and civil works
• test of ventilating and air-conditioning units
• alignment of rotating equipment coupled on site
• safety audit
• testing of site welds (non-destructive examinations)
• pressure testing, leak tests, tightness tests
• checking of pipe hangers, supports, guides, etc.
• pipe line and equipment flushing and cleaning
• chemical protection of piping systems
• checking of coating
• testing of cranes and hoists
189
• phase coincidence with 2 half-bus bars
• voltage checks'
• polarity checks in the case of DC voltages
• fuses, over current trips, short-circuit trips, time settings, relay settings
• switchgear and transformer oil levels
• safety signs and warning signs
• setting indicators, revertive (check-back) signals to the central control
room etc.
• checks on wiring and cabling for conformity with the constructional
circuit-drawings and plans
• checking and functionality testing of electrical systems according to IEC
standards
• tests on the generator main bus bar
• checking for the gas-tightness of individual main connections system
• tests on the earthing and lightning protection system
• acceptance tests and measurements of the earthing installations in
accordance with DIN 57 141 and of the lightning protection systems in
accordance with DIN 57 185
•tests on the lighting system
• proof of the minimum new value of lighting densities, checking of
correct operation both electrically and mechanically.
Mechanical equipment
Electrical equipment
• voltage tests
• trip tests
•functional tests of the equipment
Control equipment
190
• Calibration tests of instrumentation, loop checking, functional
testing of control equipment, interlocks, protection inputs, etc.
The Tests on Completion shall prove that the plant is prepared and
adjusted to ensure the correct functioning of the individual components
and of tile complete plant.
191
• protection systems/settings, in accordance with agreed design and
the requirements of the transmission system
• start-up tests
• normal automatic start to preset load
• staged automatic including start to synchronous speed, manual
synchronizing (including synchro-check), automatic synchronizing,
manual and automatic loading
• starting with stand-by auxiliaries
• operation of all auxiliaries
• verification of start up times and loading rates of power units, steam
generators and multistage flash units at various downtime
conditions ~
• power unit, to test partial and full load rejection to demonstrate
• full load rejection tests to measure transient
maximum speed and steady state speed at
normal governor droop setting
• method of resynchronize to be demonstrated
• turbine bypass operation capability
• Power unit/Plant, to verify and check
• operating stability when operated between 30% and 100%
nominal load conditions with load variations by increasing or
decreasing the electric load
• demonstration of the capabilities of the Power Units to operate
at rated voltage and frequency, at power factors and reactive
conditions between. 0.85 (lag) and 0.95 (lead)
• start-up tests of the Plant equipment, facilities and systems
including checking of automatic change-over of standby
facilities
• verification of vibration and noise emission guarantees
• environmental monitoring equipment, water quality monitoring
equipment, functioning tests and verification of guarantees
• demonstration of the teledispatching and telemetering systems.
• verification of active power response and voltage control
response according to the requirements specified in the
network connection conditions
• demonstration of proper controlling, monitoring and
recording according to the requirements of the grid code
• verification of completeness of scope of supply
• verification of 24 hours uninterrupted MCR operation. As
precondition to the start of the reliability test run no adjustments,
manual operation and other intervention are permitted during this
verification.
192
0.7.4 Reliability test run (Initial Commercial Operation)
The reliability test run shall be carried out for the power unit including
related equipment and systems and shall last for a period of six (6)
weeks each.
During the specified period, plant unit and related equipment and systems
shall be operated continuously and in accordance with the prevailing
power requirements of the transmission system or as required by the
Owner/Owner's Representative. If possible with reference to the grid, Unit
shall run at MCR.
The reliability test run will not be deemed to be completed unless the
relevant performance tests have been made.
In the event of interruptions to the reliability test run, for which the
Contractor is responsible, the length of the reliability test run can be
extended by a period equal to the total duration of the interruptions. If
such an interruption lasts more than 48 hours, the reliability test run
shall be restarted, after repairing the defect. The reliability test run
may be interrupted on three occasions, provided that the total hours of
interruption do not exceed 48 hours and that the Owner/Owner's
Representative is notified of the interruption in good time. Minor
adjustments to the control system are permitted with previous
agreement of the Owner/Owner's Representative.
After positive conclusion of the reliability test run period the Contractor
shall demonstrate by means of performance tests that the plant units
and the Plant including related equipment and systems can be tested
to prove the guarantee parameters.
193
• the boiler DIN 1942 (or ASME)
• generator ISO 2314
• steam turbine DIN 1943 (or equivalent
ISO or ASME)
• transformer IEC 76.
The curves required for the correction of the power output and
specific heat rate to the site specified ambient conditions shall be
listed in the technical schedules of the Plant performance and gas
turbine performance.
All margins required for instrument inaccuracies and for all other
reasons shall be deemed to be included in the guarantee figures.
All special instrumentation shall be calibrated for the test and supplied
by the Contractor. Meter accuracy shall be as determined mutually by
the Owner/Owner's Representative.
194
0.8 Abbreviations
195
Steam Generator Plant
196
Table of Contents
197
1.3.2.2.5 Evaporator with steam drum
198
B1. Steam Generator Plant
1.1 General
Steam generator to be installed shall be of the natural circulation reheat type. The unit
shall be designed for pulverized coal firing (PC firing), balanced operation and out door
arrangement.
The Bidder has to check and to verify all relevant information as the basis for his offer.
The scope encompasses all supplies and services necessary for fulfilling the objective of
the contract for 1 (one) complete coal-fired steam generator plant and their complete
auxiliary equipment, even if individual items are not specifically mentioned below.
Comprising essentially
• economizer with inlet and outlet headers
• evaporator system with steam drum, headers and down comers
• super heater and reheater with inlet and outlet headers
• 100% attemporator for super heater and reheater
• all internal water and steam pipes and headers
• all necessary drain-, purges-, vent- and blow-down pipes incl. valves concentrated at
valve groups (double block valve)
• blow-off pipes for safety valves and start-up valve incl. silencer
• boiler mountings, valves and accessories:
• feed water shut-off valve and feed water control valve with electric drive, check valve
incl. manual. operated control valve as bypass
• automatic condensate traps with bypass and stop valves
• complete drum-blow down valve group
• drum emergency drain valve with electric drive.
• local and remote water level indicator
• local instrumentation
• safety valves (2 x drum, 2 x super heater outlet, 4 x reheater outlet)
• start-up control and shut-off valves, each with electric drive
• live steam stop valve with electric drive
• sampling system for feed water, boiler water and live steam incl. coolers, piping and
valves
• casing, frame and supports
199
• buckstays, tie bars, stiffeners and pipe damps as required
• one complete set of doors and peepholes necessary for access, inspection and
supervision including service air nozzles connecting piping.
Comprising essentially
• 1(one) continuous blow-down flash tank (atmospheric tank) incl. Cooling system,
blow-off pipe, control valve and necessary equipment
• 1 (one) boiler drain flash tank with flanges, vent drain and connecting pipes.
1.2.4 Start-up and back-up firing system operating on diesel fuel oil
Comprising essentially:
• main isolation valves outside of the boiler area
• diesel fuel oil low-NOx burners
• electric ignition and flame detection installation
• pipework and valve stations inside the boiler area
• burner management system
• ignition and cooling air fans with motors
• analog and binary equipment
• flow meters for oil supply and return line and each burner
• local control station
200
• oil trays
• diesel oil tank including unloading station
• oil piping and valves
• oil pumps, fillers
• slop oil tank
• slop oil pumps
• slop oil pipes.
Comprising essentially:
• furnace wall steam soot blowers
• semi-stroke rotary steam soot blowers with retractable lance and
electrical drive
• long retractable steam soot blowers
• main isolating valve with electrical actuators and steam pressure reduc-
ing station with pipe work, instrumentation and valves for steam supply
as well as temperature-controlled drain valves with electric actuators
• 2 (one as stand-by) cooling and sealing air fans
• automatic soot blower control and cabling of soot blowers and limit
switches to the cubicles, cabling between electrical and control
cubicles, including cable installation material (conduits, cable clamps,
etc.)
• electrical cubicles with incoming feeder circuit breakers, motor protec-
tion and indicators for power consumption, pressure, temperature, ad-
vance and retract operation
• field switchboxes with interlocks for optional local operation
• automatic switch-over in the event of mechanical blockage.
Comprising essentially:
• lifting capacity 3,000 kg
• one lifting winch
• type external winch
• accessories
• 2 hooks to fetch the safety ropes
• 2 movable transfer drums for the safety catches
• 2 auxiliary ropes to let down the safety ropes from the cantilever
arms into the boiler
• 3 leading-strops to fasten the working platform at the boiler-walls in
the range of the entrance openings
• special tools
• lay down construction on the furnace bottom.
Comprising essentially
• moulded refractory lining and shaped fire bricks in the area of the
burners, access doors and peepholes, etc.
• furnace moulded refractory
202
• insulation and sheet cladding for thermal and noise insulation.
Comprising essentially:
• complete steel structure for boiler. coal bunker, lift shaft, pipe and
conveyor bridges and for auxiliary equipment
• 1 (one) open stairway as connection between platforms (taking into
account permissible escape route lengths)
• all necessary access galleries, stairways, ladders and platforms
• protection sheds (or hoods) for all equipment located outside such as
fans, actuators, electric drives, etc.
• roof and dust proof cladding for tripper conveyor
• dust proof enclosure for all conveyor bridges.
Comprising essentially:
Comprising essentially:
• (one) auxiliary steam boiler fired with diesel fuel oil, complete as
package with all systems and accessories including at least (to allow
start-up and critical operation without any external supply of steam):
• economizer furnace and super heater
• one forced draft fan
• complete duct work from FD fan to the oil burners
• oil burners
• complete instrumentation, control and monitoring equipment burner
management
• associated piping
• feed Water system including feed water pumps
• flue gas ducts from boiler outlet to the stack
• steel stack.
203
1.2.11 Boiler and steam/water system cleaning
Comprising essentially:
• inside cleaning of pressure parts (boiling out and blowing out of coal
fired boiler and auxiliary boiler).
1.3.1 General
1.3.1.1 Design
The unit shall be of the balanced draught design, i.e. with forced and
induced draught fans.
The prescribed design and performance data of the boiler plant are listed in
the Technical Data Sheets B1/FB.
It is to have provision for firing 100% of MCR pulverized coal and 35% of
MCR design capacity with fuel oil firing for boiler start-up and low load
backup firing.
The furnace enclosing walls and the enclosing walls of the heating surface
section are welded gas-tight. The gas-tightness has to be tested. The
furnace itself, the radiation pass and the enclosing walls of the convection
heating surface sections are comprised of vertical membrane walls.
204
Steam is used as the blowing medium for the furnace walls and
for the convection heating surfaces.
The boiler is suspended from the roof of the steel support structure and
thus allows for thermal expansion downwards during operation. The boiler
enclosure is to be arranged as an extension of the boiler steel structure
which shall be c1added with metal sheets.
Firing system
Coal is supplied to the boiler units via belt conveyors. The coal bunkers are
charged by means of belt conveyors. It is planned that the belt installation
be in one line .
Boiler unit has 4 coal bunkers each with a capacity suffices for 16 hours of
operation at MCR and with design coal. It is planned to construct the coal
bunkers of steel.
Further, the diesel oil is used for ignition, cold and hot start-up and for low
backup firing.
The air and flue gas system is designed in a double flow path, each for 60%
of MCR. Provision for later flue gas recirculation system for decreasing the
NOx emission has to be provided, if necessary.
Air system
Combustion air is supplied by means of the FD fans, following which the air
flow is separated into primary and secondary air. The primary air is further
compressed by means of the primary air fans, following which part of the
primary air is diverted to provide cold air for controlling the mill classifier
205
temperature. For both the primary and secondary air, steam air preheaters are
arranged upstream of the regenerative heater. With the steam air heater the
combustion air is preheated sufficiently for there to be no danger of corrosion at the
regenerative air preheaters in cold section. Following the regenerative air preheaters,
the primary and secondary air is routed to the, mills or to the burners. Sufficient
measurements for all air flows and all burners will be applied.
Following their exit from the boiler, the flue gases flow to the regenerative air
preheater, where they are cooled further and at the same time the primary and
secondary air is heated up. Within the downstream EP, the flue gases are free
of most of their dust burden before being routed to the stack via the ID fans.
Bottom ash
Fly ash
The fly ash from the EP and other points of the boiler where it collects is
conveyed pneumatically to the loading storage silos outside the boiler
area.
Sewage sludge
The lime slurry which are used for the power plants water pretreatment
process and amounts as lime sludge can be delivered with the coal to
the coal bunkers for burning it in the combustion chamber. Predrying of
the lime sludge is recommended.
Slag type furnace for granulation of the ash can be offered, provided that the contractor
shows evidence that he has already built at least 3 of such furnace type.
The steam generator with its auxiliary equipment is one of the principal
components fixing the dynamic capacity limits of the Power Plant. In order to
be able to follow the planned operation regime and above all the high
requirements for frequency support, during the design phase all required
206
measures shall be taken to ensure rapid availability after start-up and optimum
load-following behavior.
The excess air at the outlet of the combustion chamber when burning coal
shall be approximately 20% within the load range from 40% to 100% of
MCR.
• The superheater outlet temperature shall be kept constant within the
load range from 60% to 100% of MCR with feed water injection.
• The reheater outlet temperature shall be kept constant within the load
range from 70% to 100% ofMCR with feedwater injection.
• The exhaust gas temperature at MCR when burning coal with 20%
excess air shall be 150°C at air preheater outlet.
1.3.1.3 Fuel
The steam generator and its auxiliaries shall be designed for pulverized
coal firing. Diesel oil shall be used only for start-up and back low load up
firing. Typical analyses of coal is given in the Annex.
1.3.1.4 Feedwater
The steam generator of natural circulation water tube type shall be fed with
turbine condensate and a small percentage of make-up water. The
feedwater shall be thermally deaerated and treated with volatile chemicals.
Its chemical properties shall be within the limits of the "VGB Directives for
feed and boiler water of steam generators" (latest edition).
207
1.3.1.5 Steam purity
During continuous operation the properties of the steam leaving the super'
heater shall not exceed the limits of the "VGB Directives for feed and boiler
water of steam generators" (latest edition).
1.3.2.1 General
The steam generator and its accessories shall be designed for outdoor
installation with a suitable weather protection, insulation to completely
protect the boiler and its accessories.
The design of the steam generator and of the auxiliary equipment shall
envisage the life time of the Power Plant under the prevailing climatic and
operating conditions to be 30 years.
The pattern of the normal load jumps as dictated by the interconnected grid
are sudden due to load shedding and line faults. The Bidder shall describe
measures he has taken in the designing of the steam generator to facilitate
and secure these operating conditions.
The design of the steam generator and its auxiliaries shall consider the
possibility of preservation prior to or after commissioning by providing all
necessary connections and provisions as for example
The furnace shall be of the fully water-cooled welded membrane wall type.
The volume and dimensions of the combustion chamber shall prevent flame
impingement or excessive heat transfer upon any portion of the water-
cooled walls or other parts of the furnace enclosure at all operating
conditions.
The furnace size shall provide sufficient space for flame development and
shall allow complete and efficient combustion of the fuels specified before
leaving the furnace. Central or division walls are not accepted.
The configuration of the furnace shall be so that the air/flue gas flow will
reach all its parts and there will be not dead zones in which the formation of
an explosive gas/air mixture can occur.
The furnace outlet temperature (at first bundle heating surface inlet) shall
be selected under consideration of the initial deformation temperature of the
fuel with the worst ash specified.
The design will consider that no fouling in space superheaters for these
coals which can affect the reliability of the unit will occur. The supplier
should present detailed design of furnace and gas outlet temperature
profiles to the purchaser during the design stage of the project for the whole
band width of all fuels specified.
The furnace and burners shall be such that when burning the types of fuel
specified and under all conditions of load up to the maximum output, there
shall be no flame impingement on any surface of the furnace walls and no
accumulation of slag on the walls, tubes or hoppers or other part of the
boiler units that will interfere with the continuous operation of the units.
The furnace and convection pass shall be equipped with all necessary
access and inspection doors, access doors being located at both side walls.
A sufficient number of observation windows shall be provided in the
appropriate positions to allow for visual observation of the flames, the
combustion process and the roots and the tip of the flame of each burner.
The combustion chamber shall be welded flue gas tight whenever possible,
209
the wall panels shall be reinforced by buck stays so as to withstand a flue
gas pressure inside the combustion chamber and all flue gas pathes of at
least ±70 mbar:
All openings in the wall of the furnace shall be duly protected against
deterioration by heat.
All loads of the furnace with framing and insulation as well as burners and
ductwork shall be led by the evaporating tubes and anchors to the support-
ing steel structure at the boiler top casing without causing bending stress in
pressure parts.
• even flue gas distribution for intense heating of the furnace area
• good reswirling of the flue gas to the burner section to stabilize the
ignition of the pulverized coal;
• special deflection and removal of the flue gas flows for optimal fly ash
retention;
• no or low CO content in the flue gases.
The furnace hopper, the furnace, the evaporator membrane walls and the
membrane walls enclosing the convection tube bank shall be executed in
vertical tubing, welded completely gastight and observing the limits of the
specified design parameters. Tube penetrations through the membrane
walls as well as through the furnace roof shall likewise be executed in a
completely gastight welded design (welding sleeves).
All pressure parts of the steam generating unit shall be designed, manufac-
tured, constructed and tested in accordance with the applicable standards.
The boiler pressure parts shall be completely self-drainable.
The Bidder shall submit with his Bid a material diagram indicating for each
single pressure part whether it is heated by flue gas or not, the following
characteristics:
All stress calculation of the pressure parts shall be allow for the lifetime of
the plant as stated elsewhere with at least 50 shut-down and start-up per
year.
All tubes material shall be fabricated from hot or cold finished seamless
material and shall be ultrasonic tested.
211
To avoid high temperature corrosion the connecting piece between
supporting tubes and heating surface shall be kept short as possible so that
their metal temperature will not exceed 570°C.
The wall thickness of the tubes shall allow for the thinning of the tubes
bends. All tubes of the convection heating surfaces shall be arranged in
line. The transverse spacing of all tube banks shall not be smaller than
double the tube diameter.
All parts carrying hot media which are designed to specific creep rupture
strength shall be designed to provide a service life time of200, 000 hours.
The flue gas temperature at the inlet of the supporting tubes upstream the
first platen SH stage shall not exceed 1200°C (average measured 'versus
boiler width) considering fouling during operation. The flue gas temperature
at the inlet of final SH stage with normal fouled heating surfaces shall be
less than 1050°C.
The high pressure SH shall be divided at least into two parallel flows and
each flow shall consist of at least three (3) subsequent stages with
intermediate spray attemperators.
The RH shall be divided into at least two parallel flows with spray attem-
perators between the RH stages. RH system isolating valves shall be
provided for leakage test of reheater.
Parts of the first layer of the SH and RH with distance less than 1 m to
steam sootblowers have to be equipped with protective shells for avoiding
erosion caused by soot-blowing.
The SH and RH heating surface shall be divided into tube banks, the
heights of which shall be limited to as defined in the Data Sheets BI/FB. For
convenient access the clear height between subsequent tube banks shall
not be) less than 1.2 m with access doors on both sides.
All fittings, spacers and supporting lugs exposed to flue gases shall be
made of approved heat and corrosion resistant materials.
212
To ensure an effective SH control the final stage shall have a maximum rise
in steam temperature at MCR of not more than 75 K for final SH stage.
Each spray water control station for SH and RH shall be fitted with a least 1
control valve, 1non-return valve, 2 isolating valves and 1 hand-operated
bypass valve.
1.3.2.2.4 Economizer
The heating surface shall be formed by seamless plain tubes which shall be
fitted in line.
The economizer shall be divided into banks. The height of the tube banks
shall be limited as defined in the Data Sheets B I/FB.
Parts of the first and second layer of tubes with distance less than 1 m to
sootblower have to be equipped with protective shells for avoiding of
erosion caused by soot-blowing.
All fittings, spacers and supporting lugs of the economizer tubes exposed to
the flue gas shall be made of approved corrosion and heat resistant
materials.
The feed connections to the drum shall be fitted with thermal sleeves.
The gas-tight welded tube walls shall be tied together and stiffened by
means of buck stays which shall enclose the furnace and radiant section as
well as the convection section.
Low pressure steam shall be introduced in the lower headers to keep the
boiler warm and for heating up.
213
The design of the buckstays shall consider the expansion of the gas-tight
welded tube walls during start-up and shall not result in additional forces.
The drum shall be of the welded type with a manhole at each end. The wall
thickness of the drum shell shall be uniform throughout. It shall be amply
sized to ensure adequate steam volume to provide a suitable level control
and to preclude the possibility of carrying over of water during any transient
mode of plant operation as well as to provide adequate space for mainte-
nance work and manual cleaning operation without removing any internal
fittings.
The drum shall be fitted with the necessary internals for the uniform distri-
bution of the feedwater, with sufficient devices for efficient separation of
water from saturated steam.
Access manholes of hinged type shall be provided at each end of the drum
heads.
The drum shall be provided with dished ends and with the required nozzles
for the water and steam connecting tubes, drains, vents, blowdown, installa-
tion of safety valves, controls of pressure, temperature, analyzers and water
level. All drum nozzles for valves, fittings and mountings shall be welded to
the drums. All internal and external attachments welded to the drum shall
be made before final treatment.
The feed connections to the drum shall be fitted with thermal sleeves:
The drum shall be provided with all suitable internal fittings such as:
• removable baffle plates located close to drum internal face, in front of
riser pipes.
• centrifugal or cyclic type separators or similar distributed on both sides
of the drum and adequately supported .
• steam scrubbers made of perforated plate and located below the
saturated steam exhaust pipes .
• feed piping, perforated on its whole length, with adequate supports,
extended inside the drum to both sides .
• in case of chemicals injection into the drum for uniform distribution of
injected chemicals, adequately supported and securely attached to
structural member.
• continuous blow-down tube extended along the whole length of the
drum and perforated along its whole length.
214
The attachment of drum internals of deflectors to the dram shall be such as
to ensure against displacement while the unit is in service, but, except
where specifically approved otherwise, they shall not be welded to the
internal surfaces of the drums. Bolts and nuts inside to drum shall be fitted
with cap nut. The drum internals shall be removable through access
manholes.
The drum and the appertaining feedwater connections shall be arrange din
such a way that during interruption of the feed water supply an emptying of
the drum under the lowest water level shall not occur.
All tube banks located in zones of the gas path in which the gas
temperature is higher than 400°C, shall be supported by vertical steam or
water cooled supporting tubes. The design of the supporting tubes shall
meet the following requirements:
The pressure drop, the flow distribution and the materials shall be selected
so that a sufficient cooling of all supporting tubes can be assessed during
start-up and when the boiler operates at minimum load.
For tube banks located at the direct combustion chamber exit (which is
applicable for 11/2 or 1 pass type boilers), the supporting tubes shall form a
screen to protect the tube banks against radiation. Suspension of tube coils;
on evaporator tubes will not be permitted.
When suspension bars are required, special care should be given to the
selection of materials so that the low temperature corrosion can be
minimized.
215
13.2.2.7 Headers
The drum on headers shall be provided with shop welded tubular stubs of
the set-on type and thicker than the minimum calculated tube thickness.
These shall project a sufficient length to ensure that the welding of the
tubes will not affect the material of the drum and headers.
All fittings and mountings shall comply with applicable standards and
regulations listed
The boiler shall be valved so that start-up and shut-down can be done
remotely from the control room. Subsequently, all valves, except the
isolating ones which will be shut-off only in case of repair, shall be electro
actuated.
Double valves on vents and drains and on tapings for instruments and
sampling points shall be installed on high pressure and intermediate pres-
sure (reheat) pipes.
• superheater and reheater drains shall consist of one shut-off valve and
one throttling valve
• vents shall consist of two shut-off valves
• evaporator and economizer drains shall consist of two shut-off valves.
These valves shall be arranged so that the upstream valve when closed,
has. a spindle and gland which is load-relived and the operation shall be
performed with the downstream valve.
216
Venting, draining and spray water valve systems shall be combined in
groups. Groups of relating drains shall be discharged into common collec-
tors.
Pressure test locks, feedwater stop valve and live steam stop valve shall
close perfectly tight in both directions (so that it shall be possible to perform
the hydraulic test for the boiler and the feed water and steam pipes inde-
pendently).
The steam generator shall be equipped with devices for draining to assure
complete drainage of the boiler water/steam system. All drain lines shall
have non-dangerous dischargers.
shall be fitted to the boiler drums and superheaters and on the hot reheat
line.
The safety valves, installed on the boiler drum, superheater outlet, and
reheater shall be set to blow in a predetermined sequence. All equipment
necessary for gauging the safety valves and for hydraulic test purposes
shall be supplied.
The set pressure of the reheater safety valves and of the LP bypass
stations shall be chosen so that opening of the reheater safety valves will
be avoided to the largest possible extent. .
217
The safety valves at superheater outlet shall always lift before the safety
valve on the drum opens. The superheater safety valves shall have such
capacity that the superheater cannot be overheated when also the drum
safety valves are blowing. The safety valves shall be of the spring loaded
type.
One blow-off station consisting of one throttle and one shut-down valve
connected in series with the relating electric actuators shall be installed in
the hot reheat line. The capacity of this station shall be determined in
accordance with the following requirements:
The corresponding number of blowdown and drain valves for the drum,
furnace wall bottom headers, for superheater and headers shall be
provided, each set including two valves of an approved bore and type
arranged in series.
218
1.3.2.2.10 Water level indicators
Two local drum level gauges, showing the full scale complete with
lighting fitting shall be included. The electrical energy for these fittings
will be taken from the DC supply of the power station.
One gauge shall be fixed so that the water level can be easily seen
direct at the boiler drum level. The second bicoloured gauge shall be
fitted to enable the water level to be seen from the location of the
feedwater control valve.
The gauges shall be fitted with drains, and valves for shutting off and
blowing through. Double isolating valves shall be provided.
Two sets of nozzles and isolating valves for water level transmitters
shall be provided under the Section B9 (Instrumentation and Control
Works). All water level devices shall be provided with independent drum
nozzles.
The gauge glass fittings shall be of forged steel and shall be designed
so that they can be removed as a complete assembly without shut-down
of the boiler.
• one high and one low level water drum alarm (each independently
connected to a pair of branches)
• one independently working low water safety feature for boiler trip
• the lower limit of indicating range of the water gauges shall be at least
30 mm above the uppermost pass and at least 30 mm below the
minimum water level
• all level gauges shall be provided with a retaining device, so that at
bursting of glass the boiler does not need to be shut-down.
The sampling coolers shall be fitted with stainless steel coils and
219
stainless steel piping connections up to the take off point.
All sample coolers shall be provided with stainless steel trays. The drain
of these trays shall be laid to the waste drain system.
Sample coolers of the continuous flow type shall be installed for all
points where remote quality recording is required, but at least for,the
following points:
• feedwater inlet to economizer
• boiler water (tapped from the continuous blow-down line or from a
downcomer)
• live steam (tapped from the main steam line)
• reheat steam (tapped at reheater outlet).
Safety valve escape pipes with all necessary expansion joints, anchors,
supports, weather cowls and roof collars shall be provided. Drain pipes
to remove condensed steam in the escape pipes shall be led to
220
.collector dishes located at a convenient level.
Exhaust lines of flash tanks and safety valves to be extended above the
boiler roof level.
Soot blowers
For regenerative air preheater soot blowers shall be provided on the hot
end as well as on the cold end also.
221
Sootblowers shall be operated by electrical drives with local
pushbuttons as well as a common panel for the whole sootblower
system. The preheating of the piping system as well as its drainage and
the operation of all sootblowers in a suitable sequence shall be actuated
by a master pushbutton from this panel. Failure in the operation shall be
indicated by alarm lights of the panel and a common alarm signal will be
conducted to the unit control room.
Two cooling and sealing air fans (on stand-by) shall avoid the, tendency
for flue gas corrosion.
The PC firing as the principal firing for the boiler shall be designed for
direct firing. It shall be capable to cover the specified boiler turn-down
range. The MCR load point and partial loads of 30% MCR and greater
shall be achievable without the aid of the ignition and backup firing, but
taking into account the specified fuel range. Depending on the coal
quality, in the minimum load range it shall be permissible to operate the
ignition, back-up and support firing system.
Also the isolation arrangements shall be of low wear design and require
versionly no maintenance.
The burners shall be so assigned to the mills that if one or more of the
mills is switched off or fails, asymmetric fireside temperatures wiIl be
avoided.
Shut-down of one or more complete burner levels shall also serve the
purpose of achieving the required minimum load. Cooling measures for
223
the burners which are not in operation have to be foreseen for avoiding
damages caused by furnace heat.
It is essential that the Plant shall be dust tight in every respect and all
bearings and working parts shall have dust proof housings.
For monitoring the flames of the PC firing system, flame detectors shall
be provided. Which in the event of the failure of its associated burner
group will not be effected in its action by extraneous light or spurious
radiation from the furnace. The offer shall be accompanied by a detailed
description and drawing of the combined burners and a reference list.
The ignition and backup firing system shall be designed for the fuels and
load range as laid down in the prescribed design data, without
consideration of the PC firing equipment. The number and arrangement
of the combined ignition and backup burners shall meet the
requirements of the PC burners.
Each ignition and backup burner shall be fitted with a pure gas-electric
ignition device and gas bottle station, its own flame detector, a
combustion air control damper and all other auxiliaries connections and
slop tank shall be provided.
Piping to the ignition and backup burners shall start at the inlet of the
isolation valve outside of the boiler area, be routed to all burners, and
shall contain all safety relevant equipment, fittings and burners valves
and accessories. For each burner, two quick acting safety shut-off
valves with intermediate drains to the slop oil tank shall be provided.
Each pulverizer has to be fed from one coal bunker and one feeder.
Each boiler unit has 4 coal bunkers. The bunkers shall be provided with
a total reserve corresponding to a minimum of 16 hours of operating at
224
MCR as "active content". The "active content" of the bunkers shall be as
large as feasible, reducing the stagnant mass to a minimum.
The bunkers shall be properly integrated with the boiler steel structure,
presenting an overall neat appearance. For this reason, they should
preferably be of rectangular or square form in plain view with pyramidal
hoppers.
It shall specify all loads required for the design of foundation and of
adjacent buildings. Design interfaces shall be established as soon as
the structural concept is established.
225
For the determination of the auxiliary outlet equipment, such as shut-of
rods, assisting equipment for coal flow-out, conveying elements, etc.
increased reliability margins shall be considered.
Each bunker shall also be provided with low level detectors to operate a
position on the centralized control boiler annunciator and operate
warning lights and alarms in the coal handling panel.
The raw coal is to be fed even distributed to the centre of the mills by
means of encapsulated plate conveyors. The coal feeders shall be
designed dustproof and pressure-tight (gauge pressure of 0.5 bar). The
coal feeders are to be designed with enough margin in capacity compared
with the coal mills.
All sides of the casings of the plate conveyors - including the shaft ducts
must be absolutely tight against dust escape. The front and side walls, dis-
charge box must be at least 4 mm thick. The scraper floor must have a
thickness of 8 mm or more.
In order to prevent corrosion to the roller chains of the coal feeders, an air
seal supply with gate valve is to be connected at the outlet of every coal
feeder. Pipes and valves belong to the scope of supply of the Contractor.
The coal damper, coal fall shaft in the feeder discharge section and the
bunker passage to the feeders are to be lined with stainless steel.
In addition, the mill feeders are to be equipped with needle weirs, height
levelling frames (stainless steel) coal bed thickness controllers, pendulum
plate, tension station and automatic oil Iubrication equipment of for the
conveyor, paddle and scraper shafts, Belt or chain cleaning device, one
inspection door (0.5 m x 0.5 m) above coal feeder and at front and rear
side, chutes between feeders and mills, complete scraper equipment and
complete air seal equipment. \
Dumping of coal from the feeder to the mills shall be done vertically or
227
nearly vertically.
The pulverizers and the firing plant shall match the boiler plant overall
layout and shall be designed so that all operation requirements including
start-up and shut-down, also transient at turbine trip, emergency boiler
shut down, or failure in the internal power supply can be covered safely
and without damage.
At all partial load conditions it shall be assured that each burner has the
same and controlled fuel/air ratio.
The pulverizer shall be of Low speed Horizontal Ball mill (2 inlet 2 outlet)
type of proven design and of pressurized operation type. Coal mill shall
be designed by considering Coal Hard Grove Grindibility index (HGI) 75.
The feeding of the coal into the pulverizer shall be centric through the
classifiers. Each pulverizer has to be equipped with an automatic
operating steam smothering system.
Manhole covers and inspection hole covers at pulverizers and fans shall
be designed so that absolute dust tightness can be guaranteed. The
inner mill casing has to be manufactured without dead comers.
All pulverizers shall be equipped with adequate and insert gas protection
fire-fighting system by steam.
228
If pulverizers and feeders are stopped by an electric failure, starting-up
again shall be possible without previous cleaning.
The mills shall be designed in such a way that they can easily
rearmoured within a short time on the spot and that all other repairs can
also be executed.
It shall be possible to isolate the mills from the hot air/gas ducts and
from the dust ducts in such a way that the boiler operation will not ~e
disturbed when isolating one mill, and that maintenance work such as
rearmouring has not to be done under hard conditions. Doors of the
pulverizers shall be provided with hinges and quick acting opening
dosing facilities.
Boiler MCR shall be possible also during failure of one pulverizer and
the related burners shall be cooled sufficiently.
All parts subject to wear and tear shall be so designed that an exchange
of worn-out parts shall be possible (easy access), even while boiler is in
operation.
Each mill shall be provided with its own lubrication oil system, including
oil cooler, oil tank with heater, duplex filter and double capacity oil
pumps.
Sealing air connections and seals shall be provided on the mill journals
and on the mill casing in order to protect the bearings against the entry
of dust.
229
1.3.3.4 Pulverized coal burners (PC burners)
The pulverized fuel burners shall be designed in such a way that a good
mixing of dust coal and combustion air as well as a safe ignition of the dust
coal will be achieved.
The arrangement and alignment of the burners shall ensure an even tem-
perature profile of the flue gas leaving the combustion chamber.
The PC burners shall be selected such to comply with the properties of the
coal and shall match the pulverizing system. It must be adequate for an
optimum combustion with due consideration to the furnace dimensions in
order to keep the NOx emission to a minimum and to avoid excessive
fouling.
Each burner shall be provided with its own lighter and flame scanner. The
burners shall be robust and shall stand long operation periods. Adequate
measures shall be taken to protect coal burners which are not in operation
from being damaged by radiation of heat coming from the furnace.
The supporting steel structure of the burners and the appropriate coal ducts
shall be designed so as to serve simultaneously for the suspension of lifting
devices required for assembling and dismantling of burners and ducts.
Selection of type of coal burner shall be made also under consideration that
simultaneous operation of the steam generator with coal and with diesel
fuel oil will be possible.
Pulverized coal pipes from the mills to the burners shall be arranged in
view of maximum symmetry to achieve even distribution to all burners.
230
The individual pulverized coal pipes behind the distributors shall be pro-
vided with shut-off devices which upon shut-down of one mill shall be
closed for avoiding the recirculation of hot flue gases.
Each coal pipe has to be equipped with air sealed test opening (approxi-
mately 500 mm in diameter) to extract pulverized coal for measurement
of grain size and coal distribution. Provisions for galleries in this area
are to be made.
The dust coal pipes from mills to burners shall be as short as possible
and arranged as straight as possible.
Changes of mills load shall not cause any disturbance of the gas and
coal dust flow in the pipes.
Pulverized coal pipes shall be from steel piping or sheet with sufficient
wall thickness and all necessary protection measures against wear and
tear. Each PC pipe has to be equipped with two coal extraction studs for
sampling. The extraction studs have to be equipped with an air sealing
device for preventing the PC leaving the PC pipes during sampling.
To boost the pressure of the primary air, two radial fans with motors are to
be provided to extract cold air from behind the FD fans. Both of the radial
fans are to be designed for a mass how of at least 10% more than the MCR
primary air mass flow.
The requirements for noise protection stated in Section B06 and B07 shall
apply.
Fan vanes shall be made in welded construction. The drive shaft shall be
dimensioned to withstand the critical speed by far.
231
1.3.3.7 Inerting system for pulverizers and coal pipes
The provision of the plant with an inerting system will be mandatory. The
offer shall consider an inerting system based on nitrogen, CO2,
inertisation with steam or flue gas (according to the manufacturer's
standard and for experience).
1.3.3.8 Start-up and backup firing system operating on diesel fuel oil
The diesel oil system will be used for boiler start-up and backup firing up
to 35% MCR boiler load.
The diesel oil system to be in accordance with TRD 411 or other similar
standards shall be completely up to the burners comprising following
main items:
Type, number, arrangement and size of combined coal - diesel oil burners
shall be selected in such a way as to cope with the above requirements.
Each combined coal diesel oil burner has to be equipped with ignition and
cooling air supply, high energy spark plug ignitor and all necessary valves,
dampers and flame detectors.
Openings for burner lance, flame detectors, ignition Iance and inspection
peep holes are to be provided.
Burner shall not be subject to any deterioration by radiant heat when out of
operation. Therefore oil guns and ignition equipment shall be pneumatically
retracted in cooling position. A separate cooling air system has to be
arranged for cooling the burners, which are out of operation.
The fuel oil strainers shall be of the cage type with a maximum gap width of 0.5
mm on the suction side and 0.08 on the pressure side.
The strainer assembly shall include integral flow switching gate valves, external
valve position indicators, differential pressure gauge, steam tracing and valves
for drains and vents.
The oil pumps shall be of the rotary screwed type. The horizontal pump units
shall be coupled directly to the driving motor. Each pump shall be fitted with a
pressure relief valve preventing over-pressure in the pump casing. Pump and
motor shall be mounted on a common base plate.
Spindles of the pumps shall be approved material nitrided and ground. The
design of the pumps shall take into account the increased oil temperature in the
casing.
The pump casings shall be at least of cast steel. Cast iron is not acceptable.
The pumps must be designed and suitable both for continuous or intermittent
operation. They must also be ready for immediate service even after a
prolonged period of standstill, without any special measures being necessary.
Suitable cleaning and drain piping of the systems to the slop-tanks have to be
supplied.
The arrangement of the whole equipment shall allow access to all valves and
instruments.
Integral piping for diesel oil, cooling air and compressed air shall comply, with
the requirements of this specification.
Besides the remote control system it shall be possible to operate the burner
from local box near the burner with minimum employment of the remote control
system. The change-over from remote control to local control shall be done by
key switch for each burner located on the control room panel.
The remote control system and the interlocking system as well as the closed
loop control shall be provided under Chapter B9 in these Tender Documents.
Therefore the firing system also shall meet the requirements of Chapter B9
(Instrumentation and Control Works).
All the equipment for the diesel fuel oil system shall be of the outdoor design.
Scope of supply/ installation shall include but not limited to the following:
• One (01) diesel oil storage tank (tank capacity 2000 m3);
• Diesel oil unloading station [Two (02) diesel oil unloading pumps including
valves, pipings, filters and others as per requirement];
• Interconnection with the existing diesel oil system.
233
Basically the tanks shall be designed in accordance with the requirements of
API Standard 650 or an approved equivalent standard. If the specification
contains requirements beyond the requirements of the above standard, the
requirements of the specification shall have priority.
To prevent any damage to the tanks by storms, they shall be reliably stiffened.
If stiffening rings will be necessary, they shall be arranged inside of the tanks.
The specific gravity of all tank contents shall be considered with 1,000 kg/m3.
The tank bottom shall be pitched downwards conically to the outside with a
slope of at least 1 %.
Around the inside tank perimeter two drainage sumps shall be provided. Each
sump shall be equipped with a 50 mm diameter drain pipe connected to the
shell double flange nozzle. A shut-off valve with a blind flange shall be provided
outside the tank.
All flanges at the tank shall meet the requirements of the piping systems set out
in Section B06 General Technical Requirements, Mechanical Equipment. The
flanges shall be of the welding-neck type.
All connection and spare nozzles shall be provided with flanges inside and
outside of the tank. All spare nozzles have to equipped with blind flanges
outside the tank.
The fill nozzle is to be designed as a roof unit. A bend pointing on to the tank
wall is to be flanged on to the inside of the tank so that incoming oil ' flows
tangentially to the tank wall. Care must be taken to ensue that the bend is
located with about half its effective section above the highest liquid level. A
baffle plate is to be provided at the tank wall.
All other nozzles - with the exception of ventilation and sounding hatch and the
return nozzle of the heavy fuel oil tank - are to be arrange din the lower shell
course.
A shell spiral staircase shall be furnished from grade to the top of the tank. An
intermediate platform is to be arranged at half the tank height.
Two roof vents shall be provided and each shall be designed for 100% capacity
to pass air so that at the maximum possible flow rate of the oil, either entering
or leaving the tank, excessive positive or negative pressure will not be
234
developed. The vent intake shall be protected by a screen with a mesh width of
not more than 5 mm. The clear screen area shall be at least 125% of the vent
nozzle area.
A 100 mm high kick-plate, tightly welded around the entire tank perimeter and
acting as a gutter is to be arranged on the tank. top edge. For each tank at
least two rain downpipes, connected to the kick-plate and provided at their
bottom ends with a 45° bend, are to be provided.
Each tank. is to be equipped with a device for local and remote level indication.
All level indicators at tanks shall have scales which indicates meters and
millimeters. Corresponding volumetric tables must be made available also. This
device shall be equipped with at least three adjustable limit contacts to initiate
alarms or signals at given levels (low, high, maximum).
Each tank shall be provided with an overfilling protection device (level switch)
which shall respond when the maximum permissible level is exceeded by
initiating an alarm and switch off the filling pump of the oil truck.
The maximum limit contact of the level indicator shall also protect the tank from
overfilling by initiating an alarm.
The surface preparation, interior and exterior coating application, shall be done
in accordance with the requirements set out in Chapter BO "General Technical
Specification". Inside painting shall be applied only to the tank bottom and one
meter height of the shell above bottom.
The slop oil tank may be supplied wither as rectangular tank or as a horizontal
cylindrical tank. All necessary connections, manholes, drains and ventilation
systems are to be provided where required and made easily accessible.
The tank is also to be equipped with a local contents indicator having a sensor
arrangement to issue an alarm when the tank is full. Also to be provided is a
further level switch arranged to sever as dry-running protection for the pump
and to annunciate when the tank is empty.
235
1.3.3.11 Filters
For the diesel oil pump group, one duplex filter shall be provided on the
suction side.
The duplex filter shall be equipped with a change-over device which allows
change-over under full load conditions without operating trouble
Each slop oil pump shall be protected by a single filter arranged in the suction
line. Each filter shall mainly consist of the filter bowl with cover and removable
filter insert.
All the filters shall be fitted with a differential pressure indicator equipped with
transmitters for electrical remote indication and alarm.
The switching point of the differential pressure gauge shall be freely settable
Filter casings must be at least of cast steel. Cast iron is not acceptable
A pipe emptying system shall be provided for the entire pipework system, so
that pipes which are out of use for longer periods can be emptied and do not
require continuous heating.
The foam generators and foam pourers shall be made of process water
resistant and heat resistant materials.
The foam system for the oil tank shall be capable for foaming the complete
internal surface of oil.
The pipes and valves of the foam system shall be made of corrosion resis-
tant and heat resistant materials. Stainless steel or approved equivalent
236
materials shall be used. The nominal pressure of the foam system should
with adequate reliability be above the maximum possible operating pres-
sure.
The diesel oil pumps sl1all be controllable from the auxiliary panel in the
central control room. Indication of operating conditions, must, however,
also be available at the local control board.
Oil levels of tanks as well as all hazard, fault and monitoring information
from tanks, filters, pumps, etc., must be clearly arranged and recognizable
in the central control room.
Existing 2 x 125 MW units have 1 (one) 10 ton/ hr capacity auxiliary steam boiler.
If these capacity is not enough for the proposed 250 + 10% MW unit, then 1
(one) auxiliary steam boiler is required.
The auxiliary steam boiler fired with diesel fuel oil has to be provided if
necessary to supply steam to the steam turbine unit during the start-up
period. For an outdoor installation a respective weatherproof implementa-
tion has to be foreseen.
The boiler used as the auxiliary boiler has the characteristics of frequent
start-ups, large changes of load, quick start-up, long periods between
maintenance, start-up at any time and operating reliability; being a
packaged completely assembled and then dispatched to site.
The plat form and gallery of boiler shall possess enough strength and
stiffness shall be proved at operation, monitoring or maintenance locations.
The boiler shall be provided with the necessary observation ports, manhole
for maintenance and explosion vents.
The drum shall be provided with safety valve, vent valve, exhaust piping
237
and a motor driven valve, and a silencer shall be provided at the outlet
header of the superheater.
Connections for drum water level and furnace pressure measuring shall be
provided. Local instruments and remote instruments (in the control room)
shall be used for drum water level measuring, and the pressure,
temperature and flow rate shall have indications in the control room.
The boiler shall be provided with one set of forced draft fans, feedwater and
oil pumps. The steam pipe lines of the auxiliary boilers shall be connected
together and also with the extraction of the steam turbines. So that it is
possible, while the auxiliary boilers are shutdown, to start-up the second
steam turbine by the first, which is already in operation.
After erection of each boiler the manufacturer shall perform boiling out and
blowing out as a protection measure. If necessary, the boilers shall be
passivated after this procedure. No acid cleaning measure is required but the
coal fired boilers themselves must be designed and fabricated in such a way
that an acid cleaning process can be carried out if required by the Purchaser.
If it will be found out after boiler erection that the inside tube and header
surfaces "are rusty and dirty, acid cleaning of boiler and all other equipment will
be carried out by the supplier without any costs for the Purchaser.
At least three months before the date fixed for the internal cleaning, the boiler
manufacturer shall submit to the approval of the Purchaser a complete and
detailed specification of the procedures that will be carried out giving all
sequential events and chemical analysis required.
The contract supply shall include for the boiler all necessary connections,
valves, fittings, etc. required for acid cleaning which might be required after a
certain period of operation.
The temporary blow-off pipe and blow-off valve should have the same size as
the main steam pipe and main steam valve.
For boiler conservation before commissioning the Contractor shall provide all
necessary equipment, material and consumables to maintain the boiler parts in
a non-corrosive state in accordance with the offered procedure.
238
BPDB, Barapukuria Power Plant
Minimum requirements
Section B1: Steam Generator
Performance and Design Criteria Unit Data
1. Thermodynamic Data
Steam generator
Max continuous rating (MCR) % 104 of turbine MCR flow
Steam pressure (abs.) at HP superheater outlet bar 145
Steam temperature at HP supertleater outlet 0C 535
Steam temperature at reheater outlet 0C 535
0
Constant steam temperature forth. HP superheaters of 535 C MCR 60 -100
0
Constant temperature for the reheater of 535 C MCR 70-100
Minimum load far continuous operation without back-Up firing MCR 30
Max operating pressure at flue gas side of boiler membrane mbar + 70
walls/ducts
Load range firing with diesel fuel oil MCR 0-35
0
Feedwater temperature at economizer inlet C approx.. 207
Reheater (RH) Data at MCR
Steam mass flaw at Inlet kg/s cold and hot reheat steam pa
rammers shall correspond with
$team pressure (abs.) It RH inlet bar the relevant data resulting from the
0 heat flow diagram of the turbine
Steam temperature at RH Inlet C
model selected
Feedwater quality
B1/FB1
239
BPDB, Barapukuria Power Plant
Minimum requirements
Section B1: Steam Generator
Performance and Design Criteria Unit Data
2. Performance in Service
Cold start
from OC/bar 50/1.0
min
up to OC/bar 450/70
B1/FB2
240
BPDB, Barapukuria Power Plant
Minimum requirements
Section B1: Steam Generator
Performance and Design Criteria Unit Data
Economizer
Max. height of heating surface tube banks m 1.8
Min. clearance between two heating surface tube banks with
m 1.2
access possibility and/or where sootblowers are installed
Type of tubes used - plain tubes
Type arrangement - in-line
Transverse pitch not less than mm 100
Longitudinal pitch not less than mm 80
Add-on reserve heating surface % 10
Arrangement of access doors - on both sides
B1/FB3
241
BPDB, Barapukuria Power Plant
Minimum requirements
Section B1: Steam Generator
Performance and Design Criteria Unit Data
Reheater (RH)
Max. height of heating surface tube banks m 1.8
Minimum clearance between two tube banks where an m 1.8
access possibility is provided and! Dr where sootblowers are
installed
Design of reheater - 2-pass
Arrangement of connection pipelines between the RH stages crosswise
Number of necessary attemperators between reheater
pieces 2
stages I and II
Tube arrangement - in line
Transverse pitch RH I not less than mm 100
Longitudinal pitch RH I not less than mm 70
Transverse pitch RH ll not less than mm 400
Longitudinal pitch RH II not less than mm 70
Add-on reserve heating surface % 10
Arrangement of access doors on both sides .
Note:
1. The boiler shall attain its MCR when firingng the coal
within the band with specified at any of the local ambient
conditions.
2. Optimizing of boiler design Shall be based on the guaran-
tee coal.
242
BPDB, Barapukuria Power Plant
Minimum requirements
Section B1: Steam Generator
Performance and Design Criteria Unit Data
Excess air
Maximum excess air in furnace. for coal firing (guarantee
% 20
coal) between 60 % and 100 % MCR.
coal bunkers
Number of coal bunkers - 4
Design of the bunker cells and supporting structure - steel structure
Net storage capacity of bunker shall correspond to the coal operation
24 at MCR
demand for operation of hours
Coal feeder
Range of control, minimum 1:5
Resistant up to pressure of bar 3.5
Coal preparation and burning equipment
Number of pulverizes an which the boiler has to achieve Its
n-1
MCR with any of the coals fired
Minimum number of pulverizes In operation at minimum
2
load of the boiler of 30%.
Pulverizers
Minimum interval between two scheduled Overhauls of the
hours 8,000
mills
Design margins of each pulverize:
addition of wear- to-tear % 10
addition for control margin % 5
Distribution of pulverized coal
243
BPDB, Barapukuria Power Plant
Minimum requirements
Section B1: Steam Generator
Performance and Design Criteria Unit Data
or 1 single fan:
• capacity %MCR 60
Other data:
0 design temperature +
• temperature of regenerative air preheater exit C
5O 0K
Type . radial
inlet guide vane
Type control -
variation mechanism
0
Ingestion temperature at design point C 30
electric motor (direct
Type of drive
type)
Maximum speed min-1 1000
Sealing air fans
one fan for each
Minimum number
pulveriser.
Safety margins
• delivery head % 110
• capacity % 121
Type radial
inlet guide vane
Type of control
variation mechanism
0
Ingestion temperature at design point C 30
electric motor.(direct
Type of drive
drive}
Maximum speed min-1 1000
Start-up and back-up firing system operating
on diesel fuel oil
120 of fuel demand at
Capacity of diesel oil pumps %MCR
35 % of MCR
Firing capacity of ignition burners %MCR 35
Number of oil burners for which the boiler can
- n-1
achieve Its 35% MCR-Load
Minimum turn-down ratio of diesel fuel oil - 1:5
burners/air system
Cooling and ignition air fans
Safety margins
• delivery head % 110
• capacity % 121
B1/FB6
244
BPDB, Barapukuria Power Plant
Minimum requirements
Section B1: Steam Generator
Performance and Design Criteria Unit Data
Hot reheat temperature at
0
• 100% MCR C
0
• 60% MCR C
0
• MSL C
Range of constant reheat steam temperature %MCR
Feedwater temperature at
0
• 100% MCR C
0
C
• 60% MCR
Superheater spray water flow at
kg/s
• 100% MCR
• 60% MCR kg/s
Reheater spray water flow at
kg/s
• 100% MCR
• 60% MCR kg/s
Coal consumption for
100% MCR t/h
Boiler efficiency based on HHV for
• 100% MCR %
%
• 60% MCR
Air temperature at pulverizer inlet at
0
C
100% MCR
0
Flue gas temperature at furnace outlet at C
0
C
• 100% MCR
0
C
• 60% MCR
0
Flue gas temperature (uncorrected) at stake inlet at C
0
• 60% MCR C
0
C
• 100% MCR
Excess air in furnace at
• 100% MCR %
• 60%MeR %
• MSL %
B1/FD1
245
BPDB, Barapukuria Power Plant
Bidder/Contractor
Section B1: Steam Generator
Technical Data by the Bidder Unit Data
All design data of the data sheets refer to the MCR
conditions and are based on guarantee points, the
design coal and the reference data (Basic Design
Conditions according data sheet BO/FB-1) if not
otherwise stated.
General information
Type of boiler -
Manufacturer -
Design code for pressure part -
Design standard for material -
Live steam pressure (constant over the whole load range) bar
246
BPDB, Barapukuria Power Plant
Bidder/Contractor
Section B1: Steam Generator
Technical Data by the Bidder Unit Data
Unburned manner in raw gas dust at 100% MCR100% MCR %
Max. unburned matter in bottom ash/slag at 100% MCR %
Number of pulverizers in operation for
• 100% MCR pc.s
• 60% MCR pc.s
• MSL pc.s
Throughput of one pulverizer kg/h
Operating data
Note:
All data refer to MCR and guarantee conditions
Water/steam flows '.
Feedwater kg/s
Live steam kg/S
supemeater spray attemperator:
• attemperator 1 kg/s
• attemperator 2 kg/s
Reheater spray attemperator kg/s
Water/steam pressure (absolute) at
Economizer inlet bar
Drum /evaporator bar
superheater outlet bar
Water/steam temperature at
0
Economizer inlet C
0
Economizer outlet C
0
Drum/evaporator C
0
Supporting tubes C
0
Superheater 1 inlet C
0
Superheater 1 outlet C
0
Attemperator 1 Inlet C
0
Attemperator 1 outlet C
0
Superheater 2 outlet C
0
Atlemperator 2 outlet C
0
Superheater 3 outlet C
B1/FD3
247
BPDB, Barapukuria Power Plant
Bidder/Contractor
Section B1: Steam Generator
Technical Data by the Bidder Unit Data
0
Reheater 1 Inlet C
0
Reheater 1 outlet C
0
Attemperator 3 outlet C
0
Reheater 2 outlet C
Flue gas temperatures
0
Combustion chamber outlet C
0
After supemeater 3 C
0
After reheater 2 C
0
After superheater 2 C
0
After reheater 1 C
0
After superheater 1 C
0
After economizer C
0
After regenerative air preheater C
0
At stack inlet C
Operating times
Very cold start
(drum temperature equal with ambient temperature)
Time of preparatory measures (including time for heating
min
up the boiler via the deaerator) up to first ignition
0
Drum temperature (after preheating) C
Time from ignition of first burner up to MCR min
Cold start (at ambient conditions)
Time from ignition of first burner up to MCR min
Cold start (after 48 hours shut-down)
0
Drum temperature C
Time from ignition of first burner up to MCR min
Warm start (after 8 hours shut-down)
0
Drum temperature before start C
Drum pressure before start bar
Time of preparatory measures up to Ignition of first burner min
Time from ignition of first burner to MCR min
Hot start (after 0.5 - 2 hours shutdown)
0
Drum temperature before start C
Drum pressure before start bar
Time of preparatory measures up to Ignition of first burner min
Time from ignition of first burner to MCR min
B1/FD4
248
BPDB, Barapukuria Power Plant
Bidder/Contractor
Section B1: Steam Generator
Technical Data by the Bidder Unit Data
Controlled load reduction after turbine trip at MCR
Time from turbine trip up to operation of boiler al MSL min
Automatic control limits for steady load change
(Rate of load variation not exceeding 1% of MCR)
HP steam pressure ±bar
0
Hot steam temperature ±C
0
Hot reheat steam temperature ±C
Drum level ±mm
Excess air ±%
Automatic-control limits for max. load change gradients
Rate of load change %/ min
HP steam pressure ±bar
0
HP steam temperature ±C
0
Hot reheat steam temperature ±C
249
BPDB, Barapukuria Power Plant
Minimum requirements
Section B1: Steam Generator
Technical Data by the Bidder Unit Data
Steam drum
Manufacturer -
Cylindrical length mm
Internal diameter mm
Plate thickness mm
Material of steel plate -
3
Volume of steam drum m
3
Water volume up to normal water level m
Type of internals -
Safety valves
Manufacturer -
Type -
250
BPDB, Barapukuria Power Plant
Bidder/Contractor
Section B1: Steam Generator
Technical Data by the Bidder Unit Data
Steel structure
Manufacturer -
Design code for static calculation -
Estimated total quantity of steel for boiler -
Platforms
Elevation of operating platforms m
Elevation of auxiliary platforms m
Boiler insulation and brick lining
0
Max. temperature at outer face of insulation C
Total heat loss of boiler kW
Design heat flux density W/m2
Refractory lining material
Denomination (type) -
Manufacturer -
0
Max. service temperature C
Operational life time h
Components which will be brick lined -
Bricksetting material
Denomination (type)
Manufacturer -
Form of delivery -
Refractories
Operational rife time h
Components for which Bricksetting will be applied
Sootblowers
Number of blowing cycles per day --
soot towers of SH
Numbers of sootblowers pcs
Type
Soot blowers for economizer
Numbers of soot blowers pcs
Type -
Soot towers of RH
Numbers, of sootblowers pcs
Type -
B1/FD8
251
BPDB, Barapukuria Power Plant
Bidder/Contractor
Section B1: Steam Generator
Technical Data by the Bidder Unit Data
Soot blowers for combustion chamber
Numbers of soot blowers pcs
Blowing medium -
Type
Coal preparation and burning equipment
Coal bunkers
Manufacturer -
Number of bunkers pcs
Type of construction -
Material -
Inner lining material -
Thickness iron sheets mm
Capacity of each bunker t
Size of gate valve mm
Chute material
Coal feeders
Manufacturer -
Number pcs
Type of construction -
Capacity kg/h
Design coal density kg/m3
Operation range -
Conveying width mm
Max. bed coal height mm
For withstanding an inside explosion pressure of bar
Rated power kW
Inner lining material -
Chute material -
Design Worst
Coal mills Coal Coal
Number of mills pcs
Manufacturer -
Type / Model -
Capacity per mill. max. after 3.000 operation hours kg/s
Capacity per mill at MCR (n mills in operation) kg/s
Capacity per mill at MCR (n-1 mills in operation) kg/s
Fineness of grinding (oversize on 0.09 mm sieve at 550) %
0
Temperature downstream of mill C
Hot air mass flow rates per mill kg/s
B1/FD9
252
BPDB, Barapukuria Power Plant
Bidder/Contractor
Section B1: Steam Generator
Technical Data by the Bidder Unit Data
253
BPDB, Barapukuria Power Plant
Bidder/Contractor
Section B1: Steam Generator
Technical Data by the Bidder Unit Data
Inerting system for coal mills and coal pipes and ducts
Medium used for inertisation -
Quantity of medium required kg/h
PC burners
Manufacturer -
Type/model -/-
Number of burners per boiler pcs
Pressure loss in the burner (air side) mbar
Proportions of primary/secondary/tertiary air %
Coal flow rate per burner at MCR and design coal kg/s
Flame detection equipment type
Number of flame detectors pcs
Weight per burner t
Position or burners in furnace -
Diesel oil startup and backup burners
Number of burners pcs
Manufacturer -
Type/model -/-
Max. firing capacity per burner MW
Total diesel fuel oil now rate at 35% of MCR kg/S
Oil pressure at burner inlet bar
Flame detection equipment type -
Manufacturer of high energy electric ignition equipment -
Number of electric ignitors per burner pcs
Diesel oil supply system
Number of tanks pcs
Tank capacity m3
Tank diameter m
Cylindrical height m
Tank weight (empty) t
Number of oil pumps pcs
Capacity per pump t/ h
Oil pressure at pump outlet bar
Manufacturer of pumps -
Type
Rating kW
Rated Voltage kV
Speed. min1
Pressure at control valve Inlet bar
B1/FD11
254
BPDB, Barapukuria Power Plant
Bidder/Contractor
Section B1: Steam Generator
Technical Data by the Bidder Unit Data
Cylindrical length mm
Outside diameter x wall thickness mmxmm
Tank capacity m3
B1/FD12
255
Steam Turbine Plant
256
B2. Steam Turbine Plant
2.1 General
This specification covers the design, manufacturing and supply of one reheat
steam turbine generators with associated systems. Steam turbine generator is
rated 250 +10% MW.
Steam turbine
257
• oil tank including oil strainers
• main oil pump preferably direct driven"
• auxiliary oil pump (100%) with AC motor drive
• emergency oil pump with DC motor drive
• jacking oil pumps one with AC, one with DC motor drive (if applicable)
• control oil pumps with AC motor drive (if separately necessary)
• oil vapour extraction fans with AC motor drive with oil separation in the piping
• oil coolers
• double oil filter for the complete lubricating oil flow
• double oil filter for the complete control oil flow
• all connecting piping, fittings, non return valves. safety devices. fastenings., supports of
the oil system. Sheet metal ducts for oil piping and other oil spray protection equipment.
• connections for mobile purification plant '.
• 1 (one) common mobile oil purification plant for all turbine oil systems
Drains for oil tanks, oil coolers, etc. to liquid waste basin including all required piping,
filters, valves, instrumentation etc.
Condenser
Separate HP and IP steam bypass stations (each bypass line equipped with
258
1 (one) emergency stop valve and 1 (one) reducing valve), complete with the
associated actuating and control equipment, piping from the station(s) to the
cold reheat line/to the condenser and from the feedwater/main condensate
line to the injection points.
For steam generator 3 (three) feed water pumps , 62.5% capacity each
including flow control devices, two in operation and one as stand-by,
complete with electrical drive, nonreturn valve, hydraulic fluid couplingt
base plates, ,drive motors etc. and speed increasing gear.
259
• 1 (one) complete minimum-flow system including minimum-flow valve,
flow measuring device, start-up line etc.
• 3 (three) booster pumps complete (if applicable)
1 (one) feed water tank with deaerator complete, with supporting structure
all stub pipes, stiffeners, baffle plates, steam heated stand pipe, separate
warming up steam line strainers upstream the deaerator spray nozzles,
vapour extraction system etc.
HP feed heater 6
HP feed heater 5
LP feed heater 3
LP feed heater 2
LP feed heater 1
260
Separate desuperheater (if applicable)
All required piping as far as not included in the other sections (as e.g. steam
generator plant, water treatment systems, auxiliary systems) including all
accessories such as drains, vents, valves, safety devices, steam traps,
condensate drainers, strainers, actuators, pipe supports, anchor points,
expansion joints, nozzles for instrumentation and control fixtures, flanges,
gaskets, connection elements, calibrated pipe pieces for expansion meas-
urements, silencers for blow-off lines, lines and bypasses for start-up lines
etc.
Insulation
• Heat conservation
• Personnel protection
• For the prevention or the formation of condensation at piping, valves etc.,
with surface temperature less than dew-point of ambient air
• Noise insulation to the extent necessary
2.2.5 Vessels
261
2.3 Special Technical Requirements
2.3.1 General
Grey cast iron will not be accepted in general. If there should be grey cast
iron contained in a series-manufactured small part which is under consid-
eration, the express approval of the Owner/Owner's Representative's
Representative is necessary.
Stub pipes on the casings and larger constructional parts must have a
minimum wall thickness of 5 mm; the minimum nominal bore is 20 mm. If
flanges are provided, these are to be at least of nominal pressure 25 bar.
The control valves are to be operated in each case with auxiliary energy.
Direct acting control valves will be accepted only for gland steam controller.
Casing
The steam turbine is to be designed to ensure a very good and rapid adap-
tion of the turbine to alterations in load and alterations in the steam condi-
tions.
In order to allow for rapid assembly and dismantling, the turbine casing is to
be split horizontally and supplied with guides to permit safe lifting of the
casing.
Rotor and stator blades, nozzle segments and control parts are to be pro-
duced in erosion and corrosion resistant material (stainless steel).
262
For all rotor blades, only fully machined or pre-forged and mechanically
machined designs are permissible. For the first rotor blade stage only
milled shrouds are permitted (shroud band integral to the blade and formed
by . machining). The low pressure rotor blades are to be provided with addi-
tional edge protection, where necessary. The turbine stages operating in
the steam region are to be provided with sufficient water drains.
Rotor
The coupled critical speeds of the turbine and generator rotor must lie
outside the range from 85% to 120% of the nominal speed. The rotor is to
be statically and dynamically balanced in the factory.
In the design of the rotor, all notches, sharp inner edges or excessively
small radii are to be avoided so that fatigue failures are excluded. All
internal radii arc to be provided with a high quality surface finish.
Bearings
Gland steam
Gland steam must not be discharged into the turbine hall. The labyrinths to
be provided should have spring elements if possible. It must be possible to
inspect the outer labyrinth through a removable cover without having to
open the turbine.
The gland steam system is to be provided with a gland steam and vapour
condenser and vapour suction fans. The materials to be used for the gland
steam condenser shall be of stainless steel material.
263
Emergency stop valves, governor valves, reducing valves
In order to facilitate the safe and reliable shut-down of the machine, the
emergency stop valves and governor valves must be arranged with easy
access as near as possible to the appropriate turbine casings. In so far as
flange connections are provided on the live stearn side, these are to be
executed as high quality designs.
Turning device
If jacking oil pumps are used they are to be interlocked so that turning without
jacking oil supply is precluded. Interconnection between the lubricating oil
supply and turning operation is to be ensured by automatic interlocks.
Couplings
If toothed couplings are employed, these are to be provided with forced oil
lubrication. All parts of toothed couplings are to be fully machined. Coupling
hubs and sleeves are to be individually balanced, statically and dynamically, at
a speed corresponding to the operating speed. For the design the short circuit
shock has to be assumed at least 8 times the nominal torque on the drive
coupling for at least 100 times. If necessary, this value is to be corrected
upwards after the torsional critical speed calculations for the total plant and the
actual generator short circuit torque are known.
The turbine bleeds above I bar are to be provided with bleed steam emergency
shut off or emergency check valves.
The lubricating and control oil system serves to supply the lubrication points
and the control equipment of the steam turbine. The oil supply equipment is
to be arranged in a separate oil room.
The temperature rise of the bearing oil in the bearings must not exceed 30
K, and the oil drain temperature of the bearings must not exceed 75 0C.
The oil tank is to be dimensioned so that the content is not changed more
than 10 times per hour.
264
Oil vapour suction fans and oil separators are to be provided. The possibility
of unacceptable concentration of the oil vapour must not exist at any point of
the oil system.
The oil pipes must be seamless and connections between oil-carrying parts
must be welded or flanged. Flange connections of the oil pipes outside oil
ducts and turbine oil room must be encapsulated. The fastening of the oil
pipes must be such that excessive vibrations are excluded. Oil drain points
are to be equipped with double stop valves. It must be possible to shut off
the control oil circuit separately.
The auxiliary oil pumps should he arranged on the oil tank. The auxiliary oil
pump must be able to start automatically in the case of a drop in oil pres-
sure. If positive displacement pumps are employed, pressure relief valves
must be provided in each case for the full flow quantity. To avoid an
unallowable drop in pressure during switch over of oil pumps, a pressure
accumulator is to be installed in the oil system (if necessary).
The oil coolers are to be provided with a withdraw able tube bundle. If2
coolers are installed; they must be switch able during operation without
interruption of the oil flow and must be easy to clean. The coolers are
connected to the closed circuit of the plant auxiliary cooling water system.
The materials used for the oil coolers shall be equivalent to the materials •
specified for the gland steam condenser.
The oil filters in the lubricating oil main circuit and in the control oil circuit are to
be arranged as duplex filters which can be switchover without interruption.
In addition, an oil separator (preferably of the centrifuge type) with all auxiliary
equipment is to be provided for at least 3% of the circulating oil flow. The
separator shall be capable of being used both in operation and when the
turbine is out of service. Those parts of the oil separator in contact with fluid are
to be manufactured from stainless material. Dirt and all solid particles greater
than 5 microns are to be removed in the oil separator. However, oil additives of
any type should not be removed from the oil. It is necessary that an oil vapour
extraction must be provided for this equipment. The oil separator delivered shall
be of the self-cleaning design.
265
The scope of the system should include the lube oil transfer pump and motor,
clean and dirty storage tanks and lube oil conditioning equipment. All piping
from the lube oil storage tanks to the lube oil conditions, to the main turbine
reservoir and the lube oil conditioner to the rooftop vents is included.
2.3.4 Insulation
All external thermal insulation shall be of the blanket type and be capable of
removal and replacement for overhaul purposes without damage. Thermal
insulation shall be provided, where appropriate, to prevent adjacent concrete
surfaces from reaching excessive temperatures.
2.3.8 Condenser
266
The design of the condenser shall comply with the design data of the
turbine generator. In dimensioning the heat exchange surface it must be
assumed that all the load cases must be met even if 10% of the condenser
tubes are blocked. Under-cooling of the condensate is to be avoided. The
pressure design on the steam side must at least cover the range from full
vacuum to bar gauge and, on the water side, at least 3 bar gauge.
Dangerous vibrations of the condenser tubes must not occur during opera-
tion. Therefore a corresponding number of carbon steel tube support plates
must be employed. If necessary, baffles are to be provided to protect the
tubes. The holes in the tube plates and tube support plates shall be accu-
rately drilled, renamed and chamfered on both sides to facilitate assembly
of the tubes. Sufficient space is to be provided for withdrawal of the
condenser tubes.
Each half of the water chamber shall contain venting and water drain
connections of adequate size. Sufficient and manually actuated venting at the
cooling water side in case of sudden outage of the main cooling water pumps is
to be provided. The water side of the condenser is to be designed so that
satisfactory functioning of the continuous condenser cleaning equipment is
ensured.
In addition, the condenser must be suitable for accepting all drains occurring
during start-up or operation.
267
accepted.
The turbine bypass stations serve to remove surplus steam from the hot
reheat steam line into the condenser in case of start-up/shut-down or
turbine trip as well as HP steam into the cold reheat line. The bypass
stations arc to be provided completely with pressure and injection water
regulation. It must be suitable for automatic operation. The opening of the
by-pass valve is to be interlocked with pressure checks for injection water
pressure and condenser pressure. The pressure setting must be adjustable.
Turbine bypass operation must be possible without time restrictions. This
system should be sized for approximately sixty (60) percent, of the normal
main steam flow.
Casings and rotors are to be provided with wear rings in order to permit
easy replacement of the parts subject to wear. Condensate from the dis-
charge pipe is to be used as sealing water as far as required .
The pump motors are to be so designed that even with 25% overload the
pumps will not be switched off. Pumps and driving motors are to be sup-
plied on a common base plate.
268
The installation height of the pumps and the NPSH value of the pumps are
to be matched to one another so that there will be sufficient suction head
even under the most extreme operating conditions.
Generator
The generator shall operate satisfactorily as a single unit, in parallel with the
other unit and with the grid system under all normal working conditions and
shall be designed for continuous operation.
The connections of the generator and the auxiliaries are indicated in the
tender drawing "General Single Line Diagram".
Generator stator
The stator core has to be made of high permeability low loss stampings,
tightly clamped together to reduce noise and vibration to a- minimum.
Attention will be given to prevent excessive vibration at twice rated fre-
quency being transmitted to the generator foundations, pipes or associated
equipment.
Generator rotor
The cylindrical rotor body shall be of forged steel, comprising one solid
forging. After rough machining the forging shall be subjected to 100%
ultrasonic examination. Damper windings or damper wedges have to be
fitted as necessary to prevent cyclic irregularities and as a precaution
against local overheating of the rotor surface.
The design of the rotor cooling system should ensure that no hot spots
develop. The packing blocks used in the rotor winding has to be of
approved materials and suitable for the high temperatures and mechanical
forces which exist in the rotor.
269
Particular attention will be given to the insulating and securing of the rotor
winding and its connections to avoid vibration and the possible failure of
either conductors or its insulation. Rotor retaining rings will be thoroughly
tested before application to the generator rotor (ultrasonic penetrate
inspection).
Generator bearings
All bearing oil wells shall be provided with visual oil level indicators and
ready means of checking oil flow, filling and draining.
Provision shall be made for testing the excitation equipment without the
operation of the main generator.
The nominal exciter response has to be not less than 0.5 s1.
270
The continuous rated current and voltage of the main exciter has to be not
less than 110% of the generator excitation current and voltage required to
maintain rated output at the terminals of the generator. The ceiling voltage
must not be less than 200% of maximum continuous rating.
Rotating exciters have to be of the enclosed ventilated type. IP54. They will
be directly driven by the generator.
Anti condensation heaters shall be provided in the air circuits of the exciter.
The leads from the heaters has to be brought out to an isolator located
close to the bed plate with suitable interlocks provided to energise the
heaters with the generator at stand-still.
Generator exciter
The rectifier bridge will comprise a simple three phase full wave configura-
tion. Each bridge arm shall consist of a number of diodes in parallel per arm
with suitable protection incorporated.
Particular attention should be paid to the full load and field forcing require-
ments of the generator in addition to the protection of the diodes.
The repetitive peak reverse voltage rating of the diodes in each arm of the
rectifier bridge shall be greater than the maximum reverse voltage
appearing across an individual diode by a factor of at least 2.0. The
maximum reverse voltage appearing across the rectifier bridge will be
determined from a calculation of the induced voltage following a faulty
synchronization.
In order to protect the diodes when connected in parallel. either each diode
should be protected by an H.R.C. fuse together with individual R-C circuit
suppression and diode failure indication or. if the Bidder/Contractor can
demonstrate that individual fuse protection is not required. consideration •
will be given to incorporating such fuse protection in the AC leads from the
exciter. Preference will be given to those schemes uti!ising diodes of
sufficiently high peak reverse voltage capability such that the requirement
for individual diode R-C circuit suppression may be elimin;1ted.
The diodes in the rectifier bridge has to be continuously rated such that
generator full load. field forcing, fault conditions and a reserve capability of
at least 20% can be carried with one failed device per bridge section. A
diode failure detection device is required to monitor all diodes forming the
271
rectifier assembly. The Bidder/Contractor should describe the method used
to detect and report such failures and the resultant action of the excitation
system.
The thyristor converter shall incorporate a number of three phase full wave ,
bridges, and has to be arranged so that a minimum of20% reserve capacity
is incorporated. The converter should be of modular construction so that a
minimum of one bridge may be removed for maintenance (shut-down
required), which still allow full load excitation and unit operation without any
restrictions.
In the event that the converter derives its AC power requirements from the
main generator terminals, the excitation supply transformer should be
capable supplying full field forcing voltage at 80% of rated generator output
voltage. In addition a permanent DC control supply for electronic circuits will
be provided with such a method of converter supply.
The repetitive peak reverse voltage rating of the thyristors in each arm of
the three phase bridges of the converter has to be greater than the
maximum reverse voltage appearing across an individual thyristor by a
factor of at least 2.0.
The thyristors shall be continuously rated such that generator full load, field
forcing and fault conditions can be carried with one failed device per bridge
section.
The system shall include suitable limit control features, fault detection and
protection features and where appropriate generator transformer
overfluxing protection. In the event that dual channel operation is offered,
272
the standby AVR channel will be continuously monitored, and system operation
and protection shall be unaffected by transfer of control from one channel to
another.
The AVR shall in addition include the following protective devices which will
trip the AVR to manual control and initiate appropriate alarms and still trip
the set after a predetermined delay in the range 0-30 min.:
• Overvoltage protection
• Overcurrent protection
• V.T. fuse failure protection
• AVR failure protection
• Overfluxing protection (volts/Hz protection)
• A VR power supply failure protection.
273
Overnuxing protection must be provided and will be part of the excitation
control system and shall be operative during both automatic and manual
modes of excitation control. The protection has to prevent the transformer
magnetic flux from rising to a value at which the voltage/frequency ratio,
pre-set within the range 1.00 to 1.25, would be exceeded.
Generator control
An approved means of manually controlling the excitation must be provided
primarily for generator commissioning and maintenance purposes. Control
will be possible from approximately 0 to 110% UN.
Means for both local and remote (from central control room) operation or
the manual control shall be provided with
• auto/manual balance indicator (local cubicle and central control room).
• changeover switch (local cubicle and central control room).
All automatic limiter shall stop the automatic folIow-up device or the
manual voltage controller from reducing the manual voltage regulator
selling below the prescribed are limits of excitation for the generator when
under manual control. The characteristics or the limiter shall have the
same range of adjustment as the var-limiter of the AVR channel, but when
commissioned will be set for less leading conditions than the var-limiter.
274
Means has to be provided on the cubicles for indicating locally and
remotely whether the switches are in the 'open' or 'closed' position.
Where slip rings, commutators, and associated brush gear are provided
they must be designed to operate without injurious sparking or excessive
wear and it shall be possible to run for Ht least four months without
replacements of the brushes. The brush gear housing has to be designed to
provide maxill1umvisibility via inspection windows. Guards of insulating
material should be mounted between the slip rings and between brush
holders of opposite polarity.
Each indicator must have adjustable settings for initiating a high tempera-
ture alarm which shall be independent of the temperature indication se-
lected.
275
coolers, fans, pumps and control apparatus as required for safe and
efficient operation of the plant and has to comply with the requirements of
IEC 34-3.
As cooling systems the following has to be provided:
or alternatively
The generator coolers etc. must he sized so, that rated generator output at
class B operation can be mainlained with 10% of the tubes blocked. The
cooler and isolating valves have to be arranged to permit easy isolation and
cleaning of individual sections after shut-down. With one cooler section
withdrawn, the operation of the generator can be continued at rated genera-
tor output, utilizing the thermal limits of class F.
The cooler tubes shall be mounted and supported to allow for the effects or
expansion and vibration. Any necessary apparatus required to withdraw the
air coolers or permit repair has to be provided. Water leak detectors must
be provided for all coolers, which will initiate an alarm in the event of a leak
occurring.
CO2 equipment
276
The basic circuit of the GMC's and the instrument transformers and other
equipment is shown in Annex B8-2. All the necessary controls, regulating,
measuring and monitoring instruments including meters are to be provided
locally and/or in the central control room.
The GMC's are to be designed for the thermal and dynamic maximum
short-circuit currents occurring. All supporting and other constructions both
inside and outside the GMC, where not made of aluminum. must be made
in a hot-dip galvanized design. In the GMC-branch busduct to the unit
auxiliary transformer isolating links are to be provided in the single-phase
busbars. Anti condensation heaters are to be provided in each separate
GMC section.
The star point is to be made directly behind the generator bushing type
current transformers provided for this purpose. This high voltage section is
to be enclosed by a cubicle unit with solid metal walls. The earthing trans-
formers as required by the generator stator protection system may be
arranged also in this cubicle if applicable.
Along the indoor run of the GMC's, all further auxiliary items such as
voltage transformers, overvoltage capacitors, earthing isolators, etc. are to
be housed in steel sheet cubicles.
277
GMC earthing switches
For the generator and unit protection system, digital protection relay types
has to be used. The individual relays or relay groups are to be installed in
the plug-in principle in standardized steel sheet cubicles. The basic circuit
will be as shown in Annex B8-2.
The protective relays are to be divided into two groups with the relays in
group 2, for example, representing the back-up protection of the relays in
group 1 and vice versa.
Synchronizing
The general synchronizing point will be the 230kV circuit breaker. A plugin
type electronic parallel-switching apparatus must be provided.
278
Application of the appropriate voltage transformer outputs is to be effected
simultaneously with the choice of synchronizing point (synchronizing
selector) from the central control room.
Measuring
Electrical measuring and metering equipment must be provided locally and
in the central control room minimum as per the basic circuit shown in Annex
B8-2.
The protection system supplied has to protect the turbine generator plant in
every phase of operation from overload and damage. It must be continually
ready for operation and capable of being checked even during operation
and must not be capable of being switched off even accidentally.
Governor equipment
The description below contains the regulation tasks and a framework pro-
posal for the solution of these tasks.
279
speed under speed control with a governing accuracy of 1 % or better.
The system must also provide for proper management of automatic syn-
chronizing.
• The speed overshoot caused by a full load shedding has to be less or
equal to 8% referring to nominal speed. The same is required by only
action of the mechanical/hydraulic governor.
• A facility for limiting the rate of speed variation shall be provided.
• For the speed a set point adjustment facility with presettable slope, and
with limiting action on the jump and rate limiter corresponding to the
allowances, shall be provided .
The computed allowances are to be made available to the two set point
adjustment devices of the turbine governor for limiting purposes, and fed to
information displays and to the DCS in the central control room. On
attainment of a temperature or stress limit appropriate alarm signals arc to
he initiated.
Protection equipment
280
protection criteria must be present as a minimum:
• Steam inlet temperature and pressure greater than max.
• Turbine speed greater than maximum [at least two (2) independent speed
checks for 110/112% with the possibility of testing during continuous
operation]
• Bearing metal temperatures (thrust and journal) greater than maximum
• Shaft position not correct
• Bearing housing and/or rotor vibrations greater than maximum
• Wall temperature difference of turbine casings greater than maximum
• Control oil pressure lower than minimum j
• Lubricating oil pressure lower than minimum
• Relative extension greater than maximum
• Level in lube oil tank lower than minimum
• Generator protection operated
• Fire-protection system operated
• Unit trip operated
• Local turbine trip operated
• Condensate level in the condenser
• Remote trip from the central control room
All the mechanical-hydraulic and electrical protective circuits 011 the turbine
must be so constructed (for example using 2-channel, 2 from 3 selection,
self-monitored principles) that faults in one protective interlock cause no
erroneous release, on the one hand. but do not prevent the initiation or
rapid shut down in actual cases of danger, on the other. The protective
circuits must be supervised by checking the equipment initiated from the
central control room and it must be possible at any time to inspect the
functional correctness of the protection without causing a trip of the turbine.
The protection signals must operate on all turbine emergency stop valves
and, where applicable, on the bleed emergency shut-off valves.
The boiler feed water pumping sets shall be identical in designs and all
replacement parts will he interchangeable.
281
Special emphasis is placed on a high resistance to corrosion of the
equipment. The feedwater pumps with all parts coming into contact with the
feedwater are to be constructed in chromium steel containing at least 13%
chromium. The materials must satisfy without restriction the requirements of
erosion and corrosion resistance resulting from operation with
dematerialized water and water conditioned with volatile alkalizing agents
having a PH value equal to or greater than 7.0. Protective sleeves on the
shafts arc to be hard chromium plated, cooling sections and bearing
mountings of cast steel.
A reverse rotation locking devise shall be provided for each pumping unit.
The pumps must have generously dimensioned plain bearings (only for
booster pumps ball bearings can be offered as an alternative) and forced
feed oil lubrication. The total axial thrust of the pump shall be neutralized by
a hydraulic balancing device. A thrust bearing shall be provided, which is so
dimensioned that even in the event of short-duration cavitations no damage
to the pump will occur. The hearing metal shall have emergency running
proprieties.
The shaft seals shall be of the soft-packed stuffing box type in the case of •
booster pump and mechanical seals for main feedwater pumps. The stuffing
box and corresponding gland cover shall be cooled; the seal chamber nt
mechanical seals shall be cooled as well.
All rotating parts shall be statically and dynamically balanced. Each impeller
shall be carefully machined and polished and where it is impossible to
machine, a smooth surface shall be obtained by work.
II must be possible to start the pumps safely from cold with prior warming
up. Automatic changeover to the load point previously in use must he
possible without delay.
Strainers should be included in the suction lines to protect the pumps from
damage under all operating conditions. The strainer mesh size should not
exceed 0.4 mm. The strainer and strainer body must be matched so
th:.1lthe full area of the strainer is utilized. The free area of the strainer must
he at least equivalent to 5 times the cross-section m-ea of the
corresponding suction pipe.
282
To combat vibration, the pumps should be mounted on reinforced concrete
foundation slabs supported on spring elements.
The design pressure of the feed pumps shall be at least 1.2 times the pump
zero now pressure at the highest possible pump speed at cold conditions
and under maximum suction pressure conditions.
Oil supply
A closed oil system having separate internal working and lubricating circuits
must be provided for the feedpump and motor bearings.
The lubrication oil system shall also be equipped with an auxiliary lubricat-
ing oil pump which starts automatically in the event of a fall in lubricating oil
pressure. An adequate feed of oil shall be ensured under start-up and run-
down conditions.
The oil systems are to be equipped with all necessary filters (double filters),
strainers, pipes, valves, etc. necessary for safe operation. Changeover of
the filters during operation must be possible without interruption and they
must be easy to clean.
The deaerator connected to the feedwater tank should be of the spray type
using the "Stork" system or of cascade-type with incorporated re-evapo-
ration. In all cases the feed water tanks must have a warming-up steam line
supplied with steam from the auxiliary steam header.
The size of the deaerator must be sufficient for a water flow of at least 1.1
times the maximum boiler feed water flow plus the maximum feedwater
injection quantity.
If the feed water tank pressure falls, a supplementary steam supply is taken
from the cold reheat manifold. The supply from the cold reheat manifold is
also taken during start-up/shut-down operation, in order to maintain the
required minimum feed temperature.
The deaerator spray nozzles and the nozzle strainers shall be or stainless
steel.
The deacration area must be lined with stainless steel. The entire vapour
extraction system must be manufactured from stainless steel.
To allow for possible slopping of the contents of the feed tank, a horizontal
impact force of 10% of the maximul11 vertical load l11ust be assumed.
283
nesses for the feed tank and deaerator shal1 have a corrosion allowance of
at least 3 mm. The tank must be suitably stiffened to safely withstand Cull
vacuum.
All valves and fittings directly above the feedwater tank must be accessible
from platforms.
Interconnection work
Piping systems > DN 80 and > 1200C must be stress analyzed from anchor
point to anchor point, regardless of battery limits or individual contracts.
The wall thickness for shells and ends shall be at least 8 mm. The heat
exchanger tubes shall be scam less with an inside diameter of at least 15
mm.
The stub pipes shal1 he welded wherever possible, both internally and
externally. Stiffeners with inspection holes for stub pipes should be welded
in place where necessary.
Similarly, the emergency drain of the LP feedheaters and the steam side
safety) valves shall be suitable for discharging the maximum rate of
condensate flow according to the requirements
284
The LP feed heaters shall be of standard horizontal tube-plate type with U-
tubes. A welded-on hotwell shall be provided for water level control (if
required). The material of the tubes shall be of stainless steel.
All pipe collections and all connections on the vacuum side shall be welded.
Shell and tube bundle shall be equipped with effective baffle plates and
protection at the steam and drains inlet. Particular care shall be taken for
proper air extraction so that no air pockets can form inside the heat ex-
changers.
HP feedwater preheaters
In case of pipe burst in the HP heaters the 2 out of 3 high level trip shall
initiate immediately the isolation of the HP heaters and bypassing the
feedwater.
285
different temperature conditions. The complete tube bundle must be stress-
relieved.
Effective baffle plates and protection must be incorporated in the shell and tube
bundle adjacent to the steam inlet.
2.3.19 Tanks
The drain condensate tank must be dimensioned for the maximum volume
of condensate arising from the atmospheric flash tank and tundish drains.
The inside tank overflow line is to be so dimensioned that the maximum
inflow of condensate can be discharged without the outflow velocity in the
line exceeding 0.8 m/s. The tank is to be of the horizontal cylindrical type
and mounted as low as possible so that an adequate head exists for all
infeeds.
286
2.3.20 Drain condensate pumps
All parts of the pumps coming in contact with the water arc to be manufactured
in stainless material. Casings and rotors arc to be provided with wear rings in
order to permit easy replacement of the parts subject to wear. Condensate
from the discharge pipe is to be used as scaling water as far as required.
In normal cases one pump will be in operation. The second pumps shall
start automatically if the operating pump trips.
The pump motors arc to be so designed that even with 25% overload the
pumps will not be switched off. Pumps and driving motors arc to be supplied
on a common base plate.
The installation height of the pumps and the NPSH value of the pumps are
to be matched to one another so that there will be sufficient suction head
even under the most extreme operating conditions.
The following technical schedules comprise part of this specification. The data
and requirements specified in the respective forms arc to be adhered to and
the missing data of forms arc to be completely filled in. The completed
technical schedules arc to be submitted with the Bid.
287
BPDB, Barapukuria 250 MW Power Plant
Minimum Requirements
Section B2: Steam Turbine Plant
Performance and Design Criteria Unit Data
Turbine
1.5 or according to
Minimum cooling water velocity in condenser tubes m/s requirement of
sponge ball
cleaning equipment
Minimum tube bore of condenser tubes mm 17
B2/FB-1
288
BPDB, Barapukuria 250 MW Power Plant
Minimum Requirements
Section 82: Steam Turbine Plant
Performance and Design Criteria Unit Data
Generator
Rated voltage at generator terminals kV Select between
(11 - 15.75) ± 5%).
Rated frequency Hz 50
Rated power factor (lagging) cos phi 0.80
Rated power factor (leading) cos phi . 0.92
Unsaturated subtransient reactance x"d (without minus % 17
tolerance and at rated generator output)
Earthing switch
289
BPDB, Barapukuria 250 MW Power Plant
Minimum Requirements
Section B2: Steam Turbine Plant
LP feedheaters
Design pressure of LP feedheaters (steam side) 120% of respective
maximum turbine bleed
pressure and full
vacuum
B2/FB-3
290
BPDB, Barapukuria 250 MW Power Plant
Bidder/Contractor
Section B2: Steam Turbine Plant
Technical Data by Bidder Unit Data
Exhaust moisture %
Steam Turbine
Manufacturer -
Type -
Casings
Number of casings
Casing design HP -
Casing design IP -
Casing design LP -
Rotors -
LP shaft mm
B2/FD-1
291
BPDB, Barapukuria 250 MW Power Plant
Bidder/Contractor
Section B2: Steam Turbine Plant
Technical Data by Bidder Unit Data
Blading
HP regulating stage:
Type of wheel
Mean blading diameter mm
Pressure in the regulating wheel chamber at MeR bar
HP/IP blading:
Type of H.P./I.P. blading (impulse/reaction)
Number of stages
Length of blades last row mm
Mean blading diameter last row mm
LP blading:
Type of LP blading (impulse/reaction) -
Number of stages
Length of blades last row mm
Mean blading diameter last row mm
Exhaust area of last row (axially) m2
Materials
HP/IP outer casing -
HP/IP inner casing
HP/IP blade carriers
LP outer casing
LP inner casing
LP blade carriers
HP/IP rotor
LP rotor -
HPIIP nozzles -
HP/IP rotor blades -
LP nozzles -
LP rotor blades -
Casing of emergency stop valves -
(HP-steam; reheat-steam)
Casing of HP-steam governor valves -
B2/FD-2
292
BPDB, Barapukuria 250 MW Power Plant
Bidder/Contractor
Section B2: Steam Turbine Plant
Technical Data by Bidder Unit Data
Emergency stop valves
Number of valves
•HP-steam
•reheat-steam
Turbine speeds
Rated rpm
Overs peed trip - electrical rpm
- mechanical rpm
HP-steam governor valve
Number of valves
Size mm
Type
Actuator
Reheat-steam governor valve
Number of valves
Size mm
Type
Actuator
Bleed steam emergency shut-off valves Type
Manufacturer
Type
Bearings
Number of journal/thrust
bearings Type: Journal
Thrust
Maximum oil outlet temperature 0
C
B2/FD-3
293
BPDB, Barapukuria 250 MW Power Plant
Bidder/Contractor
Section B2: Steam Turbine Plant
Technical Data by Bidder Unit Data
Dimensions
Total length of turbine generator m
Length of foundation m
Width of foundation m
Height of foundation m
Weights
Heaviest part to be handled by crane -
B2/FD-4
294
BPDB, Barapukuria 250 MW Power Plant
Bidder/Contractor
Section B2: Steam Turbine Plant
Technical Data by Bidder Unit Data
Gland steam condenser
Number of condensers -
Materials:
Tubes -
Shell -
Gland exhauster
Number of exhausters -
Type -
Rating kW
Oil Supply
Tank capacity m3 .
Number of recirculation (per hour) I/h
lubrication oil system pressure bar(g)
Main oil pump
Type -
Drive -
Speed rpm
Material of pump casing -
Auxiliary oil pump
Number/capacity of pumps -/%
Type -
Rating kW
Speed rpm
Material of pump casing -
Emergency oil pump
Number of pumps -
Type -
B2/FD-5
295
BPDB, Barapukurla Power Plant
Bidder/Contractor
Section B2: Steam Turbine Plant
Technical Data by Bidder Unit Data
Rating kW
Speed rpm
Material of pump casing -
H.P. jacking oil pump
Number of pumps -
Type -
Rating kW
Speed rpm
Material of pump casing -
Oil vapour extraction
Number of extraction fans -
Type -
Rating kW
Oil cooler
Number of coolers -
Capacity per cooler %
Erection (horiz.lvert.) -
Max. oil outlet temperature °C
Cooler length mm
Materials:
Tubes -
Shell -
Oil separator .
Manufacturer -
Type -
Flow rate per separator of lubrication oil flow %
Heat rating kW
Rating of drive kW
Lubrication oil filter
B2/FD-6
296
BPDB, Barapukuria 250 MW Power Plant
Bidder/Contractor
Section B2: Steam Turbine Plant
Technical Data by Bidder Unit Data
Type -
Flow rate per filter %
Grade of filtration µm
Control oil system
System pressure bar(g)
Control oil pump (where applicable)
Number of pumps -
Capacity per pump %
Type -
Rating kW
Speed rpm
Material of pump casing -
Condenser
Total number of condensers -
Manufacturer -
Type -
Arrangement -
Condensing Operation at MCR:
Steam flow kg/s
Cooling water flow m3/h
Cooling water temperature rise K
Cooling water pressure loss bar
B2/FD-7
297
BPDB, Barapukuria 250 MW Power Plant
Bidder/Contractor
Section B2: Steam Turbine Plant
Technical Data by Bidder Unit Data
Diameter of tubes (bore) mm
Wall thickness of tubes mm
length between tube plates mm
Number of tube support plates
Number and size of cooling water connections -/mm
Materials:
Tubes -
Tube plates -
Shell -
Water boxes -
- lining of water boxes -
Hotwell capacity minutes
Main condensate pumps
Number/capacity of pumps - / %
Manufacturer -
Type -
Nominal capacity m3/h
Delivery head m
Motor rating kW
Closed valve head m
Speed rpm
Type of bearings -
Material of pump casing/shaft/impeller -
Designation of system -
298
BPDB, BarapukuriaPower Plant
Bidder/Contractor
Section B2: Steam Turbine Plant
Technical Data by Bidder Unit Data
Type or name of system
Vibration Measurement
Manufacturer -
Designation of system -
Type or name of system -
Total number of shaft vibration sensors -
Total number of bearing vibration sensors -
B2/FD-9
299
BPDB, Barapukuria 250 MW Power Plant
Bidder/Contractor
Section B2: Steam Turbine Plant
Technical Data by Bidder Unit Data
Synchronous generator
Applicable standards -
Manufacturer -
Type -
Protection class -
Generator power characteristic curve No . -
Rated generator output MVA
Rated power factor lagging cos phi
Rated power factor leading cos phi
Rated active power (at rated gen. output) MW
Rated voltage kV
Voltage variation range %
Rated current (at rated gen. output) A
Rated frequency Hz
Rated speed rpm
Direct axis sub-transient reactance saturated x"d
%
(unsaturated, minimum value)
B2/FD-10
300
BPDB, Barapukuria 250 MW Power Plant
Bidder/Contractor
Section B2: Steam Turbine Plant
Technical Data by Bidder Unit Data
Stator
Number of bushings -
Type of winding -
Insulation Class -
Type of insulation -
Rotor
Diameter of rotor body mm
Length between bearing centers m
Type of windings -
Type of damper winding -
Insulation class -
Type of insulation -
Shut down heating
Rated power kw
Rated voltage V
Excitation System
Type of excitation system (short description) -
At no load: Exciter current A
Exciter voltage V
At rated generator output: Exciter current A
Exciter voltage V
Exciter machine
Manufacturer -
Type -
Power Input KW
Insulation class -
Voltage regulator
Manufacturer -
Type -
Voltage regulation range ± %
Generator dimensions
Total length m
Total height m
Total width m
Generator weights
Stator weight t
Rotor weight t
Transport weight complete generator t
Heaviest part and its weight to be lifted during -/t
maintenance in machine hall
B2/FD-11
301
BPDB, Barapukuria 250 MW Power Plant Bidder/Contractor
Section B2: Steam Turbine Plant Unit Data
B2/FD-12
302
BPDB, Barapukuria 250 MW Power Plant
Bidder/Contractor
Section B2: Steam Turbine Plant
Technical Data by Bidder Unit Data
Current and voltage transformer
Secondary current of current transformers A
Accuracy class: measuring -
metering -
protection
Secondary voltage of voltage transformers V
Accuracy class: measuring -
metering
protection
voltage regulation
Earthing switch
Manufacturer -
Type of earthing switch -
Rated voltage kV
Rated frequency Hz
Rated current A
Rated short circuit making current kA(peak)
Rated short time withstand current (3 sec.) kA
Power frequency withstand voltage kV .
Rated impulse withstand voltage kV(peak)
Rotor driven earthing switch yes/no
Protective capacitors
Type
Number of capacitors Nos.
Rated voltage kV
Rated frequency Hz
Rated capacity nF
Enclosure of steam turbine generator
Type
Manufacturer
Max. noise pressure level at 1 m distance dB(A)
B2/FD-13
303
BPDB, Barapukuria 250 MW Power Plant
Bidder/Contractor
Section B2: Steam Turbine Plant
Technical Data by Bidder Unit Data
Number -
Number -
Feedwater pump
Number of pumps /each pump capacity -/%
Manufacturer -
Type -
Minimum capacity m3/h
No. of stages -
Type of journal bearings -
Method of axial thrust hydraulic compensation -
Type of axial bearings -
Type of bearing lubrication -
-
Oil supply from
Type of glands or seals -
Closed valve head m
Materials:
Pump casing -
Shaft -
Impeller
Total power requirement of feed pump sets when the
kW
turbine is running at MCR
VOITH,
FWP Hydro coupler manufacturer
Germany
One pump set in single operation (at max.
speed):
Delivery rate HP/IP m3/h/m3/h
Delivery head HP/IP m/m
Net position suction head required m
Power requirement of one pump set at motor terminals kW
304
B2/FD-14
BPDB, Barapukuria 250 MW Power Plant
Bidder/Contractor
Section B2: Steam Turbine Plant
Technical Data by Bidder Unit Data
Pump efficiency at rated capacity % ..
Coupling
Type -
Number of pumps -
Manufacturer -
Type -
Type of journal bearings -
Type of thrust bearings -
Type of bearing lubrication -
Oil supply from -
Materials:
Pump casing -
Shaft -
Impeller -
B2/FD-15
305
BPDB, Barapukuria 250 MW Power Plant Bidder/Contractor
Section B2: Steam Turbine Plant
Technical Data by Bidder Unit Data
Feedwater pump motor
Manufacturer -
Type -
Rated power kW
Rated voltage kV
Rated speed rpm
Rated efficiency %
Rated power factor -
Starting time sec.
Protection system -
Insulation class -
Type of bearings -
Type of lubrication -
Method of cooling the motor -
(external fan/internal fan/water-cooled)
Deaerator for feedwater system
Manufacturer -
Type -
Mode of operation -
Maximum outnow rate of deaerator kg/s
Outside diameter (where applicable) mm
Total length (where applicable) mm
Materials
Shell (where applicable) -
Internals -
B2/FD-16
306
BPDB, Barapukuria 250 MW Power Plant
Bidder/Contractor
Section B2: Steam Turbine Plant
Technical Data by Bidder Unit Data:
Feedwater tank
Manufacturer -
Nominal capacity m3
Normal working capacity m3
Outside diameter mm
Total length mm
Materials:
Shell -
Internals -
Operating weight kg
Weight during testing kg
Water pressure loss at inlet (MCR) bar
Design temperature deaerator °C
Design pressure deaerator bar
High pressure feedheater 1
(Design data at MCR of turbine unit) -
Manufacturer -
Type -
Heat rate kJ/s
Heat transfer coefficient (outside diameter) condensation/drain kJ/m2sK
Terminal temperature difference
Steam side K
Drain side K
Total heat exchanging surface (outside diameter) m2
- Shell outside diameter mm
Total length mm
Tube outside diameter mm
Tube wall thickness - mm
Materials:
Tubes - .
Tube plate -
Shell -
Weight kg
B2/FD-17
307
BPDB, Barapukuria 250 MW Power Plant
Bidder/Contractor
Section B2: Steam Turbine Plant
Technical Data by Bidder Unit Data
High pressure feedheater 2
(Design data at MCR of turbine unit) -
Manufacturer -
Type -
Heat rate kJ/s
Heat transfer coefficient (outside diameter) condensation/drain kJ/m2sK
Terminal temperature difference
Steam side K
Drain side K
Total heat exchanging surface (outside diameter) m2
Shell outside diameter mm
Total length mm
Tube outside diameter mm
Tube wall thickness mm
Materials:
Tubes -
Tube plate -
Shell -
Weight kg
Low pressure feed heater 4
(Design data at MCR of power unit) -
Manufacturer -
Type -
Heat rate kJ/s
2
Heat transfer coefficient (outside diameter) condensation / drain kJ/m sK
Terminal temperature difference
Steam side K
Drain side K
2
Total heat exchanging surface (outside diameter) m
Shell outside diameter mm
Total length mm
Tube outside diameter mm
Tube wall thickness mm
Materials:
Tubes -
Tube plate -
Shell -
Weight kg
B2/FD-18
308
BPDB, Barapukuria 250 MW Power Plant
Bidder/ Contractor
Section B2: Steam Turbine Plant
Technical Data by Bidder Unit Data
Low pressure feedheater 5
(Design data at MCR of power unit) -
Manufacturer -
Type
Heat rate kJ/s
Heat transfer coefficient (outside diameter) condensation/drain kJ/m2sK
Terminal temperature difference
Steam side K
..
Drain side K
Total heat exchanging surface (outside diameter) m2
Shell outside diameter mm
Total length mm
Tube outside diameter mm
Tube wall thickness mm
Materials:
Tubes -
Tube plate -
Shell -
Weight kg
Low pressure feed heater 6
(Design data at MCR of power unit) -
Manufacturer -
Type -
Heat rate kJ/s
Heat transfer coefficient (outside diameter) condensation /drain kJ/m2sK
Terminal temperature difference
Steam side K
Drain side K
Total heat exchanging surface (outside diameter) m2
Shell outside diameter mm
Total length mm
Tube outside diameter mm
Tube wall thickness mm
Materials:
Tubes -
Tube plate -
B2/FD-19
309
BPDB, Barapukuria 250 MW Power Plant
Bidder/Contractor
Section B2: Steam Turbine Plant
Technical Data by Bidder Unit Data
Shell -
Weight kg
(Technical data for further feed heaters to be filled
in as required above)
Atmospheric flash tanks
Number of tanks for each boiler and turbine unit -
Cold condensate tank
Number of tanks for each boiler and turbine unit -
Net capacity of each tank m3
Drain condensate tank
Number of tanks for each boiler and turbine unit -
Installation level -
Drain condensate pumps
Number of pumps for each drain condensate tank -
Capacity of pumps %
Manufacturer of pumps -
Electrical motor rating kW
B2/FD-20
310
Coal Handling System
311
B3. Coal Handling System
3.1 General
Existing coal handling system capacity is 300 MT/ hr which is being used
for existing 2 x 125 MWe units.
Existing Coal handling system is receiving coal from the adjacent coal
mine mouth with storage arrangement in the Power Plant coal yard,
transportation and storage in coal bunkers.
The raw coal from the coal mine to the coal storage area is transported
by a single line conveyor belt system. For the transportation of the
crushed coal from the coal storage area up to the coal bunkers of
existing 2 x 125 MW e units, a double line belt conveyor system is being
used.
A ‘Coal Processing Plant’ to remove iron, hard materials, waste & large
size coal and to control moisture of coal (within the limit of 10%) shall be
provided at the upstream of existing ‘Magnetic Separator’ with necessary
modification of relevant coal conveyer system.
A single line coal conveyor belt system with two (02) crusher units shall
be provided from the upstream of existing crusher unit to the new coal
yard with necessary modification of relevant coal conveyer system.
A coal conveyor belt system shall be provided in between new coal yard
and old coal yard.
Extension of existing two coal supply belt conveyors shall be provided from
existing unit no. 2 to the new 250 MW unit complete in all respect to feed
coal to the coal bunkers of the 250 MW unit.
Comprising essentially:
312
• Dryer
• Processed coal weighing belt scale etc.
• belt conveyor up to the new coal crusher
• two coal crusher complete with feed hopper, electric drive, necessary
supports, explosion and fire protection measure, dust proof housing,
classifier, inertisation devices, screening system
• traversing and reversible distribution belt conveyors for coal
transportation from the crusher to the new coal storage area (open and
covered storage area)
• extension of existing two coal supply belt conveyors from existing unit
no. 2 to the new 250 MW unit complete in all respect to feed coal to the
coal bunkers of the 250 MW unit
• ventilation and dust collecting equipment for all transfer points
• steel structure, stairs, ladders, walkways, conveyor bridges, necessary
supports, discharge hoods
• all associated equipment such as belt drives, idlers, pulley, belt and
pulley scrapers, hold barks
• auxiliary equipment such as belt weighing scale, coal sampling devices,
all necessary belt safety and protection devices
• washdown system to clean the conveyor systems and walkways
• weighing facilities (belt scale)
• dust extraction and suppression system including water spray system,
piping, valves, etc.
• passive safety measure to protect the stored crushed coal against self-
ignition
• coal bunker ventilation system
• scaling system
• PLC safety interlocking system
3.3.1 General
The following factors shall be taken into account on system design and
equipment selection:
• safety
• reliability
• maintainability
• minimize indoor and outdoor environmental pollution
• standardization of components.
The scope of design and supply of coal handling system include all the
313
processes and facilities as mentioned.
For conveyors of short length, fixed installed tension devices may be used,
while for conveyors of longer length tension carriages or equivalent self
regulating tension devices to be used.
Junction towers shall consist of steel frame work and outside cladding.
Intermediate stairs and steps shall be provided with grid floorings.
Above the conveyor heads or take-up stations respectively trolley beams for
a payload of 3 tons shall be provided.
314
Distribution of coal to the individual coal bunkers shall be done preferably
by a horizontal tripper conveying system. It remains at the latitude of the
Contractor if the tripper conveyors will be provided with carriages,
movable on rails or whether one reversible conveyor will be attributed to
each pair of bunkers. Special care shall be given to the selection of the
sealing system "bunker-tripper conveyor".
One inline magnetic separator in conjunction with two tramp iron detectors
shall be installed in the conveyors feeding to the coal crusher. One of the
tramp iron detectors shall be installed upstream of the magnetic separator
and shall activate the magnet, while the other one shall be installed
downstream of the magnetic separator and shall stop the conveyor system
in case that iron is detected.
The magnetic separator shall use an electric magnet and shall be provided
with its own rectifier.
Removal of tramp iron may be made manually by using a trolley. This trolley
shall be supplied with the system.
The belt scale of the electronical type shall be integrated in the conveyor
system leading to the boiler.
Suitable traveling type of stacker shall be provided to stack the crushed coal
to a height relevant to the availability of space. Necessary platform with
drainage facility shall be considered. Soil improvement to improve bearing
strength and other requirement shall be considered as required. Reclaim
from both coal storage areas (covered and open storage area) shall be
315
done by front end loaders and loaded to underground hoppers for further
feeding to downstream conveyors of inplant coal handling. Required number
of front end loaders shall also be supplied. Number of front end loaders
shall be adequate to feed the conveyors at 110% MCR of boilers.
The inplant conveyors capacity shall be adequate to fill the boiler bunker in
8 hours operation.
The coal storage areas shall be provided with necessary fire water system
and compacting/dust suppression system.
Coal received shall be screened and crushed to the required size of the mill
system in the crusher prior to sending to boiler bunkers.
Crushers shall be of suitable heavy duty impact type. Crusher and screens
shall be supported suitable and isolated from other foundation work.
Necessary antivibration dampers shall be provided for crushers and screen
foundations.
316
tripper arrangement shall be given for bunker filling. This system shall
also include bunker sealing arrangement, bunker ventilation system and
traveling tripper conveyor.
Dust extraction system shall be provided in all the junction towers and
crusher house to minimize the air pollution problem. Process water shall be
used for dust suppression system. I
Dust suppression system shall also be provided to the coal storage area.
Necessary spray system and arrangement shall be provided in both coal
storage areas.
Bunker ventilation shall be provided to extract the dust due to bunker filling
operation.
A PC based PLC safety interlocking system for coal handling system shall
be such that sequential starting/shut-down of all the equipment due to trip
condition of downstream conveying equipment is ensured. The trip-off of
the minimum equipment in the safest sequence during abnormal operating
conditions shall be ensured. The functions of safety interlocking system is
as follows:
The inplant coal handling system starting from the crusher up to boiler
bunker feeding trippers operation shall be controlled from inplant coal
handling control room located in the Plant near to crusher house. Other
equipment/components shall be operated from local stations (see also
Chapter 9).
317
BPDB, Barapukuria Power Plant
Minimum Requirements
Section B3: Coal Handling System
Performance and Design Criteria Unit Data
B3/FB-1
318
BPDB, Barapukuria Power Plant
Bidder/Contractor
Section B3: Coal Handling System
Technical Data by Bidder/Contractor Unit Data
Coal handling equipment
Belt conveyors
Type -
Manufacturer -
Belt widlh mm
Height of borders mm
Handling capacity kg/h
Belt velocity m/s
Material of belt -
Drive power kW
Coal crusher
Number pcs
Manufacturer -
Type -
Capacity t/h
Screen dimension mm
Final grain size mm
Motors:
• manufacturer -
• type -
• rating kW
• rated voltage kV
• speed rpm
Magnetic separator and tramp Iron detectors
Type/ Manufacturer -
Number' pcs
Location -
Rated power kW
B3/FD-1
319
BPDB, Barapukuria Power Plant
Bidder/Contractor
Section B3: Coal Handling System
Technical Data by Bidder/Contractor Unit Data
Weighing scale
Type -
Manufacturer -
Capacity kg
Accuracy %
location -
Tripper conveyor -
Manufacturer -
Type of construction -
Number pcs
length m
Capacity kg/h
Width mm
Belt velocity m/s
Coal bulk density kg/m3
B3/FD-2
320
Air and Flue Gas System
321
Table of Contents
4.1 General
322
B4. Air and Flue Gas System
4.1 General
The air supply and flue gas system shall be designed in a double flow path.
Each of the components shall be provided twice. In case of failure of any
equipment within the air and flue gas system the steam generator shall be still
able to obtain 60% of its MCR. Dampers in the air and flue gas ducts shall
consider a cross over operation (e.g. operation forced draught fan left side.
regenerative air heater right side)
Provision for flue gas recirculation system for decreasing the NOx emission has
to be provided, if necessary.
Comprising essentially:
• all measures necessary for damping out vibration and for noise
attenuation including silencer.
Comprising essentially:
• Flue gas ducts with reinforcements and support structure. isolating and
regulations dampers with electric actuators expansion joints, Venturi
measurements devices, etc. consisting of raw gas duct with ash hopper
between the steam generator out- let and the regenerative air preheater
323
inlet duct, from the regenerative air preheater exit to the inlet hood of the
electrostatic precipitator (ESP), clean gas duct from the exit hood of the
ESP to the induced draft fan (ID fan), common duct between ID fans and
further to the stack inlet
• 2 (two) ID fans (with special type impeller blade considering 100% ash
with flue gas causing no damage or unbalance) including electric motor,
forced lubrication system
• all necessary isolating dampers (for all ID fan, Coal mill, ESP, flue gas
recirculation fans for plant running maintenance) and regulation dampers
with electric actuators. expansions joints
• all measures necessary for damping out vibrations and for noise
attenuation including silencers.
Comprising essentially:
4.3.1 General
The air flue gas system shall be of the balanced draft type and designed
in two parallel lines. The system shall be completely gas tight.
324
any tool. The inspection doors have to be provided for inspection of
each heating surface at flue gas inlet and outlet.
All necessary gas flues and air ducts shall be provided including
auxiliary plant. Wherever necessary, balance ducts fitted with
isolating dampers shall be provided. It shall be so arranged to
maintain an even draught across the width of the boiler unit at the
exit from the boiler.
One (1) Venture throat shall be installed for measuring the air flow of
air heaters primary and secondary air pulverizers hot and cold air and
burners,
The secondary air dampers of the burner must permit the exact
proportioning of the combustion air to each burner which has to be
proved during commissioning tests.
All necessary isolating and control dampers shall be provided lor the
reliable and convenient operation of boiler unit .
325
operation with one FD fan etc. and reverse
• operation with two (2) regenerative air heaters but one (I) FD fan
respectively one (1) ID fan
• to take each burner group into and out of operation
• to control the combustion air flow of each single burner.
Dampers in flue gas ducts shall be designed and located so that the build-
up of ash behind the damper blade is reduced to a minimum and their
opened and closed position has to be used for the FD fan and boiler
interlocking.
Tapping holes suitably and correctly located for its purpose shall be
provided for permanent instruments and for checking and testing
purposes for pressure readings and flue gas sampling. All ducts shall be
designed to minimize resistance to air and gas !low and to give good
distribution of air flow particularly to boiler sides and the burner air
registers or to the burner wind box.
The air or flue gas leakage of the dampers when closed shall not exceed 1
% of the maximum flow.
All flue gas dampers which are installed for isolation of components during
operation of the unit shall be provided double. When closed. sealing air
shall be supplied between the dampers.
326
regenerative air preheater will be possible. The flue gas damper in the
bypass shall be suitably interlocked to avoid that the maximum
permissible temperature of stack will be exceeded.
Due attention shall be paid for the material selection of the flue gas duct in
which during continuous operation the flue gas will be stagnant.
Selection of ducts and dampers within the air and flue gas system shall be
done so that the wet washing of one regenerative air preheater will be
possible. while the boiler will operate on partial load with the other air
preheater in operation. Nevertheless the Contractor has to guarantee
continuous operation of the regenerative air pre heaters without wet
cleaning for the duration stated under "Guarantees" (Guarantee data
sheets BO/FG).
In general, the air and flue gas ducts shall be interconnected by welding.
Only in places where maintenance or repair is required (dampers,
expansion joints, fans, etc.). flanged connections may be provided.
Air boxes for burners shall be designed so that at least each row will be
fed separately.
Connection between boxes for burners and the membrane wall shall be
done by steel expansion joints.
All ducts which are not insulated shall be suitably cleaned and painted for
resistance to corrosion. ducts and flues requiring thermal insulation shall
comply with the requirements of this specification.
327
4.3.3 FD fans and ID fans
Two (2) FD fans of radial type with backward curved blades shall be
supplied. Each fan shall be designed for a combustion air !low which
corresponds to 60% of MCR when operating with design coal and
20% excess air at furnace outlet. Furthermore, the design of the FD
fans shall allow a margin for fouling of heating surface. The design of
the ID fans shall consider a rise of flue gas temperature and of flow
resistance due to fouling of heating surfaces.
Load operation between .30% and 60% MCR shall he possible with
just one FD fan, one air preheater and one ID fan.
The casing shall be securely braced with structural shapes and all
seams continuously welded. The inlet sections shall be fitted with
inlet cones which also form inlet seals with the fan impeller. The fan
shall be supported on foot angles welded to the extended sides of
the casing. A casing drain not less than DN 50 shall be provided.
The material for the shaft shall be thermally stabilized prior to final
machinery.
The shaft forged and machined from mild steel or high tensile steel
shall be designed to have its first critical speed not less than 125% of
rated speed. The impeller shall be statically and dynamically
balanced before shipment commissioning.
328
cooling water supply, the bearings must be capable of performing
without cooling and be safeguarded against over-temperature.
The fan casings shall be insulated against heat and noises. The
insulation shall be divided into pre-fabricated sections which can be
easily moved, and comply with the specification of Chapter B06.
Silencers are to be provided on the suction and discharge side.
To ensure that the boiler exhaust gas temperature docs not fall short the
dew point the primary and secondary air shall be preheated by steam air
preheaters.
The steam heated air heaters shall be arranged in each air duct between
FD fan and the regenerative air preheater.
The tube ends shall be welded into mild steel tube plates and the element
supporting framework and headers shall be of all-welded construction.
The position or the steam air preheater shall allow for the complete
draining of all pressure parts.
The heating surface shall consist of finned tube elements which shall be
hot dip galvanized after assembling. Aluminum fins are not acceptable.
329
The air heater shall be equipped with a 100% bypass at the air side.
The steam supply can be taken from suitable bleed points on the turbine
(see Heat Balance Diagram). During start-up the steam can be taken from
the auxiliary steam line. The condensate shall be cooled in a cooling stage
at the air inlet to at least 80°C when working at MCR.
Two (2) AHs shall be provided. They shall be designed to cool down
the flue gases to 150°C when operating with coal at MCR with the
designed excess air at furnace outlet of 20%. This design condition
shall take into consideratiol1 the leakage of combustion air in the AH
after an operating period of at 'least 1000 hours without adjustment of
the sealing elements. The design air inlet temperature when burning
coal shall be at least 80°C. However, the Contractor shall take into
consideration the sulphur content of coal to avoid corrosion in the
AH.
330
coolers and all other equipment required for the safe and efficient
operation of the Plant. .
The heating elements shall consist of low alloy steel sheets of not
less than 0.5 mm thickness and shall be properly packed in baskets.
The hot and cold end elements shall be arranged in casings with
removable compartments and the design shall allow for the removal
of the cold and hot end element baskets through access doors
provided in the AH housings.
For on-load cleaning integral steam soot blowers for cold and hot
side shall be arranged. The blowing pressure shall be designed with
respect to the thickness of the heating elements. The Contractor shall
take the steam for soot blowing from a source within his limits of
supply. Steam blowing equipment. bearings and other parts which
so require. shall be air sealed to avoid infiltration of corrosive flue
gases.
331
supplied.
The seals between the primary and the secondary portion shall be
designed like those between the secondary portion and the flue gas
ducts. i.e. with moveable. multi-part, radial sector plates, capable of
following automatically the rotor deformation as well as with shell
seals likewise moveable. Both. the radial and the shell seals shall be
readjustable from outside during operation.
332
4.3.7 Electrostatic precipitators (ESP)
Two ESPs shall be provided for each steam generator. Each ESP
shall be designed for the maximum flue gas flow with at least 40%
excess air in the furnace (ESP capacity= 140% MCR) and a flue gas
temperature of 180°C (in case of AH stop 350°C for 10 min.).
The dust burden of the flue gas entering the ESP shall be determined
by the Contractor.
Electrical part:
Each ESP shall consist of a single steel casing with sufficient equal
mechanical and electrically independent treatment zones in series. It
shall be possible to keep the ESP in service. even when one zone
becomes unavailable. The supporting structure shall be made of
steel.
A corrosion and heat resisting steel grid shall be provided at the inlet
to each precipitator to prevent large pieces of partly burned particles
which may be present to the gas stream. from entering the collecting
zone.
333
The spraying and collecting electrodes shall be designed for easy
replacement. , Sectionalized collecting electrodes would be preferred.
The gas-tight casings. access doors and peep holes in the casings of
electrical and mechanical connections shall be designed to minimize
air leakage into the ESP. Internal pockets or ledges where ash might
accumulate shall be avoided wherever possible. The rapping gear for
the collecting electrodes shall as far as possible be arranged inside
the ESP. The intensity and frequency of the rapping shall be variable
and the gear shall operate without undue noise.
The Contractor shall take all necessary steps to ensure free ash flow
out of the hoppers. A rapping mechanism which raps intermittently at
the hopper shall be provided to avoid bridging of fly ash in the
hopper.
The hoppers shall be furnished with double rotary locks for isolation.
The local control panel for the precipitator shall be provided and
placed near the ESP and shall cont61in all equipment and
instrumentation for both automatic and manual controls. There shall
be remote indication for from this cubicle to the mimic diagram of the
central control panel to indicate precipitator operation status (e.g. ON
and OFF). All precipitator and rapping gear fault alarms for the ESP
shall be brought up by a common signal at the control room to all
alarm panels.
334
A safety interlock system shall be provided to prevent any access into
the ESP unless the electrical equipment is isolated and earthed.
The dust level in the ESP hopper shall be monitored and an alarm
given if the dust level becomes too high.
335
BPDB, Barapukuria Power Plant
Bidder/Contractor
Section B4: Air and Flue Gas System
Technical Data by BIdder/Contractor Unit Data
Air flows
Forced draught fan m3/s
Primary air fan m3/s
Flue gas flows
Regenerative air preheater primary side:
m3/s
wet/dry (m3 at 0 0C, 1013 mbar)
m3/s
Regenerative air preheater secondary side:
m3/s
wet/dry (m3 at OC, 1013 mbar)
m3/s
Flue gas recirculation fan:
m3/s
wet/dry (m3 at 0 0C, 1013 mbar)
m3/s
Stack inlet:
m3/s
wet/dry (m3 at 0 0C, 1013 mbar)
m3/s
Air pressure
FD fan outlet mbar
Secondary steam air heater outlet mbar
Primary air fan outlet mbar
• Primary side
336
BPDB, Barapukuria Power Plant
Bidder/Contractor
Section B4: Air and Flue Gas System
Technical Data by BIdder/Contractor Unit Data
Air temperatures
Ambient °C
Primary steam heated air heater outlet °C
Secondary steam heated air heater outlet °C
Regenerative air healer outlet:
• Primary part °C
• Secondary part °C
Pulverizer inlet °C
• Related voltage kV
• Speed rpm
• Cooling water consumption kg/s
B4/FD-2
337
BPDB, Barapukuria Power Plant
Bidder/Contractor
Section B4: Air and Flue Gas System
Technical Data by BIdder/Contractor Unit Data
Number -
Type of bearing -
Fan speed rpm
0
Inlet temperature C
Steam air preheaters
Manufacturer -
Heat exchanged MW
Total heating exchange area m2
Hot end layer height m
Cold end layer height (ceramic/enamelled) m
Stator diameter resp. rotor diameter m
B4/FD-3
338
BPDB, Barapukuria Power Plant
Bidder/Contractor
Section B4: Air and Flue Gas System
Technical Data by Bidder/Contractor Unit Data
Hot end plate thickness mm
Cold end plate thickness mm
B4/FD-4
339
BPDB, Barapukuria Power Plant
Bidder/Contractor
Section B4: Air and Flue Gas System
Technical Data by Bidder/Contractor Unit Data
RAH washing installation
Washing medium -
wash water flow kg/s
Duration of washing process h
B4/FD-5
340
BPDB, Barapukuria Power Plant
Bidder/Contractor
Section B4: Air and Flue Gas System
Technical Data by BIdder/Contractor Unit Data
Type of construction -
Speed rpm
kg/s
Cooling water consumption
Electrostatic precipitator (ESP)
Manufacturer -
Number of ESP pcs
Number of treatment zones in series per ESP pcs
Specific absorption surface m2/m3/s
Collecting electrodes
Type -
Thickness mm
Material -
Number per treatment zone -
Total number per unit -
Effective height m
Projected area per zone m2
2
Total projected area per unit m
2
Effective area per unit m
Pitch mm
B4/FD-6
341
BPDB, Barapukuria Power Plant
Bidder/Contractor
Section B4: Air and Flue Gas System
Technical Data by Bidder/Contractor Unit Data
Discharge electrodes
Type -
Thickness mm
Material -
Number per treatment zone -
Steel casings
Thickness mm
Casing design temperatures °C
Casing design static gas pressure mbar
Hoppers
B4/FD-7
342
BPDB, Barapukuria Power Plant
Bidder/Contractor
Section B4: Air and Flue Gas System
Type of rapping -
CO2 content %
Gas temperature °C
• dry m3/s
• wet m3/s
Treatment time s
B4/FD-8
343
Ash Handling System
344
B5. Ash Handling System
5.1 General
345
B5 Ash Handling System
5.1 General
The design and supply of the ash handling system shall include all ash
handling equipment necessary to remove the ash from following sources:
The ash from the furnace pulverizers and economizer shall be integrated into
the bottom ash removal system.
The ash from AH shall be conveyed to a ash mixing vessel/ash conveyor pump
slurry pump). By this ash slurry pump the ash shall be pumped via pipe lines to
the ash settling pond.
The ash from the ESP and economizer shall be transported by a pneumatic
conveying system.
This specification covers the systems required for extraction transportation within
the boundary or the power station storage and for lading of the bottom ash and fly
ash together with the relevant ancillaries corresponding to the design date of this
section (data sheets B5/FB).
This section sets out the scope of the installations covered by this specification as
well as requested supplies and services but without excluding other necessary
components and services not mentioned.
Comprising essentially:
• 1(one) drag link scraper ash/slag extractor complete with driving unit for
variable speed air tight casing tensioning device for drag link all electric drives
base frames. steel structure, etc designed for operation with process water
• ash/slag chute for feeding the scraper conveyor
• complete process water cooling system
• connecting pipes separating valves. controls to the process water circulating
system
• complete ash, slag crusher including gear, motor coupling base plates and
anchoring holts
346
• complete ash conveying system starting from ash/slag crusher outlet up to the
bottom ash silo inlet including belt conveyor tripping conveyor (or shuttles)
driving units complete with gear and motors
• protection devices corner tower und transfer stations (if necessary), supporting
structure together with galleries stairs, gangways, cladding of steel structure.
structural members Il)r fixing lining appliances for dismantling of various com-
ponents
• bottom ash silo including lining, steel support structure, shut-off gate,
loosening and discharge equipment, hopper, all mechanical, electrical and
control equipment associated with the silo
• protection facilities to protect equipment against the adverse effect of process
water
• drag link conveyor below the bottom ash silo
• truck unloading facilities
• hydraulic ash discharge including mixing vessel.
• ash hoppers under the second flue gas path (if any) regenerative air
preheater and ESP including one manually operated shut-off valve and one
automatic opening gate for each hopper
• complete electrical trace heating system to all hopper, ash chutes, rotary
locks, cellular wheel sluices
• jet conveyors for each extraction hopper together with compressed air cock
and fans for jet conveyors (one 100% standby) including base frames electric
motors. Sound attenuation facilities (silencers. sound insulation)
• all interconnecting pipe work and valves for jet conveyor air
• all connecting pipes from the jet conveyor up to the intermediate fly ash
bunker
• Intermediate fly ash bunker, together with cyclone separator for waste air
purification; electrically or pneumatically actuated gates to be installed under
the bunker and electric heating facilities for heating of the bunker hoppers
• ash pressure vessel conveyors (one in standby) consisting of pressures
vessels ash inlet valve air intake valve control and vent valves drainage
valves pressure nozzles and all sensors actuators and instruments for
functional group control
• rotary air compressors inclusive bed plates anchoring bolts coupling electric
motors, silencer, air suction, filters non return valves, safety valves, air
coolers air storage tanks. all necessary instruments and sound attenuating
insulation (if required)
• fly ash silo waste air filters of the bag filter type, including filler with bunker
mounting collar, rappers with actuators, suction and scavenging air fans,
inclusive coupling and motors
• all necessary interconnecting pipe lines and valves between ash pressure
vessel conveyor, intermediate bunker, fly ash silo rotary air compressors blow-
off silencers .
• fly ash silos including lining, steel support structure, with bottom fluidizing
equipment (fans, gates, pipes, hopper, all mechanical electrical and control
347
equipment associated with the silo).
Comprising essentially:
The design of the fly ash and bottom ash (slag) handling system shall be based
on the following considerations:
The ash and slag disposal are (ash settling pond) will be located inside the bound-
ary of the Power Station. There for transportation or ash and slag shall be made by
suitable conveyor systems. Silo discharge facilities for bagging (50 kg bag) and
truck Ioading has also to be provided.
The location of storage and loading facilities (silos, bunkers. etc.) shall allow a
centralized handling or fly and bottom ash irrespective or the design/system
variant chosen. The arrangement of these facilities shall not interfere with the
operation area of the boiler.
All possible measures shall he taken to protect components which are coming into
direct contact with process water against its adverse effects (use of material, etc).
The ash handling system shall be designed and constructed in view of a "dust
free" operation.
Fly ash shall be collected from the flue gas pathes of the steam generator (if
applicable), the air hoppers and from the hoppers of ESP. It shall be envisaged
to conveyed as much as possible fly ash with pneumatic conveyors. A dense
lean phase dry pneumatic system (e.g. air slide) under each fly ash hopper to
convey the fly ash to the fly ash silo shall be installed.
The discharge of the ash resulting from some of the above points into the
bottom ash removal system will also be accepted, provided the ash
temperatures necessitate it for safety requirements.
348
In order to prevent clogging of ash in bunkers, silos and lines appropriate
measures such as provision of ash fluidizing air, lining (or manufacturing from
special material) of the bunker bottoms, etc shall be taken.
The air slide fluidization and conveyor air are each generated in two ventilators
respectively compressors whereby one is “on standby", the air shall be dried
and, if necessary, heated. The fly ash silo shall be isolated and heated.
The 4 (four) ventilators (compressors) for the two pneumatic conveying systems
are parallel connected to a pipeline, so the four ventilators /compressors can be
spare for each other.
Insofar as the conveyor piping is place over long distances in the open
atmosphere. These parts are to be isolated.
All the pneumatically charged intermediate and collecting silos and loading silos
are each equipped with two exhaust air Filters - designed as bag filters and two
exhaust air ventilators, of which one or each is "on standby". Exhaust air
installations in the open air shall be enclosed.
The bottom ash from the furnace drops into a drag link scraper extractor.
Ash extraction from the furnace shall be accomplished in continuous
operation. The drag link scraper extractor conveys the bottom ash from
the process water filed slag extractor box to a slag/ash crusher. A suitable
conveyor system transports the slag to the bottom ash silo. Construction
(e.g. number of components, elevation, etc.) and accessories shall ensure
the decantation of water and the loading into trucks.
The bottom ash slag removal system has to be designed for worst coal
operation. The submerged scraper conveyor is to be constructed in such a
349
way that the wet slag can be cooled in the water basin and extracted by
conveyor equipment without a problem at all boiler loads and the total coal
range.
One submerged scraper conveyor is to be arranged under each ash/sing chute of'
the boiler furnace. The submerged frame in the water basin must guarantee an
absolutely tight seal against air ingress into furnace.
The drag link scraper ash/slag extractor shall be of the semi-wet type. The lowest
part of the conveyor shall be located under the furnace hopper. Consideration shall
be made with regard to the relative expansion of the furnace and the drag link
scraper and to exclude the intrusion of false air via the extractor into the boiler.
Bottom and side walls of the extractor shall be lined to avoid excessive erosion.
The quenching water shall be injected into the conveyor in the part were the slag is
falling into the water bath in order to smash the big pieces of slag.
The drive motor of the conveyor chain is to be connected to a hydraulic item and
via elastic coupling to a step-down transmission. By means of a continuously
variable adjustable gear the conveyor speed shall be adjustable to the respective
quantities of ash/slag as to minimize wear.
The capacity of auxiliaries shall be selected under the consideration that for load
changes the ash flow may reach three times the ash now at normal continuous
operation. Due to the above the conveyer shall be equipped with drive with
variable speed and with safety clutch.
The slag extractor shall be equipped with a device enabling to change over from
dumping on the conveyor belt to dumping into a small hopper from which the
bottom ash can he taken over by a trolley.
5.3.2.1 Crusher
The crusher shall he provided with dust proof shaft passages. Casing doors shall
with quick look for checking and exchanging wear pans.
The shaft shall be supported from both sides in amply sized and dust proof self
aligning roller bearings.
For conveyors or short length, fixed installed tension devices may he used while
for conveyors of longer length tension carriages or equivalent self-regulating
350
tension devices to be used.
Corner towers if necessary) shall consist of steel frame work and outside
cladding. Intermediate stairs and steps shall be provided with grid floorings.
Above the conveyor heads or take-up stations respectively trolley beams for a
payload of 3 tons shall be provided. The bottom ash supply into bottom ash
bunker shall be done by means of a horizontal tripper conveyor. For drives,
brakes, etc. the general provisions stated in other specifications for cranes and
hoists will apply.
The bottom ash bunker associated to the mechanical ash handling system shall
fulfill the following requirements:
Inclination of bottom, lining of bottom and loosening and discharge facilities shall
be selected in order to exclude clogging of the bunker to the maximum possible
extent. The bottom ash bunker shall be of welded construction from steel plates.
Provisions shall be made for draining the rest water of the bottom ash. Bunker
shall be designed to be suited for loading into trucks. Truck loading may be
performed. Feeders for truck loading shall be provided with electrically or
pneumatically actuated shut-off devices and rubber chutes.
For decantation of water and for storage and/or loading also separate bunkers
or
separate compartments of one bunker may he used.
Because the system operates with process water, bunker shells shall be of
suitable material.
Each fly ash hopper shall be fitted with two valves: one gate shut-off valve hand
wheel operated and one automatic opening gate (with pneumatic or electric
actuator).
The transfer chute with built-in grate (e.g. light mesh size of about 100 x 100 mm)
and a flap to a belt conveyor connected down stream is to be installed behind
the scraper conveyor. In case ash/slag parts do not fall through the above grate,
they are to be directed from the grate to a crusher, to be crushed and then also
transferred on to the belt conveyor.
The crushing tools shall he manufactured from highly wear resistant special
material. The bearings shall he manufactured so as to prevent the ingress or dirt
and ash/slag granules.
Between electric motor and gear a flexible coupling shall be provided, while be-
tween gear and crusher slipping clutches are required.
351
5.3.2.4 Belt conveyors for ash handling
A unilateral walkway with open grid flooring shall be provided parallel to all
conveyors. Idler sets shall be provided with labyrinth seals and shall run true.
Bearings shall be of the maintenance free type, i.e. lubrication shall be required
not more frequent than once per year.
Belt scrapers shall be arranged at the discharge pulley and, if necessary, for
tail pulleys.
Material and construction of covering plates between upper and lower discharge
hoods and product guides shall be chosen in view of optimum sliding behaviour
of the product, avoidance of clogging and limitation of noise. Material shall be
stainless steel, reinforced fibre glass or equivalent. Rubber aprons for guidance
shall be provided.
Retention assemblies such as limit switches, true run switches, belt monitors,
lanyard switches shalI form part of the mechanical equipment of the
conveyor plant
The ash accumulated under the boiler second path (if applicable), at the air pre
heater and under the ESP shall be discharged pneumatically in continuous
operation by means of jet conveyors. If necessary, the jet conveyors shall
deliver the ash into an intermediate bunker. The intermediate bunker shall be
arranged near to the steam generator. Compressed air for the air jet conveyors
shall be supplied by two rotary fans (one of which will serve as standby). For
heating up of the conveying air a steam coil air heater (or an electric heater)
shall he provided.
The transport of the ash from the intermediate bunker and fly ash silos shall be
made by conveying systems suitable for transport of fly ash over longer
distances (so called “air pressure vessel conveyors”). The fly ash shall be
conveyed to a joint fly ash silo and loading plant which serves both units.
Exhaust air from intermediate bunker and fly ash silo shall be removed via
adequate filters. At the fly ash silos exit, the ash shall be wetted by a humidifying
352
worm conveying system using process water. For fly ash silo fly ash fluidization
shall he provided.
• all the pressure vessel conveyors, conveyor lines and switch points are
to be provided for 100% quantity at five conveyor cycles per hour
• the exhaust air filter unit-located on the intermediate bunker (if necessary) is
to be supplied redundantly
• all the bends and loops in the conveyor lines to the fly ash silo are to be
provided with wear protection lining (fusion-cast basalt) .
• all the service and instrumentation air stations are to be designed
redundantly in total
• the service air for low pressures up to 1.5 bar is to be generated by rotary
piston blowers; the service air for higher pressures and the instrument air
are to be generated by screw type compressors. All the compressors must
be completely designed as dry running compressors '
• air receivers and adsorption dryers are to be connected down stream of the
screw type compressors; air heating is 10 be provided for the rotary piston
blowers (if necessary)
• all the units are to be provided with a sufficient number of inspection, poker
holes and drain holes
• all fly ash pipes have to be equipped with tube connections (studs) and
valves for blowing fee the pipes in case of blockages
• all hopper gates, ash chutes, rotary locks, air conveying chutes, etc. are
to be equipped with electrical heating systems (if necessary)
• all ash silos have to be equipped with anti-bridging devices
• all fly ash conveying equipment, the complete exhaust air filter unit as well as
the piping with heated air are to be provided with insulation as well as
insulation cover plates
• exhaust fans connected down stream of the exhaust air fillers are to be
equipped with vane controllers to keep the vacuum in the ash silo constant
• a sufficient number of duct isolating valves are to be installed in the air
slide system so that certain chute sections can be closed for repairs
during operation
• fine meshed grates above the duct cloths installed in the air slide are to be
provided.
• fans and blowers must be designed with two bearings
• shafts of dust conveying units must in addition to the usual seals, also be
provided with grease seals to avoid dust exit (with arrangement of
bearing and seal in and housing).
Jet conveyors shall be designed for the maximum flue gas temperature
prevailing at their branch point. One separate jet conveyors shall be attributed to
each ash extraction point. Above the jet conveyors electrically (or pneumatically)
operated shutoff gates and pipe switch points for optionally discharging the wash
water or ash shall be arranged.
353
5.3.3.2 Intermediate fly ash bunker (if necessary)
Intermediate fly ash bunker shall be of welded construction from steel plates.
The intermediate bunker shall be equipped with a cyclone separator from where
the waste air shall be laid to the gas duct before the ESP.
Pressure vessel ash conveyors shall be used for conveying heads which cannot
be mastered by jet conveyors.
Ash pressure vessel conveyors shall be suited for dry (purely) pneumatic
transport of fly ash.
Pressure vessel with all piping connections electrically controlled loading and
unloading fittings inspection doors electrical level measurements including auto-
matic control system shall be provided.
Air slides are to be provided with inspection glass and hand hole covers at
intervals of at least 3 m.
The insulation must be split designed and be provided with quick action service
locks.
The rotary seal and traversing chutes are to be equipped with hand hole covers
so that impurities can be removed. The rotary seal sluices arc to be provided
with protruding stub shafts and square shafts so that they can be turned back
by hand for the purpose of removing impurities.
All the hopper gates in the ESP, collecting bunker coal chutes rotary locks cellular
wheel sluices and air conveyor chutes are to be equipped with steam trace heating
including the necessary isolating valves and condensate separators. If steam is
not available they arc to he equipped as electrical trace heating (at least 400
Watt/m2).
A list showing which plant parts are to be provided with heaters must accompany
the offer.
354
5.3.3.8 Exhaust air filters, exhaust fans, air supply system
The exhaust air filters are to be designed as bag filters with compressed air pulse
dedusting, differential pressure monitoring including remote display access doors
exhaust air filter bunkers including electrical trace heaters (400 Wattlm2) and
exhaust fans including vane controller system,
The two fly ash silos and two storage bunkers are to be equipped with one
exhaust fan and one exhaust air filter each.
Every exhaust air filter shall be designed for the dedusting of the conveyor air from
the pressure vessel conveyor unit of ESPs of both storage bunkers as well as the
exhaust air from loading equipment.
The fly ash silo shall be of welded construction from steel plates.
Inclination of bottom, lining of bottom and discharge and/or ash extraction devices
shall he selected to exclude clogging to the maximum possible extent.
For loosening of ash each silo shall be provided with a bottom fluidizing system
operating with air.
The fly ash silos shall be air tight and shall be protected with bunker over
pressure/under pressure flaps.
Arrangement of silos shall permit direct loading of ash into trucks or rail wagons.
The silos shall be equipped at the outlet with a gate and humidifying system (worm
or equivalent).
Optionally the fly ash shall be carried from the ash silo to the drag link conveyor
below the bottom ash silo. By this conveyor, the fly ash is fed into the mixing
vessel at the hydraulic ash system.
355
This also includes all the piping to the jet conveyors as well as their continuation
to the fly ash silo, respectively intermediate bunkers including all fittings and the
jet conveyors.
The pumps mentioned above shall be able to handle ash slurry and dirty water.
Therefore pumps with low speed (low circumferential velocities) shall be selected.
Number of pumps shall be selected according to the function of the specific
physical arrangement. All pumps shall be provided with double capacities.
The pyrites collected ill the pyrite container of each mill shall be conveyed to
the bottom ash handling system by belt conveyors and/or hydraulic conveyors.
Parts having a particle size larger than 40 mm shall be removed manually
using a trolley.
356
BPDB, Barapukuria Power Plant
Minimum Requirements
Section B5: Ash Handling System
Boiler rating for capacity determination of ash handling plant - MCR of boiler
• combustion chamber % 25
• second pass/air pre heater % 15
• ESP % 90
Net storage capacity of fly ash bunker corresponding to the ash production
days 2
at MCR
Net storage capacity of the intermediate fly ash bunker corresponding to the
hours 8
ash production at MCR
Net retaining capacity of the hoppers of the ESP corresponding to the ash
hours 4
production at MCR
Capacity of bagging system and truck loading devices shall permit the
hours 4
emptying of the bunker content within
Max. velocity of belt conveyors m/s 2.0
357
BPDB, Barapukuria Power Plant
Bidder/Contractor
Section B5: Ash Handling System
Technical Data by Bidder/Contractor Unit Data
Operating data
B5/FD-1
358
BPDB. Barapukuria Power Plant
Bidder/Contractor
Section B5: Ash Handling System
Technical Data by Bidder/Contractor Unit Data
Design Data
Bottom ash handling system
Submerged link scraper slag extractor
Number pcs
Type -
Conveying capacity kg/s
Turndown range -
0
Gradient of the inclined section
Type of chain -
Chain speed at MCR m/s
Clearance width of trough m
Trough volume referred to max. water lever m3
Motors:
• manufacturer -
• type -
• rating / rated voltage kW/ kV
• speed rpm
Required water quality -
Water mass flow rate kg/s
Chemical additives (if any)
• type -
• quantity kg/h
Weight of conveyor t
Content of sediment in the water mg/l
Water content in ash/slag at extractor outlet %
Crusher for ash/slag
Manufacturer -
Type -
Number pcs
Capacity t/h
Power demand kW
Bulk density kg/m3
Screen dimension mm
Final grain size mm
B5/FD-2
359
BPDB. Barapukuria Power Plant
Bidder/Contractor
Section B5: Ash Handling System
Technical Data by Bidder/Contractor Unit Data
Motors
• manufacturer -
• type -
• rating kW
• rated voltage kV
• Speed Min-1
Belt conveyors
Material
• shell --
• bottom lining -
Type of bottom ash silo extractor shell ---
Capacity of bottom ash silo extractor kg/h
B5/FD-3
360
BPDB, Barapukuria Power Plant
Bidder/Contractor
Section B5: Ash Handling System
Technical Data by Bidder/Contractor Unit Data
Fly ash handling system
B5/FD-4
361
BPDB, Barapukuria Power Plant
Bidder/Contractor
Section B5: Ash Handling System
Technical Data by Bidder/Contractor Unit Data
Jet conveyor air heater (if any)
Type -
Number -
Heat rate MW
Heating surface m2
0
Air inlet temperature C
0
Air outlet temperature C
Intermediate fly ash bunker (if any)
Number of bunkers -
Type -
Net volume m3
Overall dimensions (length/ width/ height) m/m/m
Number of compartments -
Number of tapping points from bottom -
0
Inclination of bottom
Type of outlet gates -
Material
• Shell -
• bottom (lining) -
Air pressure vessel conveyors
Type -
Manufacturer -
Number -
Handling capacity of each kg/h
Conveying distance m
Air demand (m3 measured in 00 C, 1013 mbar) 3
m /s
Air pressure bar
Rating kW
Speed rpm
B5/FD-5
362
BPDB, Barapukurla Power Plant
Bidder/Contractor
Section B5: Ash Handling System
Technical Data by Bidder/Contractor Unit Data
Air compressors for pressure vessel conveyors
Number pcs
Type -
Air now rate for each m3/h
Delivery pressure bar
Rating kW
363
BPDB, Barapukuria Power Plant
Bidder/Contractor
Section B5: Ash Handling System
Technical Data by Bidder/Contractor Unit Data
Motor rating kW
Mixing worm conveyors
Number pcs
Worm length -
Product to be handled -
Conveying capacity kg/h
Number of inlets pcs
Rating kW
Motor speed rpm
Material:
• casing -
• worm -
Process water demand kg/s
Ash slurry system
Slurry pumps
Number pcs
Manufacturer -
Type/arrangement -
Flow rate per pump kg/h
-1
Speed min
Rating kW
Material:
• impeller -
• casing -
Slurry water recirculation pumps (if applicable)
Number pcs
Manufacturer -
Type/arrangement -
B5/FD-7
364
BPDB. Barapukuria Power Plant
Bidder/Contractor
Section B5: Ash Handling System
Technical Data by Bidder/Contractor Unit Data
Speed min-1
Rating kW
Medium handled
Material:
• impeller
• casing
B5/FD-8
365
Water Storage and Treatment
Systems
366
B6. Water Storage and Treatment Systems
6.1 General
367
B6. Water Storage and Treatment Systems
6.1 General
Discharge water from coal mine after required treatment will be used as
cooling water and the existing deep tube well water will be used for potable
water & demi water production of the proposed 250 MW. At present approx.
1200 MT/ hr is discharged from the Coal mine. Coal mine discharge water
quality is mentioned below:
The water storage and treatment system of this section includes the
following parts
• Cooling water
Coal mine discharge water receiving system from coal mine discharge
water tank, Clarifiers (2 x 1200MT/ hr), Settling water tank (capacity 5000
m3), Pumps, Coal slurry tank, filters, chemical dozing system, Clear water
tank(capacity 2000 m3), Cooling water supply system, Interconnection with
the existing cooling water system.
• Demineralised water
Raw water receiving arrangement from existing deep tube well system,
Raw water tank (1000 m3), Filters (Fe-Mn filters, Multimedia filters,
Cartridge filters), Clear water tank, RO plant ( 2 x 60 m3/ hr), Decarbonator
(tank capacity 2 x 200 m3), Mixed bed ion exchanger, pumps, Demi water
tank (2 x 1000 m3), Demi water supply system, Interconnection with the
existing demi water system.
368
Drainage system must be incorporated with all tanks/ reservoirs.
The waste water system or this sub-section shall be designed to cope with
the waste water emission regulations.
The design of the water storage and supply systems shall consider
necessary measurements for start-up and commissioning of the power
plant. The requirements specified in BO.3.6 under Section 'Supply and
Services' are to apply.
This section sets out the scope of the installations covered by this
specification as well as requested supplies and services, but without
excluding other necessary components and services not mentioned.
Deleted
The scope of this equipment includes the complete raw water supply for
demineralised water , service water, and potable water system. Raw water
storage shall be done by one raw water storage tank.
Raw water tank shall be equipped with 2 x 100% raw water pumps as
supply pumps. The raw water supply to potable water system
demineralised water system and service water within the power plant shall
include a filtration system and the complete piping system to the
consumers valves, fittings and an adequate numbers of taps at the service
water system. Raw water for demineralisation plant, service water and
potable water system shall be existing deep tube well water.
369
6.2.3 Demineralised water treatment plant
Included are chemical storage and dosing tanks, pumps, all necessary
accessories and the complete electrical and instrumentation installation
including one (1) local control panel at the water treatment building with
monitor or mimic diagram indicators alarm systems terminal strips for
transfer signals and all other electrical equipment for closed or open loop
control function.
The scope of this system includes all work required to install the
demineralised water system including the demineralised water storage tanks
(2 x 1000M3) and pumping station. It includes demineralised water supply
pumps (2 x 100%) instrumentation, valves, piping, fittings, air-resp. CO2-
sealing device for storage tank, welding, hangers and supports.
The scope of this equipment includes the chemical handling and storage
facilities including at least one HCI-storage tank. one caustic soda storage
tank complete with inlet. outlet level indicator drainage manhole vent with
acid vapour absorption transfer pumps complete with connecting
pipework. truck unloading station with unloading manifold hose
connections. all necessary equipment and installation for safe operation of
the station and a drum store for dosing chemicals.
6.2.6 Dosing system for condensate. boiler feed water and cooling water
conditioning
370
Chemical feed - condensate
The system will provide temperature, pressure and now control for
continuous automatic analysis and recording. The equipment will consist
of freestanding sampling panels, sink, conductivity cells, pH cells, oxygen
analyzers, silica analyzers, sodium analyzers, hydrazine analyzer,
recorders, components for either returning samples to the condensate
system or dumping them to waste tubing piping valves instrumentation
and controls.
371
3. Condensate deaerator outlet
4. Boiler feed pump discharge
5. Economizer inlet
6. Main Steam
7. Boiler blowdown
8. Condenser hotwell
9. Polisher outlet(after chemical feed)
10. Auxiliary boiler feed pump discharge
11. Auxiliary boiler blowdown
1. Boiler blowdown
2. Condensate polisher outlet
3. Economizer inlet
4. Main steam
372
2. Condenser hotwell
3. Condensate polisher outlet
4. Economizer inlet
5. Main steam
6. Boiler blowdown
The scope of this equipment includes the cooling water conditioning feed
system which will consist of a feed tank with mixer and dosing pumps all
mounted on a skid along with piping, valves, fittings, welding
instrumentation and controls, hungers and supports.
According to the bidder’s design of the cooling system the quality of the
cooling water has to prevent negative effects by fouling and scale
deposits.
373
The quality of potable water shall be further adjusted if required to ensure
that the water has a slightly positive Langelier Saturation Index and is
non-corrosive.
The scope of this system includes the chemical wastewater collection and
treatment system.
The wastewater output of the ion exchanger plant and Leakage from the
regeneration station shall be fed into the chemical drain system. In
addition any chemicals escaping from the indoor or outdoor chemical
preparation and storage plant in the event of leakages are also to be led
to the chemical drains.
The pre-treated chemical polluted wastewater shall be discharged to the ash pond.
All waste water discharge to the environment shall comply with the
Environmental Quality Standard of Bangladesh. Annex shows the relevant
standard values effluent. Additional equipment to comply with these
regulations shall be considered in the scope or supply and services.
The scope of this system includes the chlorine feed system to chlorinate
the cooling water of Power Plant at the cooling water towers and to
chlorinate the potable water system. One (01) sodium hypochlorite (Naocl)
plant (free chlorine concentration shall be minimum 1%) having minimum
capacity 10 ton/ day shall have to be provided.
374
6.2.11 Laboratory
• service water
• water-steam-condensate water
• waste water and
• coal and ash
• oil
Analysis
Laboratory instruments
375
Sl. Name of instruments Quantity Remarks
No
10 DO meter (Digital) ppb level. 02 (two) pcs Complete set with spare
for each
11 Oil Centrifuge machine (3000 rpm) 02 (two) pcs 100 pcs test tube (100ml
label marking) with
spares
12 Flash point testing device (Open cup) 02 (two) pcs Complete set with spare
for each
13 Flash point testing device (Closed 02 (two) pcs Complete set with spare
cup) for each
14 Di-electric constant tester for oil 01(one) pc Complete set with spare
analysis. for each
15 Electric Furnace with temperature 02 (two) pcs Complete set with spare
regulator for each
16 Electric Oven with temperature 02 (two) pcs Complete set with spare
control for each
17 Distillation apparatus (ASTM 02 (two) pcs Complete set with spare
method) for each
18 Ion selective meter (Digital) 02 (two) pcs Complete set with spare
for each
19 Pour pointer 02 (two) pcs Complete set with spare
for each
20 Electron Microscope 01(one) pc Complete set with spare
21 Contamic kit (for oil sediment test) 01(one) pc Complete set with spare
22 Decicator (big size) 04 (four) pcs Complete set with spare
23 Incubator 01(one) pc Complete set with spare
24 Autoclave 01(one) pc Complete set with spare
25 Computer (Inter Core two dual Core) 01(one) pc Complete set with spare
26 Temperature meter (for pump motor) 02 (two) pcs Complete set with spare
for each
27 Coal crusher (For laboratory analysis) 01(one) pc Complete set with spare
28 Coal disintegrator machine with sieve 01(one) pc Complete set with spare
29 Specific gravity meter (0.4 to 2.0) 02 (two) pcs Complete set
30 Viscometer with oil temperate 02 (two) pcs Complete set with spare
regulator
31 Refrigerator (14 cft) 01(one) pc Complete set with spare
32 Electric heater 01(one) pc Complete set with spare
33 Colorimeter for free chlorine (Cl2) 02 (two) pcs Complete set with spare
test.
Chemicals
376
General glassware and tools
13 Plastic type volumetric flask Each 10 (ten) pcs. Good quality, total
(250ml, 100ml, 50ml) thirty pcs.
14 Pipette filler 20 (twenty) pcs Good quality,
different size twenty pcs.
15 Conical flask with lid (250ml) 20 (twenty) pcs Good quality,
twenty pcs.
377
Laboratory furniture
When furnishing the laboratory, there may he no gaps left in the working
surfaces. Adequate numbers or control elements for water, electricity,
compressed air supplies etc. shall he provided and so arranged that they
can be easily operated.
Adequate provision shall be made for storage space liter glass equipment
chemicals, etc. and likewise there shall he adequate working surfaces and
stowage surfaces for analysis equipment.
Spare parts.
Spare parts for the warranty period and LTSA period are to be included
in the price schedules.
378
The water storage and treatment system shall afford:
The dual media filter is to remove suspended matter from the raw water to
protect the ion exchangers from fouling by mechanical impurities.
The dual media filter is to be provided with differential pressure gauge with
adjustable high alarm and 2 (two) sight-glasses.
Ion exchangers
The cation and anion exchangers are to be equipped with two (2) sight-
glasses one (1) at the upper resin level one (I) in the upper section at the
exchanger vessel.
The above mentioned requirement applies for ion exchange vessels with a
now rate > 20 m31h. Smaller plants could be constructed with GRP
vessels.
The mixed bed exchangers are to be equipped with three (3) sight-
glasses. one (1) at the upper resin level, one (1) in the upper section at
the exchanger vessel and one (1) at the level of the resin interface .
379
The exchanger resins selected must have a high resistance to fouling.
• Starting
• Stopping
• Selection of a particular step and
• Repeat of each step of the program
The program sequence shall stop at predetermined points in order that the
operator may check, for example, that the mixed bed resins have
separated or mixed correctly.
The program must stop when regeneration has finished. The line, which
has been regenerated is to be brought back into operation by a control
action from the water treatment local control room.
The correct position and actual position of the various valves for each
stage of the program must be monitored automatically. In the event of a
fault, the program must stop and the fault indicated on the local control
panel. An alarm must also be given. if the operating programme is not
completed within a given time. Suitable precautions must be taken to
ensure that no switching errors can occur and no critical situation may
arise in the case of voltage or compressed air failures.
Regeneration (end or the service cycle) of the mixed bed exchanger shall
be initiated based on first occurrence of anyone of the following:
380
Special consideration has to be given to the corrosion protection of all
surfaces coming into contact with HCL .
The wastewater output of the ion exchanger plant and leakage from the
regeneration station shall be fed into the chemical drain system. In
addition, any chemicals escaping from the indoor or outdoor chemical
preparation and storage plant in the event of leakages are also to be led
to the chemical drains.
The dosing station for hydrazine shall be designed and erected in full
compliance with regulations for storage and handling of hazardous
substances.
381
with adjustable high alarm.
382
BPDB, Barapukuria Power Plant
Bidder/Contractor
B6: Water Storage and Treatment Systems
Technieal Data by Bidder Unit Data
B6/FD-1
383
BPDB, Barapukuria Power Plant
Bidder/Contractor
B6: Water Storage and Treatment Systems
Technical Data by Bidder Unit Data
Raw water storage (from existing deep tube well
water)
Number of tanks No.
3
Net capacity m
Material -
Raw water pumps
Number of pumps No.
3
Rate of delivery m /h
Power consumption at coupling kW
Material: Housing/impeller
Raw water pumps (other consumers)
Number of pumps No.
3
Rate of delivery m /h
Power consumption at coupling kW
Material: Housing/impeller
Clear water storage
Number of tanks No.
3
Each tank Net capacity m /h
Material
Demineralisation water plant
Number of lines No.
3
Net continuous flow rate each line m /h
Net treated water volume per cycle each line m3
Cycle length h
Regeneration time h
Regeneration mode
Chemical consumption
• HCI 100% each line kg/cycle
• NaOH 100% each line Total kg/cycle
3
waste water discharged m /cycle
Quality of treated water:
• Conductivity µS/cm
• Silica mg/I
B6/FD-2
384
BPDB, Barapukuria Power Plant
Bidder/Contractor
B6: Water Storage and Treatment Systems
Technical Data by Bidder Unit Data
Dual media filter
Number of filters No.
3
Throughput: Minimum/Maximum m /h
Material .
Diameter mm
Cyl. jacket length mm
Total height mm
Number of air blowers No.
Rate of delivery N m3 /h
Degasifier No.
Number of unils Throughput: m3 /h
Number of pumps No.
3
Flow rale of pumps / Delivery head m /h / bar
Diameter of degasirier lower
Height mm
Material tower mm
Number of air blowers .
Rate of delivery No.
B6/FD-3
385
BPDB, Barapukuria Power Plant
Bidder/Contractor
B6: Water Storage and Treatment Systems
Technical Data by Bidder Unit Data
Ion exchange washing unit
Number of units No.
Volume tank
Material: I
Regeneration station for hydrochloric acid
Number of regeneration stations No.
Number of pumps No.
Type of pump
Rate of delivery I/h
Material .
Concentration of diluted acid for regeneration %
Volume of dosing tank I
B6/FD-4
386
BPDB, Barapukuria Power Plant
Bidder/Contractor
B6: Water Storage and Treatment Systems
Technical Data by Bidder Unit Data
Regeneration station for caustic soda
Number of regeneration stations No.
Number of pumps No.
Type of pump
Rate of delivery I/h
Material -
Concentration of diluted acid for regeneration %
Volume of dosing tank I
Pump for. regeneration water
Number of pumps No.
3
Rate of delivery m /h
Power consumption at coupling kW
Material: Housing/impeller -
Air blower
Number of blowers No.
Rate of delivery Nm3/h
Delivery head Bar
Power consumption at coupling kW
Pump for make-up water
Number of pumps No.
Rate of delivery m3/h
Power consumption at coupling' kW
Material: Housing/impeller -
Demineralised water storage tank
Number of tanks No.
3
Each tank net capacity m
Diameter mm
Cylindrical height mm
Material: .
B6/FD-5
387
BPDB, Barapukuria Power Plant
Bidder/Contractor
B6: Water Storage and Treatment Systems
Technical Data by Bidder Unit Data
Chemical handling
Hydrochloric acid system
Number of storage tanks No.
Capacity mJ
Diameter/cy!. height mm
Material
Caustic soda system
Number of storage tanks No.
J
Capacity m
Diameter/cy!. height mm
Material
Waste water treatment system
Sump pumps
Number of sump pumps No.
Pumping rate m3/h
Material
Intermediate storage basin/tank
Capacity
Material
Diameter/cy!. height or length/width/height mm
Discharge pump
Number of pumps No.
Pumping rate m3/h
Power consumption at coupling. kW
Malerial
Neutralisation tank
Number of tanks No.
Capacity mJ
Diameter/cy!. height mm
Material -
Power consumption agitator kW
B6/FD-6
388
BPDB, Barapukuria Power Plant
Bidder/Contractor
B6: Water Storage and Treatment Systems
Technical Data by Bidder Unit Data
Discharge pump
Number of pumps No.
3
Pumping rate m /h
Material
Settling tank
Number of tanks No.
Capacity m'
2
Surface area m
Material
Sludge dewatering
Type of sludge dewatering
Conditioning station
Medium: Ammonia solution
Number of dosing stations No.
Medium: Hydrazin
Number of dosing stations No.
Material: Tank -
Pipes, Valves -
Number of dosing pumps No.
Material: Head/Piston -
B6/FD-7
389
BPDB, Barapukuria Power Plant
Bidder/Contractor
B6: Water Storage and Treatment Systems
Technical Data by Bidder Unit Data
Medium: Trisodiumphosphate
Number of dosing stations No.
Number of dissolving tanks No.
3
Capacity of dissolving tanks m
Material: Tank
Agitator
Number of transfer pumps No
3
Rate of delivery m /h
Material:
Number of lifting and tipping devices No.
Capacity of dosing lank m'
Material:' Tank
Pipes. Valves
Number of dosing pumps No.
Pumping rate variable from - to I /h
Material: Head/Piston
Diaphragm
Medium: corrosion inhibitor
Number of dosing stations No.
Number of dissolving tanks No.
3
Capacity of dissolving tanks m
Material: Tank
Agitator
Number of transfer pumps No.
3
Rate of delivery m /h
Material:
Number of lifting and tipping devices No.
Capacity of dosing tank m3
Material: Tank
Pipes, Valves
Number of dosing pumps No.
Pumping rate variable from - to I/h
Material: Head/Piston
Diaphragm
B6/FD-8
390
BPDB, Barapukuria Power Plant
Bidder/Contractor
B6: Water Storage and Treatment Systems
Technical Data by Bidder Unit Data
Condensate system
Net treated water volume per cycle of each ion exchanger line m3
Chemical consumption: h
Regeneration time h
Regeneration mode
Chemical consumption:
• HCI 100% each line kg/cycle
• NaOH 100% each line kg/cycle
Total waste water discharged m3/cycle
B6/FD-9
391
8PDB, 8arapukurla Power Plant
Bidder/Contractor
86: Water Storage and Treatment Systems
Technical Data by Bidder Unit Data
Anion exchanger
Total exchange capacity max. eq/IE
Velocity of operation flow (min./ max.) m/h
Velocity of backwash flow m/h
Design pressure bar
Diameter mm
Cyl. jacket length mm
Total height mm
Regeneration station for hydrochloric acid
Number of regeneration stations No.
Number of pumps No.
Type of pump
Rate of delivery I/h
Material -
Concentration of diluted acid for regeneration %
Volume of dosing tank I
Regeneration station for caustic soda
Number of regeneration stations No.
Number of pumps No.
Type of pump
Rate of delivery I/h
Material .
Concentration of diluted acid for regeneration %
Volume of dosing tank l
Pump for regeneration water
Number of pumps No.
Rate of delivery m'/h
Power consumption at coupling kW
Material: Housing/impeller -
B6/FD-10
392
393