HTP-ER-OM-A-0 General Introduction

Revision: Language: Page:
HEPE
Dept:
0 EN 124 HTP-ER-OM-A-0
File no.:-
O&M Harbin Huitong Electric Power Engineering Co., Ltd.

Project: Plant section:
Ecuador Esmeraldas II Thermoelectricity Project General

Prepared: Checked: Approved:
Jiang Peng Zhou Shugang Tie Sijia

Form No.:
O & M DOCUMENTATION
Date:
2014-01-01 Operation Regulation
GENERAL INTRODUCTION
哈尔滨汇通电力工程有限公司
Harbin Huitong Electric Power Engineering Co., Ltd

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Content
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CONTENT
1 User’s Guide ................................................................................................................................ 3

1.1 Purpose ............................................................................................................................... 3
1.2 Brief Description about O&M Structure ...............................................................................3
1.3 Outstanding Documents......................................................................................................5
1.4 Instruct to Operation Staffs .................................................................................................5
1.5 Instruct to Maintenance Staffs............................................................................................. 6
1.6 Instruct to Safety Staffs .......................................................................................................6
2 Plant Overview ............................................................................................................................. 7
2.1 General................................................................................................................................ 7
2.2 Configuration of Combined Cycle Power Plant ..................................................................7
2.3 List of Main Systems ...........................................................................................................8
3 Basic Data and Information of Combined Cycle Power Plant .............................................. 11
3.1 General Description .......................................................................................................... 11
3.2 Diesel Engine .................................................................................................................... 11
3.3 HRSG ................................................................................................................................ 17
3.4 Electrical Part Description .................................................................................................34
3.5 Chemical Part Description ................................................................................................ 69
3.6 I&C Part Description .........................................................................................................82
4 Plant Performance...................................................................................................................100
4.1 General............................................................................................................................100
4.2 Efficiency .........................................................................................................................107
4.3 Availability........................................................................................................................108
4.4 Reliability ......................................................................................................................... 113
4.5 Productivity (Utilization) .................................................................................................. 114
5 Safety ........................................................................................................................................ 114
5.1 Introduction ..................................................................................................................... 114
5.2 User Responsibilities ...................................................................................................... 115
5.3 Operator Adequate Training & Skills ............................................................................... 115
5.4 General Safety Instructions............................................................................................. 116
5.5 Access Permit & Work Permit ......................................................................................... 119
5.6 Personal Protective Equipment ......................................................................................120
5.7 Management of Hazards.................................................................................................121
Serial No.：HTP-ER-OM-A-0 R e v. 0 Issued Date:01/01/2014

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1 User’s Guide
1.1 Purpose
This user’s guide is basically established to:
- describe the structure of O&M manual
- explain how to use this O&M manual
- establish the ways to find necessary information for management, operation,

maintenance, etc.
1.2 Brief Description about O&M Structure
Total four (4) sections are involved in this O&M manual for 12x8MW Thermoelectricity
Project, please see form attached for more detail.
There are:
- General Introduction
- Operation & maintenance Manual
- Systems & OEM (Original Equipment Manuals)
1.2.1 General introduction
In this section, following items could be found for better understanding about the
power plant layout, configuration, commissioning procedures etc.;
- User’s guide
- Plant Overall Description
- Basic introduction of main equipment and systems
- Plant Performance

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- Safety Consideration
1.2.2 Operation manual
In general, the operation manual covers the following content.
- Operation procedures
- Device and Settings
- Troubleshooting
- Special procedures
1.2.3 Maintenance manual
This section generally covers maintenance considerations, recommendations or

procedures of main equipment such as gas turbine, steam turbine and HRSG and so
on.
The following content could be found in this manual.
- General Maintenance description and procedures on main equipment
1.2.4 System & OEM
More detailed data and information related to the operation and maintenance in terms
of equipment and systems could be found in this section which including the contents
as follows:
- System description
- P&I Diagram
- OEM (original equipment manuals)

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1.3 Outstanding Documents
It is strongly emphasized that following documentations are not within this O&M Manual.
They are contained in other separated systems, hence related drawings, such as
building and piping arrangement, could not be found in this O&M Manual:
- As-built drawing
- Commissioning
- Civil & Erection
1.4 Instruct to Operation Staffs
1.4.1 Management of power plant
Regulations and recommendation are written in section 1 (general introduction),

where performance is highlighted on, related elements which influence performance
are also explained so as to be considered by management.
Comparing with other kinds of plant, giving an example, as a method is also

demonstrated in right position to be easily understood.
1.4.2 Operation management & efficiency
Useful rules & suggests are specially recommended for persons of operation
management so as to improve the efficiency of operating activities, and economy as
well.
Those documents are described in section 2 of Operation Manual
1.4.3 Operation staffs
The following information is supplied to operation staffs

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- Routine Test recommendation in Operation Manual
- Recommended operation regulations necessary for Thermoelectricity plant in

Operation Manual
- Useful settings including in Operation Manual
- System description in Systems & OEM
1.5 Instruct to Maintenance Staffs
1.5.1 Maintenance management & planning
Useful rules & suggestions are specially recommended for persons of maintenance
management so as to ensure the health & quality of device & equipment.
Those documents are described in Maintenance Manual
1.5.2 Maintenance staffs
The following information is supplied to maintenance staffs
- Routine Test and periodic inspection recommendation in maintenance Manual
- Recommended maintenance procedures of main equipment in maintenance

Manual
- System description and instruction book in Systems & OEM
1.6 Instruct to Safety Staffs
The priority in any power plant in the world is the safety issues. Any accident on safety
will damage all the attempts on improving performance

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2 Plant Overview
2.1 General
Esmeraldas II Project 12×8MW Thermoelectricity units located in Ecuador, The

coordinate of location of power plant is north latitude of 0°41'13'' and west longitude of
79º41'37''.Annual average atmospheric temperature is 28.3℃.Total installed capacity
of 12×8MW diesel engine-steam combined circulation units, the three host devices
are: the boiler from the No.3 703 Research Institute of CSIC. Diesel engine supply by
SXD of CSIC Co., Ltd. Generator supply by ABB. The power station belongs to
CELEC.
The project of Esmeraldas II Thermoelectricity power plant installs twelve sets of

Diesel-steam combined cycle generating unit, each one unit includes one (1) Model
12PC-6B diesel engine, one (1) HRSG and one (1) generator.
The power plant is designed to operate continuously in both open cycle mode and
combined cycle mode. During open cycle operation, the flue gas exhausted from
diesel engine will go through bypass stack to the atmosphere directly (only for
combustion diesel oil). During normal combined cycle operation, the heat of exhaust
gas is introduced to the heat recovery steam generator (HRSG) whereby superheated
steam is produced which in turn impinged on heavy oil to increase oil temperature and
the exhaust gases with lowered temperature will be released from the exhaust stack
of HRSGs into atmosphere.
Start compressed air is used for diesel engine start-stop.
2.2 Configuration of Combined Cycle Power Plant

 Twelve (12) identical diesel engine units, the model of diesel engine is 12PC-6B,
supply by SXD along with twelve generators provided by ABB.
 Twelve (12) identical HRSGs, HRSG is type of single-pressure, horizontal duct,

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natural circulation and manufactured by 703 boiler factory of Harbin in china, each
HRSG has a bypass stack and three way damper.
 Fuel oil handing, supply system and oil tank within boundary of the power plant
 Power and auxiliary transformers.
 Instrumentation and control system configured to enable operation from a

common location.
 Low voltage house service
 HT&LT cooling water system
 Nozzle cooling water system
 Air radiator system
 Compressed air system
 Fire fighting system
 Communication system
 Demineralized water system
 Industrial water system
 Oily wastewater treatment
 Water supply & drainage system
 Etc.
2.3 List of Main Systems
As per design and actual status on the site of Esmeraldas II 12x8MW thermoelectricity
Power Plant, following description on main systems is listed:
2.3.1 Diesel engine auxiliary systems

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No. System Remarks
1 Lube oil supply module
2 Lube oil separation module
3 Lube oil transfer module
4 Fuel oil supply module
5 Leakage oil pressurized module
6 Oily water module
7 Leakage oil module
8 HT&LT cooling water
9 Nozzle cooling water
10 Heavy oil transfer module
11 Heavy oil transfer pressurized module
12 Light diesel oil transfer module
2.3.2 HRSG auxiliary system
No. System Remarks
1 Feed water system
2 Auxiliary steam header system
3 Adjust pressure flash tank
4 Blow-down system

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2.3.3 Common systems
No. System Remarks
1 Compressed air system
2 Fuel purification system
3 Industrial water system
4 Demineralized water system
5 Fire fighting system
6 Air condition and air blower system
7 Air radiator system
8 Condensate water system
9 Sampling & dosing system
10 Domestic waste water treatment system
11 Oily waste water system
12 Bridge crane
2.3.4 Electrical systems
No. System Remarks
1 DG electrical system
2 138kV electrical system
3 13.8kV electrical system
4 4.16kV electrical system

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5 480_125V electrical system
6 Emergency diesel generator system
7 DC system
8 UPS system
3 Basic Data and Information of Combined Cycle Power

Plant
3.1 General Description
The Thermoelectricity power plant is mainly comprised of diesel engine generating

unit, HRSG (heat recovery steam generator), electric equipment, auxiliary system etc.
A brief introduction of the main equipment and systems of the combined cycle facilities
is given hereto respectively. For more detailed data and information in connection with
the equipment and systems, please refer to the OEM (Original Equipment Manual)
volume of the O&M.
3.2 Diesel Engine

3.2.1 General description
A package power plant, as furnished for most installations, is comprised of the

crank-shaft, simple cycle, diesel engine unit driving a generator. Fuel and air are used
by the diesel engine unit to produce the shaft horsepower necessary to drive certain
accessories and ultimately the driven load generator.
Compressed air from the compressor flows into the twelve cylinder. The fuel nozzles
introduce the fuel into each of the twelve cylinder where it mixes with the combustion
air and is ignited by compressed air (air in the cylinder is compressed, air temperature

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and pressure will increase continuously; normally, the temperature of compression

final point: Tc=750~950k, diesel oil self-ignition temperature of engine is about
543~563K).
Engine working has 4 strokes to complete from air intake, compression, combustion
(work) and exhaust; these 4 processes make up a working circulation.
The first stroke-air intake, its task is to fill the cylinder with fresh air. When air intake
stroke begins, the piston is located at top dead centre. These is some exhaust gas
remained in the combustion chamber of cylinder. When the crankshaft rotates, the
connecting rod makes piston moved from the top dead centre to the bottom dead
centre; meanwhile make use of the driving gear to open the air intake valve. With the
movement of the piston downwards, the volume above the piston inside the cylinder
gradually increasing makes the pressure inside the cylinder lower than that of in the
air intake pipe; so the fresh air from outside continuously fills with the cylinder. When
the piston moves downwards near to the bottom dead centre, the gas flow inside the
cylinder still has the high speed with high inertia; in order to make use of the inertia of
gas flow to increase gas volume, the air intakes valve is closed only after the piston
has passed the bottom dead centre. Although the piston is moving upwards at this
time, the gas can still be filled into the cylinder because of the inertia of gas flow.
The second stroke-compression, the piston moves from bottom dead centre to top
dead centre during the compression and there are two functions of this stroke: one
increases the air temperature for the preparation for self-ignition of fuel. The other
creates the condition for gas expansion to work.
The third stroke-combustion expansion, at the beginning of this stroke, most of the
fuel injected into the combustion chamber is burned. A great deal of heat is released
when burning, so the pressure and temperature of the gas increase dramatically; the
piston moves downwards due to the high temperature and pressure of gas and make
the crankshaft rotated by the connecting rod and do work. So this stroke is called

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doing work or working stroke.
The forth stroke-exhaust, the function of exhaust stroke is the removal of the exhaust
gas after expansion in order to fill with the fresh air to prepare for the next circulation.
When the piston during the working stroke moves downwards near to the bottom dead
centre, the exhaust valve is opening; the piston is driven by the crankshaft and
connecting rod, moving from the bottom dead centre to the top dead centre to remove
the exhaust gas out of cylinder
The exhaust gas from the cylinder into exhaust pipe. Then gas enters to turbocharger.
Working principle of 4-stroke engine
3.2.2 Diesel engine general specifications
Diesel engine technical data table:
Item Unit Data Remark
Diesel engine Type 12PC2-6B

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Item Unit Data Remark
Rated Speed r/min 600
Exhaust gas temperature ℃ 320
Exhaust gas flow kg/s 18.029
Power output at MCR KW 9000
Rated power output KW 8608
Diesel engine Generator Technical Data
Item Unit Data
Generator type ABB AMG1120MP12DSE
Power out at MCR kW 8500
Rated power output kW 8350
Power factor 0.85
Frequency HZ 60
speed r/min 600
3.2.3 General description of diesel engine
3.2.3.1 Water system
It is to ensure the cooling of engine parts, especially cylinders, cylinder heads,

exhaust valves, injector nozzles which undergo very high temperatures during the
combustion phase. The used materials for manufacturing these parts do not allow
them to resist to such high temperatures without being damaged, therefore they need
cooling. The fluid used, water, which provides the best quality to- price ratio, is well

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adapted for cooling “Diesel engines”.
3.2.3.2 Lube oil system
- To lubricate:
The engine (bearings, pistons-liners, connecting rods, timing gears, and so on),
The auxiliaries (turbocharger bearings, pumps and so on).
- To keep the engine inside clean (piston grooves) as well as the system (clogging
of filters).
- To keep the piston heads cool.
- To set an oil seal on the injection pumps (if fitted).
- To fight against the corrosive action of acid combustion products.
- To withstand oxidation and water.
3.2.3.3 Fuel system
The liquid fuels which can be used are:
- Pure distillates
- Light and medium black oils (a mixture of distillates and distillation residues in
variable proportions)
- Distillation residues.
3.2.3.4 HP & LP air system
Power potential used to:
- Start the engine (including slow barring)
- Protect the engine in operation (stop jack, air flaps, raising of fuel pumps).
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3.2.3.5 Crankcase deaeration system
Continuously discharge the gas and oil vapors from the crankcase to prevent excess
pressure.
The gas is coming from the combustion chambers and the flow rate is therefore
directly related to the quality of the ring-liner tightness.
3.2.3.6 Inlet air and exhaust gas system
Air filtration:
To avoid a premature general wear of the engine components, namely when engines
are located in desert areas subject to sandstorms, or near quarries or cement works,
and particularly:
- As regards cylinders, piston rings and grooves;
- As regards links, further to the pollution of oil by siliceous residues;
- As regards the turbochargers, and particularly the compressor wheels. Below 1µm
they are fouled by solid particles, from 1 to 10µm they are cleaned by them, beyond
10 µm they are eroded by them.
Supercharging:
Mainly to make it possible to increase the power of an engine by increasing its air
supply (increase of the weight of air for the same cubic volume), which makes it
possible to burn more fuel.
- To increase the global yield, as the necessary energy for driving a turbocharger is
recovered from the exhaust gases.
Air cooling at engine inlet:

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When flowing through the turbocharger, the air temperature is substantially increased,
it is necessary to cool it, in order to improve cylinder filling.
Regulation of air temperature at engine inlet
To maintain the temperature:
- Approximately constant whatever the power,
- At a sufficient value, in order to eliminate condensation phenomena. Depending

on the atmospheric conditions, (ambient temperature, degree of moisture), the
operator may have to increase the air inlet temperature.
3.3 HRSG
3.3.1 General description
The aim of HRSG is to recover the heat from exhaust of diesel engine. The whole set
of HRSG system comprises of bypass gas system and HRSG itself. HRSG comprises
of the body, inlet flue and the main stack; bypass system is compose of three-way
operation valve and bypass flues. This set of HRSG system is adopted the type of
single-pressure without complementary combustion, single-drum, integrated
deaerator, horizontal flue vertical spiral finned piping and natural circulation
water-pipe. The layout of HRSG is as follows:

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3.3.1.1 Meteorologic condition
The power plant is located in Ecuador. The detailed meteorologic condition at the
plant is as follows:
Atmospheric Pressure (mmHg)
Many years’ mean air pressure 750
Air Temperature (℃) and Relative humidity (%)
Annual average air temperature 28.3

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Annual average relative humidity 88.7
Extreme highest air temperature 34
Extreme lowest air temperature 18
Design temperature 25
Rain Fall (mm)
Annual average rain fall 810mm
Wind speed (m/s)
Biggest wind speed 6.1
Annual average wind speed 3.48
Seismic intensity 8.5
Annual leading wind direction west and southwest
3.3.1.2 Design working condition
Design temperature: 25℃;
Atmosphetic Pressure: 750mmHg
Relative humidity: 88.7%
Load rate of diesel engine: 100%
Temperature of Codensed water of HRSG: 100℃
3.3.1.3 Fuel of diesel engine

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The fuel of diesel engine is heavy oil, the start-up fuel is light diesel.
3.3.1.4 Gas-discharging characteristics of diesel engine
The data of discharge of diesel in design condition is as follows:
1 Load rate of diesel engine (%) *100%
2 Atmospheric Temperature (℃) 25
3 Atmospheric Pressure (mmHg) 750
4 Diesel engine exhaust temperature (℃) 320
5 Diesel engine exhaust flow speed (kg/s) 18.029
6 Diesel engine exhaust component (v %)
7 O2 12.38
8 N2 77.186
9 CO2 5.8
10 H2O 4.57
11 SO2 0.064
12 SO3 /
3.3.1.5 Bypass flue system
The function of the bypass flue system is to let out the exhaust gas when the diesel
system is in the condition of single circulation and adjusting of HRSG load or
examined and repaired in trouble.
The bypass flue system comprises of diesel engine outlet flue, three-way diverter
damper, squire-round transitional part, expansion joint, bypass stack and the main
stack. For easier dismantlement and installation, the bypass flue and squire-round
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transitional part are supported by the steel frame, and each part of flue is connected
by the flange.
The three-way damper is adopted the type of one-layer valve door with drive by
electric equipment. The sealing is adopted sealing mat of compressed aluminium
silicate fibre cloth. The characteristic of one-layer valve door is to be able to avoid
blocking off of exhaust from diesel engine by misoperation, therefore, to ensure
smooth discharging of the exhaust of diesel engine.
3.3.1.6 Outlet flue of diesel engine
The outlet flue comprises of several parts which are connected by flanges for easy
disconnecting and assembling. It is installed between the outlet expansion joint and
the three-way diverter damper, adopting the structure of outer stiffening and inner
insulation. Its shell is made of 6mm steel plate (carbon steel) wielded together. The
flat steel is wielded outside the shell as stiffening frame. The outer insulating material
is aluminium silicate fibre felt and covered by 0.7mm aluminium plate.
3.3.1.7 Three-way diverter damper
The three-way diverter damper is adopted the type of single-layer and driven by
electric equipment.
 Technical specification:
Design temperature: 360℃ Design pressure: 2500Pa
Rated connecting passage: 1.69m2
Closedown or start-up time of damper: 120s
Working medium: Exhaust gas of diesel Leakage rate: ≤5%

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Aluminium silicate fibre cloth is installed between turning door and interface of
connecting passage to avoid the great leakage of gas.
 Transmission system and main shaft
The three-way diverter damper adopted the type of single-shaft drive by electric
equipment. The main shaft is installed on the bypass side so that the gas can flow
through the passage smoothly without any part in it to lessen the pressure loss when
the HRSG side is in 100% openness.
The reducer with tubine and volute pole is equipped at one end of the door shaft. The
opening or shut of the valve door is through the main shaft driving by torsional
moment generated by the electric equipment. The main shaft is made of carbon metal .
At the end of the main shaft, a maze-type shaft sealing system is equipped to ensure
the sealing of the hole through the door.
 The bearing
The main bearing is adopted self-positioning ball bearing with its center of gravity
adjustable. It is installed outside not to contact the high-temperature gas, so it can run
well in warm state.
 Valve door
The frame of the valve door is made of carbon and it connects main transmittion shaft
as a integrated part. To avoid the deformation of turning door and cracked at the
connecting place between the turning door and the main shaft, we strengthen the
turning door by adding profiled bars and strengthen the connecting place by adding
flat steel.
 Frame of shell

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The shell is adopted self-support structure ,with the lower foot to support the full
weight. Beause distances between two feet are smaller and outlet flue of diesel
engine is equipped with outer insulation, the expansion is big, so the four feet shall be
slidable. The outer shell is made of steel plate, wielded with profiled bar to strengthen
the frame and its whole stiffness. The fiber is laid on the inner side of the shell, with
alloy metal mesh on the bottom of the inner casing to protect it. The inner casing is
adopted joint structure and can expand freely. The connecting of inner casing and
outer casing is the insulation screw.
3.3.1.8 Expansion joint
The horizontal outlet flanges of the three-way diverter damper are connected to the
expansion joints. The expansion joint is adopted non-metal type, with insulation inside
and stronger expansion rate ,so it can meet the demand of safe operation in hot-state
expansion.
3.3.1.9 Bypass flue
The bypass flue is installed between the squire-round part and the main stack. Its
inside shell is made of 6mm carbon steel plates with profiled steel as strengthening
frame. And its outer insulating material is adopted aluminium silicate fibre felt covered
with 0.7mm-thickness aluminium plate. It is separated into several parts in order to
make transportation and installment easier. After connected by flanges, every two
neiboughing parts are wielded in sealing condition.
3.3.1.10 Squire-round transition part
The Squire-round transition part is installed on the three-way diverter damper,

connecting with bypass flue. It is adopted the structure of inner strengthening and
outer insulating. Its inside shell is made of 6mm carbon steel plates with profiled steel
as strengthening frame. And its outer insulating material is adopted aluminium silicate
fibre felt covered with 0.7mm-thickness aluminium plate. To the convenience of
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transportation and installation, it is fitted with installing lugs on its sides and top which
are removed after installation.
3.3.1.11 Painting for equipments of bypass flue system
After all the parts of the bypass flue system are processed mechanically, all the
surfaces must be sprayed sand, cleared rust and filth and burrs. After process, all the
metal surfaces should assume gray (original color of metal), dried and nonoxiDatad
on the surface, without rust speckles. The detailed operational steps and
requirements are shown in Code for HRSG painting(SB.1-2006). After being sprayed
sand, all the parts with the exception of the three-way diverter damper shall be
brushed with bottom paint or surface paint which is antiseptic and can bear 400℃,
recoating at the welding area after the welding at site. For more information, consult
the rules of painting stipulated by design insitute.
3.3.2 The proper of HRSG
3.3.2.1 Statement
The HRSG system comprises of inlet flue, the body (pressure parts and frame and
casings), the main stack (silencer) ,attaching parts, expansion joints, relative flue
fittings and control system. To save space, the whole HRSG system (except the main
stack) is installed on the elevation of 6m, the same as the basal elevation of HRSG
body. For safety, the main stack is installed on the 0-meter ground, with 0-meter as its
basal elevation.
The main function of HRSG is to recover heat from diesel engine exhaust which
generate low-temperature and low-pressure superheated steam which is supplied to
the owner as industrial steam .At the same time, it supplies low-pressure superheated
steam to the deaerator to remove oxygen from condensed water when the deaerating
evaporating pipe group can’t generate enough steam.

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3.3.2.2 Type for HRSG
This HRSG is adopted the type of natural-recycled water pipe with horizontal flue and
vertical spiral finned pipe. All the spiral finned pipes are arraged inside the horizontal
flue.
The type of HRSG: Q50.1/320-4-0.7/240.
3.3.2.3 Code for HRSG design
The pressure parts of boiler is designed and made in accordance with intensity
calculation of water-pipe boiler pressure part (GB/T9222-2008), Code for steam boiler
safety technology supervision and other other relative codes, but they meet the
demands of ASME SEC.I-ED2010 on the whole.
The design of steel structure is in accordance with steel structure design criteria.
3.3.2.4 HRSG structure
3.3.2.4.1 The body of the HRSG comprises of superheater, evaporator, economizer,

evaporating deaerator and the HRSG frame, the flatform and stairs, waterproof shed
and other necessary parts. The inside flue of the boiler body is designed as
single-passage.
3.3.2.4.2 The superheater is adopted the type of vertical spiral finned pipe as heated
surface with two headers. The spiral finned pipes are wielded together as heating pipe
group. The pipe group is layed out in sequential form and divided by two rows as one
group. The diameters of the above header is Φ133×10 and the low header of is
Φ133×6, both of their materials are 20/GB3087;the diameters of the heating pipes are
Φ25×3, the materials are 20/GB3087, the material of its fins is 08AL. The steam-gas
outlet header is equipped with pipe-holders for safety valves, start-up emptying,
reverse rinsing, pressure gauge, thermometer, nitrogen-charging and so on, at the
bottom of it is equipped with scattering (discharging) pipe joints. A flow consists of the
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heating surfaces and their connecting parts .The steam has one-time cross flow with
the gas flow direction. The base connecting header of the superheater is fitted with
scattering pipe joints and saturated steam pipe joints.
3.3.2.4.3 HRSG evaporator comprises of evaporating pipe group, drum and its
internal equipments.
The evaporating pipe group is adopted the type of vertical spiral finned pipe as heated
group. The pipe group is layed out in staggered form and divided into twenty-one rows,
arranged as seven group totally. For the two heating surfaces, the diameters of the
above header is Φ133×10 and the diameter of low header is Φ133×6, both of their
materials are 20/GB3087; the diameters of the heating pipes are Φ25×3, the material
is 20/GB3087 and the material of its fins is 08AL. The above header of HRSG
evaporating pipe group is connected with drum by connecting pipe and the bottom
header is connected with basal connecting header by connecting pipes. Downcomers
are installed between the drum and the connecting header. The natural-circulation
loop is composed of drum, seven double-header and connecting header, the above
and low connecting pipes and downcomers. The connecting header is fitted with
regular blowdown pipe joints at its bottom.
The type of drum: horizontal; the inner diameter of drum body: Φ1000mm; The wall
thickness: 10mm; Thickness of end cover:10mm; Material of drum body and end
cover: Q245R.The end cover is fitted with man-hole. The drum is fitted with the pipe
joints of safety valves, pressure meter, saturated steam connecting pipes, water level
gauge, feedwater, continuous blowdown, balance vessel and the saturated steam
connecting pipe has the pipe joint of sampling equipment.
Drum has second separating components in it: (the steam-water separating

equipment) steam-equizing holed plate, holed plate in water. The drum also is

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equipped with feedwater pipe, chemical reagent pipe and continuous blowdown pipe
and so on.
3.3.2.4.4 The economizer is adopted the type of vertical spiral finned pipe as heated
group. The pipe group is layed out in sequential form and divided into two rows,
arranged as one group. For the two heating surfaces, the diameters of the above
header is Φ133×10 and the diameter of low header is Φ133×6, both of their materials
are 20/GB3087; the diameters of the heating pipes are Φ25×3, the material is
20/GB3087 and the material of its fins is 08AL. Two horizontal isolated plates are
installed in the above header and bottom header separately, total four plates. The
feedwater has five flows crossing with the gas. The bottom header has water-charging
pipe joint and water-discharging pipe joint. The above header has water-discharging
pipe-holder and gas-discharging pipe-holder.
3.3.2.4.5 The evaporating deaerator comprises evaporating pipe group and deaerator
and its internal equipments. It is adopted the type of vertical spiral finned pipe as
heated surface with two headers. The spiral finned pipes are wielded together as
heating pipe group. The pipe group is layed out in staggered form and divided into
three rows, arranged as one group. For the two heating surfaces, the diameters of the
above header is Φ133×10 and the diameter of low header is Φ133×6, both of their
materials are 20/GB3087; the diameters of the heating pipes are Φ25×3, the material
is 20/GB3087 and the material of its fins is 08AL. The above header of HRSG
evaporating pipe group is connected with deaerator by connecting pipe and the
bottom header is connected with basal connecting header by connecting pipes.
Downcomers are installed between the deaerator and the connecting header. The
natural-circulation loop is composed of deaerator, one double-header and connecting
header, and downcomers. The connecting header is fitted with regular blowdown pipe
joints at its bottom. The deaerating evaporating pipe group is installed behind the
low-presssure economizer.

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The type of drum: horizontal; the inner diameter of drum body: Φ800mm; The wall
thickness: 10mm; Thickness of end cover: 10mm; Material of drum body and end
cover: Q245R. The end cover is fitted with man-hole. The deaerating drum is fitted
with the pipe joints of safety valves, pressure meter, water level gauge, continuous
blowdown, balance vessel; The deaerating head is equipped with the pipe joints of
safety valves, pressure meter, water-charging and steam-supplying.
Drum has second separating components in it: steam-equizing holed plate, holed
plate in water water-discharging pipe, and continuous blowdown pipe.
3.3.2.4.6 The frame and casings of HRSG are adopted one-piece structure, with
beam (material as Q345B) and pillars (material as Q345B) and outer casing welded
together. The dead center of expension of frame and casing along the flow direction of
gas is at the pillar foot (near the inlet). The HRSG has four steel pillars and every two
steel are equipped with one piece of side casing (two pieces of side casing in total).
There are one piece of top casing and one piece of bottom casing. All the heating
surfaces of pipe are connecting with the above header supported on the profiled bar
connecting side outer casing. Fixed supporting seat and slip supporting seat of drum
are fixed on the beam. The positioning of low-pressure drum and deaerator are
adopted the type of one end fixing and the other end slip. The slip supporting seat has
expansion indicator.
3.3.2.4.7 The HRSG casing is composed of inner casing, outer casing, insulating pins,
insulating material, strengthening equipment. In shop it is separated into bottom
casing, two side casings and top casing. And it is assembled together with pressure
parts into trunks.
3.3.2.4.8 The side casings are equipped with inspection door in order to inspect and
repair the HRSG. The standing places are fitted with platform, stairs, protecting
handrails and kick plates. To avoid slip , the footplate and platform are made of steel

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grids. The above equipments can ensure the operator reach every place needing
regular operation and inspection.
3.3.2.4.9 On top of HRSG, a waterproof shed is equipped against the rain.
3.3.2.4.10 The low-pressure system is composed of superheater, evaporator,

economizer and evaporating deaerator and piping, valves and meters within the
scope of HRSG; the deaerating system comprise of evaporating deaerator and meters
within the scope of HRSG. The steam used as deaerating of feedwater is the
saturated steam from deaerating evaporating pipe group; Industrial steam is
superheated gas from low-pressure boiler system. In non-design condition, if the
saturated steam from deaerating evaporating pipe group is not enough, steam shall
be drawn out from low-pressure steam system to supply the deaerator to deaerate the
condensed water.
3.3.2.4.11 Start-up emptying pipe of low-pressure superheater is fitted with

steam-discharging silencer to drop the noise level of discharge of steam.
3.3.2.4.12 Because the heavy oil is chosed as the fuel of the diesel engine ,the side
casing of HRSG is equipped with steam ash-removing equipment to remove the
accumulative ash on the fins of the heating surfaces.
3.3.2.5 Materials for pressure parts of HRSG are shown in the following table:
No. Name of equipment Material
1 Superheater, economizer
1.1 Header 20/GB3087
1.2 Pipe as heating surface 20/GB3087
1.3 Fin 08AL

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No. Name of equipment Material
2 Low-pressure evaporator, Evaporating deaerator
2.1 Drum Q245R
2.2 Header 20/GB3087
2.3 Pipe as heating surface 20/GB3087
2.4 Fin 08AL
2.5 Steam-water connecting pipe 20/GB3087
2.6 Saturated water connecting pipe 20/GB3087
2.7 Downcomer 20/GB3087
3.3.2.6 Delivery state for equipments of HRSG
All the parts of the boiler is designed according to the principle of modularization. In
the condition of transportation permitted, all the modules will be transported to the
installation site.
3.3.2.6.1 All the heating surfaces (superheater, evaporating pipe group, economizer
and evaporating deaerating pipe group) and frame and casings are made into
integrated trunks in shop; inlet flue and the three way operation valve are fabricated in
shop and delivered in the state of whole equipment.
3.3.2.6.2 The low-pressure drum and deaerator are packed by themselves (including
their internal equipments).
3.3.2.6.3 Bypass flues, outlet flue and the main stack are adopted the form of
prefabricated modules, and they are assembled on site.

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3.3.2.6.4 Valves and meters and the on-site parts for installation are packed in box or
binding for delivery.
3.3.2.7 Installation of HRSG
After checking of groundwork, installation of HRSG trunks begins, and then the
installation of low-pressure drum and deaerating drum. After the above work , the
installation of piping and the perfection of frames. The last work are installation of
HRSG accessories (including pumps, ash-removing equipment and donkey
machinery) and insulating work of all the necessary parts of HRSG.
3.3.2.8 Paint
Before delivery, all the parts of HRSG have been painted in accordance with
JB/T1615-91 “The Technical Requirements For Boiler Painting and Packing” and the
criterion or regulations of the manufacturer.
After on-site installation, all the parts of HRSG should be painted the last finish paint
according to detailed requirements in the relative technical files.
3.3.2.9 Characteristics of HRSG
3.3.2.9.1 Safe and reliable in work.using G.T natural-recycled HRSG extensively

applied home and abroad as its original shape in design, this HRSG is advanced and
ripe in shape.
3.3.2.9.2 The HRSG has both the strong points of natural-recycled and coercive
-recycled boiler. The process inside the internals is natural circulation and the process
inside the furnace is as good as forced circulation boiler.
3.3.2.9.3 Small in weight and size. This type of HRSG not only take a lead in the same
type of natural-recycled boiler in weight and size, but also is as good as average
coercive-recycled boiler.
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3.3.2.9.4 High flexibility. This type of HRSG has a small water volume, high start-up
speed leading home and abroad. This characteristic is more important for G.T power
plant with more frequent start-up and shut.
3.3.2.9.5 Lower running expenditure. This type of HRSG not only has no reliable
working equipments, but has a lower electricity cost itselfand lower running cost.
3.3.2.9.6 Simpler structure, easier to manufacture and install.
3.3.2.9.7 Good shape of flue section. This type of HRSG has a better proportion
between length and width of flue section compared with other G.T HRSG. With a
better fullness of the gas ,evener heat in the furnace, smaller heat diviation and a fuller
gas flow on the heating surfaces, it has an advantage of better heat transfer inside the
furnace, better working reliability and smaller gas flow resistance.
3.3.2.9.8 The integral structure improves the coefficient of utilization, so the

comsuption of work on site declines.
3.3.2.9.9 Lower gravity center, better stability to resist gust and stronger-intensity
earth-quake.
3.3.2.9.10 Operation of boiler without water. Heating surfaces can run without water in
the process of start when the temperature of gas is less than 330℃ In the condition of
operation without water, the temperature of boiler must be lowered to less than 100℃
to start the boiler. It is necessary to note that running without water will reduce the life
span of the boiler.
3.3.2.10 HRSG flue system
HRSG flue system comprises of inlet flue, the main stack and outlet expansion joint .
Its function is to lead the exhaust of diesel engine into HRSG and its section shape is
in favor of diffusion. The gas delivery equipment at the outlet can ensure that after the
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diffused gas enter the body of HRSG it has good flow field and small resistance and
enough sealing effect and the ability of counter heat impact. The flue is adopted the
structure of inner insulation and outer strengthening with the inner casings lapped.
The accessories of flue include all the expansion joints and all kinds of interfaces.
They ensure that all the parts of flue can expand freely in high temperature and meet
the need of interface of inspection.
To meet the need of discharging of gas, the main stack is design as 30m high and with
its inner diameter as 1.3m. It is separated into several parts for easy transportation
and all the parts are connected by flanges on site. After they are connected, they shall
be sealed by wealding. It is made of steel and has self-supporting equipment. At its
bottom it has water-discharging valve and the low part of it connected with the boiler
has man-hole. All the parts are assembled in shop.
The main stack is equipped with a silencer to absorb the noise from exhaust of diesel
engine to improve the working condition. The silencer is equipped with the
disconnectable noise-absorbing slice inside the steel shell of the silencer. Its frame of
slice is made of carbon steel and equipped with fibre noise-absorbing material.
3.4 Electrical Part Description

3.4.1 General
3.4.1.1 The prime intent
a) Electrical standards and modes of power station operation will meet the
requirements and standards, such as IEC, and Chinese National and Professional
Standard.
b) The electrical equipment supplied is suitable for heavy industrial service being
drawn from standard ranges of equipment having a record of proven operating
experience i.e., affording the necessary high level of reliability and availability, in a
tropical environment.
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c) A color coding system will be used to identify AC phase and neutral, DC polarity and
earthing functions. The system employed will be subject to approval and be in
accordance with owner’s practice.
d) The voltage level
The system voltage levels will be selected to accommoData the range of plant
required and be in accordance with owner’s practice.
Number of
System Rated volt. Number of wire Voltage range Fault level
phases
Diesel
generator main 13.8kV 3 3 ±5% 31.5kA
circuit
138KV system 138kV 3 3 ±10% 31.5kA
Medium voltage
13.8kV 3 6 ±5% 40kA
system
Low voltage
480/280V 3 28 ±5% 50kA
system
AC UPS system 120V 1 2 ±1% 16kA
+10%
DC system 125V 1 2 16kA
-12.5%

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Number of
System Rated volt. Number of wire Voltage range Fault level
phases
Middle voltage
13.8kV 3 3 ±5% 50kA
system
Middle voltage
4,16kV 3 3 ±5% 50kA
system
Motor voltage 480V 3 3 ±10% ------
+5%
Lighting voltage 208V 1 2 30kA
-5%
e) Degree of protection of electrical equipment
Outdoor equipment and all indoor equipment subject to an aggressive environment

will have suitable environmental protection.
The minimum equipment enclosure classifications for non-rotating electrical

equipment shall be as follows:
Indoors only in totally enclosed rooms with provision for limiting ingress of dust: IP31
Indoors, except as noted otherwise: IP54
Outdoors and indoors in areas subject to water spray, or heavy condensation: IPW55
3.4.2 Electrical general connection
3.4.2.1 General

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The power plant includes twelve (12) Model AMG1120MP12DSE generating sets,
(DG).
The phase two have two 13.8kV busbar, Each Six (6) DGs will be connected to
relative Step-up transformer via Generator Circuit Breaker (GCB) and 13.8kV busbar.
One (1) Unit Auxiliary Transformers (UAT) for combined cycle unit will be connected to
the busbar. The generators, GCB and UAT will be connected by Isolated Phase
Busduct (IPB). 13.8kV Busbar and Step-up transformers are connected by
non-Isolated Phase Busduct.
Through step-up transformer, the generated power will be delivered to the 138kV Grid
Sub-station which will be built this stage. Six (6) DG relative step-up transformers will
be connected to the138kV Switchgear.
The neutral of 138kV side of the step-up transformer will be grounded through the
earthing disconnecting switch. The neutral of generator will be grounded through a
single phase transformer with resistor on the secondary side. The LV neutral of the
UATs will be grounded.
For details, Please refer to drawing HEI-EC-C-EL-0101-002 for ELECTRICAL

GENERAL SINGLE LINE DIAGRAM.
3.4.2.2 Main generator
The generation system is required to produce rated output during normal operating
conditions.
The generator can operate for a short time during the following abnormal modes:
- Under-frequency operation
- Overload operation
- Abnormal voltage operation
- Transient and fault conditions
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- Unbalanced current conditions

- Motoring
The ratings of the equipment will be suitable for continuous operation at maximum
continuous generator output.
3.4.2.3 Generator main leads
The generator main leads are isolated phase bus, slight pressure design, capable of
carrying the maximum generator rating continuously.
The generator main Leads package shall include flexible connectors, potential
transformer, bus earthing disconnecting switch and surge arrester cubicles.
Isolated phase bus bars (IPBs) will be used to take the electrical power from generator
to transformer. All DG IPBs tee offs from this main connection to unit auxiliary
transformers. Along the DG IPB there will be a generator circuit breaker (GCB).
3.4.2.4 Diesel generator circuit breaker
The Generator Circuit Breaker unit will be assembled in common frame unit and will
be connected to generator by means of an isolated phase bus duct.
Each DG unit will contain a generator circuit breaker, the breaker and it’s earthing
connector be mounted on high voltage switchgear cabinet, the will be included in the
scope of supply.
The circuit breaker unit will be equipped with all necessary auxiliary equipment for
remote control, earthing switches. The circuit breaker will be provided with one close
coil and with one trip coils with separate auxiliary power supply. The circuit breaker will
be equipped also with local operating panel (for back-up operation) with position
indicators. Circuit breaker unit’s alarms will be connected to the DCS of power plant.

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3.4.2.5 Generator transformer
Two (2) Step-up transformer will be arranged to relative 13.8kV Circuit.
The main transformer is to boost the generator voltage to the transmission level
(138kV).
3.4.2.6 Data
Diesel Generator
• Function
Generating electrical power
• Type
AMG1120MP12DSE
Brush less excitation system
• Parameter
Rated power: 8350kW
Rated voltage: 13.8kV
Rated current: 411A
Rated power factor: 0.85
Brushless excitation system with digital automatic voltage regulator (AVR) and Power
System Stabilizer (PSS)
Diesel Generator Main Leads

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• Function
High current, 13.8kV busbar and main transformer connection.
• Type
Self cooled isolated phase bus, slight pressure, taps for PT’s
• Parameter
Ambient temperature: 50℃
Main generator leads
Rated current: 411A
Potential transformer taps
Rated current: 1000A
• Arrangement
Length kept to minimum for economic considerations
• Criteria
Current: Maximum generator output
Diesel Generator Main Leads
• Function
High current, generator and main transformer connection
• Type

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Self cooled isolated phase bus, slight pressure, taps for PT’s
• Parameter
Ambient temperature: 50℃
Main generator leads
Potential transformer taps
• Arrangement
Length kept to minimum for economic considerations
• Criteria
Current: Maximum generator output
Diesel Generator Circuit Breaker
Type Vacuum
Rated Voltage 17kV
Rated Current 3150A
Breaking current 40kA
Main Transformer
• Function

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Step-up generator voltage
• Type
NLTC
Oil-immersed, 3-phase, two windings
• Parameter
Rated capacity: 63MVA
Rated voltage (LV SIDE): 13.8kV
Rated voltage (HV SIDE): 145 kV
Impedance: 12.5%
Vector group: YN, d11
• Arrangement
Three (3) phases
• Criteria
a) Sizing
Guaranteed maximum DGs output
System voltage levels and insulation level
Low-loss
Fault current level

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Environment (altitude, ambient, dust, salt, etc.)
b) Location
Adjacent to DG building connected to generator and high voltage system.
3.4.3 Auxiliary power system
3.4.3.1 System function
The auxiliary electrical system distributes power to plant auxiliaries.
Main components and subsystems:
- Unit auxiliary transformer

- Medium voltage systems
- Low voltage systems
- Motors and other electrical loads
3.4.3.2 Design criteria
The system voltage will be within the limits of the continuous rating of the connected
equipment. Voltage drop for normal +5% and -5%.
The arrangement of auxiliary electrical system is to permit at least partial operation in

the event of the loss of one bus.
Modes of operation of the auxiliary electrical system:
- Startup operation
- Normal operation
- Normal shutdown operation
- Emergency shutdown operation

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3.4.3.3 System description
The auxiliary power system will consist of 13.8kV, 4.16kV and 480V power distribution
system.
a) Medium Voltage System
Power from the main transformer is fed to13.8kV bus via unit auxiliary transformer.
Two 13.8kV bus will be furnished for each relative DG unit to feed unit load.
Standby power is a 4.16kV line from phase one, via a standby transformer feed unit
load.
b) Low Voltage System
480V distribution system will be of PC-MCC distribution system. The neutral point of
480V distribution system will be earthed solidly.
Two PC buses and one frequency conversion MCC will be furnished for each block
DGs unit. The PC buses will be arranged in the main building to feed motors, other
electrical loads and four MCCs and some common MCCs. MCC switchboard will be
arranged in local center to feed motors of less than 75kW and other electrical loads.
One MCC buses and one LV unit transformer will be furnished for Oil Area and
radically fed to motor and other loads nearby.
3.4.3.4 Data
Unit auxiliary transformer
• Function
Step-down generator voltage for auxiliary

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• Type
Dry type
3-phase, two windings
No-load tap-changer ±2×2.5%
• Parameter
Rated capacity: 2000kVA
Rated voltage (HV SIDE): 13.8kV
Rated voltage (LV SIDE): 0.48kV
Impedance: 6%
• Arrangement
Three (3) phases
• Criteria
a) Sizing
Guaranteed a block auxiliary load.
b) Location
Adjacent to main building
Medium Voltage Switchgear
• Function

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Supply auxiliary service transformers (13.8kV/0.48kV, 4.16kV/0.48kV)
• Type
Vacuum circuit breaker
• Parameter
a) 13.8kV switchgear
Rated short-circuit breaking current: 3000A
Thermal withstand current (3S): 40kA
b) Vacuum circuit breaker
Rated voltage: 17kV
Rated short-circuit breaking current: 3150kA
Thermal withstand current (3S): 40kA
c) 4.16kV switchgear
Rated short-circuit breaking current: 600A
Thermal withstand current (3S): 31.5kA
d) Vacuum circuit breaker
Rated voltage: 12kV

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Rated short-circuit breaking current: 3150kA
Thermal withstand current (3S) : 12kA
• Arrangement
Indoor
• Location
Medium voltage distribution room in the control building
Low Voltage Switchgear
•Function
Supply motors less than 150kW, PC and MCC
•Type
Indoor dry type service transformer
Circuit breaker for PC and MCC
•Parameter
Rated voltage: 480/280V
Interrupting current: 66kA/1s
•Arrangement
Indoor
Centre of load

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•Location
Dry type service transformer next to PC
•Connection
To 13.8kV and 4.16kV switchgear by cable
To PC by isolation-bus
3.4.3.5 Emergency diesel generating set system
System Function
Emergency diesel generating set for whole power plant will be provided for
emergency shutdown. During normal operation, no power of emergency power MCC.
In the case of power failure of UAT, the diesel generator set will be started
automatically for supplying unit shut-down power.
Main components:
- Diesel engine and synchronous generator
- Emergency distribution control panel
Design Criteria
One diesel generator set is provided.
The diesel generator set should be high availability at continuous operation.
The diesel engine will be remote, manual or automatic starting. It will reach full speed
and be ready for loading in <15s, and pick up full rated load in 30s.
System Description
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The diesel generator supplies the emergency power MCC
The emergency power MCC supplies PC vital AC load.
The diesel generating set is provided with the necessary accessories such as
lubricating oil system, instrumentation and control equipment, auto voltage regulator,
protection system, and so on.
The generator is capable quick response and reliability for the startup of heavy load.
Its neutral is solid grounded.
Data
•Function
Provide ability for fast restart
•Type
Diesel engine
Air cooled
•Parameter
Rated capacity: 500kW
Rated voltage: 480V
Rated power factor: 0.8
Rated frequency: 60Hz
•Criteria

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Sizing-load and voltage
High availability at continuous operation.
Quick starting and loading in <10s, full load in 30s
•Location
A separate diesel generator room.
3.4.4 DC system
3.4.4.1 General
Diesel generator (DG) shall have one set of 125V DC system.
138kV switchyard shall have one set of 125V DC system.
Each system shall consist of a battery, a separate battery charger and a separate
distribution panel. DC system will be of single bus system. The battery will be Valve
Regulated Lead Acid (VRLA) type, and each battery will be 50% rated capacity.
Chargers will be of High-frequency Switch module type and N+1 modules will be
adopted. Each charger will be 100% rated capacity.
The DC system is an unearthed system. A microcomputer insulation monitor will be

provided with each DC bus-bar, which will transmit alarm signal to DCS presence of
an earth fault.
3.4.4.3 Diesel generator (DG) DC technical data
Battery number 2 set

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Battery rated capacity at 5 hour discharge rate 1200Ah
Battery normal voltage of cell 2V
Battery number of cells 59
Battery voltage of discharging end 1.89V
Battery voltage of float charging 2.23V
Chargers type high-Frequency Switch Module
Chargers module number 6 set
Chargers cooling mode Natural air-cooled
Chargers input 60Hz, 480V
Chargers output 125V, 400A
3.4.4.4 220kV switchyard DC technical data
Battery number 2 set
Battery rated capacity at 5 hour discharge rate 200Ah
Battery normal voltage of cell 1.2V
Battery number of cells 168
Battery voltage of discharging end 1.10V
Battery voltage of float charging 1.39V
Chargers type high-Frequency Switch Module

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Chargers module number 4 set
Chargers cooling mode Natural air-cooled
Chargers input 50Hz, 400V
Chargers output 240V, 60A
3.4.5 UPS
3.4.5.1 General
An uninterruptible power supply (UPS) system rated 35kVA will be provided for diesel
generator (DG) and 138kV switchyard.
Each uninterruptible power supply shall be an integrated system consisting of UPS

main panel (include of a rectifier, a static inverter, a state rotary switch), bypass panel
(bypass transformer, stabilization, manual bypass switch, diode), and a mini circuit
breaker distribution panel.
The UPS changeover time will be less than 4ms. Normal power supply to the vital
power supply units will be from the normal power centre through the rectifier, inverter
and load transfer switch to the vital bus, 120±2%, 60Hz. If incoming AC supply system
or the rectifier fails, the input to the inverter will be transferred automatically and
without interruption by DC bus through the blocking diodes. If the output of the inverter
fails, the vital bus will be transferred to bypass essential power by means of the load
transfer switch and fed through the regulated bypass AC power supply.
3.4.5.3 Technical data
Voltage output 120V AC  2%, single-phase, 60Hz  0.5%

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Input (battery) 125 Volts DC
Harmonic distortion No more than 5%
Duty Continuous
Cooling Forced ventilation
3.4.6 Control, automatic device and measuring system of electric system
3.4.6.1 General
Electrical system of the diesel generator (DG) with auxiliary and 138kV switchyard will
be controlled and monitored by DCS. DCS will control the electrical equipment by the
keyboard or mouse. And the important signals will be sent to the DCS.
3.4.6.2 Control
The equipment of the electrical system controlled and monitored by DCS as following:
--138kV circuit breaker
--138kV isolating disconnect switches
-- Diesel generator (DG) circuit breaker
--Diesel generator (DG) exciting system
--Synchronizing system
--MV incoming and feeder circuit breaker
--LV power centers incoming circuit breaker
--LV power centers feeder circuit breaker for motor control centers

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--Diesel generator unit
--LV necessary motor
The equipment monitored by DCS as following:
--DC systems
--UPS system
3.4.6.3 Automatic device
Automatic synchronizer system (ASS) will be used for Diesel generator (DG)’s 13.8kV
circuit breaker and main transformer LV side circuit breaker.
There will be standby power supply automatically changeover devices for the power
changeover between 480V PC’s bus.
Net and generator fault recorder will be used for the analysis of electrical fault.
3.4.6.4 Measuring system
Plant electrical parameters will be metered to the extent required for proper operation
and monitoring of plant conditions. The following metering will be provided for the
equipment indicated, and will be sent to DCS by transducer.
a) Diesel generator (DG)
Current, voltage, vars, watts, watt-hours, varhours, frequency, power factor and
measured at the generator terminals, and exciter/field current and voltage.
b) Main transformer (MT)
Current, watts, vars, measured on the high voltage side of main transformer.

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c) Unit auxiliary transformers (UAT)
Current, watts, vars, watt-hours measured on the high voltage side of unit auxiliary
transformers.
d) 138kV line
Voltage, current, frequency measured at 138kV line.
e) 13.8kV and 4.16kV switchgears
Current, watt-hours measured for each13.8kV and 4.16kV switchgears.
Voltage measured on each bus.
f) 480V switchgears
Current measured on incoming circuit breaker
Current measured on feeder circuit breaker for motor control center.
Current measured on each motor above 30kW.
Voltage measured on each bus.
3.4.7 Protection
3.4.7.1 General
The protective relaying for 138kV line, diesel generator (DG), main transformer (MT),
and unit auxiliary transformers (UAT) will adopt the microcomputer type relays.
3.4.7.2 Protection for diesel generator (DG)
- Generator Differential Protection (87G)

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- Generator O/C with Under-voltage Restrained Protection (51/V)
- Generator Stator Earth Fault Protection (64S)
- Generator Rotor Earth Fault Protection (64R)
- Generator Overload Protection (49)
- Generator Negative Phase Sequence Overload Protection (46)
- Generator Loss of Field Protection (40)
- Generator Voltage Abnormality Protection (59/27)
- Generator Reverse Power Protection (32)
- Generator Under/Over Frequency Protection (81)
3.4.7.3 Protection for 138kV line:
- Differential Protection (87L)
- Directional O/C Phase and Ground (67/67N)
- Over and Under Voltage (59/27)
3.4.7.4 Protection for main transformer (MT)
- Transformer Differential protection
- Transformer O/C with Under-voltage Restrained Protection
- HV Side Earth Fault Protection
- HV Side Gap Earth Fault Protection

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- Overload Protection
- Cooling Initiation
3.4.7.5 Protection for 13.8kV busbar
- Differential Protection (87B)
- Circuit breaker failure protection (50BF)
3.4.7.6 Protection for unit auxiliary transformers (UAT)
- Differential Protection (87T)
- Instantaneous O/C (50)
- O/C Protection with Under-voltage Restrained (51/V)
- Neutral O/C (Earth Fault Protection) for HV Side (50/51N1)
- Neutral O/C (Earth Fault Protection) for LV Side (50/51N1)
3.4.7.7 Protection for 4.16kV standby transformers
- Differential Protection (87T)
- Instantaneous O/C (50)
- O/C Protection with Under-voltage Restrained (51/V)
- Neutral O/C (Earth Fault Protection) for HV Side (50/51N1)
- Neutral O/C (Earth Fault Protection) for LV Side (50/51N1)
3.4.7.8 Protection for 480V motor

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480V motor will adopt the microcomputer type relays. The protection relay will be
installed in 480V switchgears.
3.4.8 Excitation system
Excitation system for diesel generator (DG)
The DG will be equipped with a brushless excitation system. Characteristics and

parameters of excitation system shall meet the requirement of various operation
modes of power system and all operation conditions of generator.
a) Data of exciter field:
Excitation voltage: 77.2V
Excitation current: 9A
Forced excitation time: 1.6-2Times, ≥ 10S
Accuracy: voltage regulation ﹤ 0.1%
Adjust compensation range: ＋20% - －20%
b) System description
The regulator is suit to the generator, which the capacity is under 60MW and the
power supply is from the exciter on the shaft of the machine. The double-channel
excitation system DAVR is designed for automatic voltage regulation of synchronous
machines. It satisfies high demands for availability in parallel operation with an active
network or other synchronous machines. Channel I is in operation in the normal way
and is there for also called the main channel. It performs the actual voltage regulation
of the machine (AVR). Channel II is also operating and is able to replace the main
channel completely at all times, even for an extended period, without endangering

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operation of the machine. It is also called the standby channel below. In this case it is
designed as an excitation current regulator and therefore operates independently of
the voltage measurement of the machine (e. g. also for loss of voltage actual value)
and is accordingly also highly suitable for commissioning and maintenance work
(e.g. short-circuit tests). When it is in operation the excitation current must be
continuously matched manually to the machine loading conditions. In addition to the
two basic control modes, there are PF or VAR regulators, open loop regulator.
Otherwise, in order to protect the main machine operated in the safety range, there
are the following limiters, three-step delayed maximum excitation current limiter,
maximum generator’s stator current limiter, minimum excitation current limiter,
minimum reactive current limit as a function of active power, V/Hz limiter etc. Also the
device provides the following signals and alarms, supply fault, rotating diodes fault,
mistake forced excitation, PT failure, limiter active etc.
c) AVR
AVR will be digital microcomputer type with reliable performance and shall have fine
regulation characteristic and can improve generator transient stability. It shall have at
least manual and dual automatic channels. Channels shall be mutually independent
and either channel can be put out of service for maintenance at any time.
AVR will be provided at least the following additional units:
Remote/local setup unit;
Over-excitation limit;
Over-excitation protection;
Under-excitation limit;
V/Hz limit and protection;

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Power system stabilizer (PSS)
3.4.9 Grounding and lightning protection
3.4.9.1 The grounding system
a) System function
The grounding system for equipment and electrical system will be provided to insure
safety to personnel and equipment from electrical equipment failure and lightning/
static electricity. The grounding system dissipates lightning discharges to protect the
personal and equipment.
b) Design criteria
Transferred potential, touch potential and step potential should not exceed the
tolerable potential difference. Grounding system consist of a ground grid formed by a
number of rods placed in a mesh formation by all welded joints, riser connections from
ground grid and aboveground flat for grounding of equipment. Ground electrodes will
also be provided at intervals and driven to solid earth. Sizes of belowground conductor
will be selected based on unrestricted ground fault current and maximum duration of
fault clearing time will be 1 sec. Connections to individual equipment will be sized
based on the fault clearing time. All non-current carrying structural will be grounded at
one point and all the electrical devices/equipment will be grounded.
c) System description
A station grounding grid consisting of bare copper cables buried beneath grade will be
furnished to limit step and touch potentials to safe values under all fault conditions.
Bare copper risers will be furnished for all electrical underground ducts and equipment,
and for connections to the grounding systems within buildings.
Each building will be provided with grounding system connected to the station
grounding grid. Connections are to be made to metallic tanks, equipment, cable trays,
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and exposed metal structures. Every other perimeter copper-clad steel column will be
connected directly to the grounding grid.
All switchgears, motor control centers and control cabinets will be furnished with a
ground bus. The ground bus in switchgears, MCC’s will be connected to the grounding
system with one or two copper ground cable at each end, tied to the building steel or a
ground pad set in the floor. The ground bus in control cabinets will be connected to the
grounding system.
Bare stranded copper cables will be buried directly in the soil under all foundations
and metal structures in the steam turbine generator areas, transformer yard areas and
the switchgear and transition facility. The conductors will be arranged as a rectangular
grid with all intersections connected by exothermic weld material consisting of copper
and aluminum.
Maintenance:
Most part of grounding system requires no maintenance.
3.4.9.2 Lightning protection system and surge arrester
a) System function
Lightning rod or belt will be equipped for protecting outdoor transformers and higher
building from lightning. The lightning protection devices provide a path for lightning
current to be safely discharged to earth.
Protection of electrical equipment insulation from damage due to lightning and over
-voltage surge.
b) Design criteria
The lightning protection system should be fully operational at all time to provide a low

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impedance path to grounding.
The protected equipment, persons, building and structure should be within protection
zone by air terminals and conductors.
c) System description
The basic configuration of a lightning protection system consist of a number of air

terminals distributed along the upper part of the structure(s) and interconnected by
one or several conductors, which form a closed loop. These conductors will be
electrically continuous with the Station Grounding System and ground rods are
installed connected to the ground cable loop around the structure under protection.
The air terminal used cable connects to grounding system.
Maintenance:
A visual inspection is at periodic interval. When found to be damaged or destroyed,

replacement of components should be required.
3.4.10 Lighting system and maintenance power supply system
3.4.10.1 General design concept
The lighting system shall comprise the following sub-systems:
a) Normal AC lighting
Lighting will be provided by AC lighting fixtures distributed throughout the power plant.
These lights can be ON as long as the station AC supply is available.
AC lighting fixtures will be fed from respective area lighting distribution boxes, which
will be connected from the closed MCC or PC. MCBs will be provided to supply power
to various lighting distribution boxes located in different floors of all the buildings. The

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lighting distribution boxes will be provided with at least 20% spare MCBs.
b) Emergency lighting
AC emergency lighting will be provided at important locations all the plant. The power
supply shall be available to these fixtures from 480V Emergency MCC via emergency
lighting distribution boxes.
AC emergency lighting fixtures will be installed at staircases, operation level of turbine

hall, electronic equipment rooms, switchgear rooms and all similar locations. These
fixtures will be equipped with batteries for AC supply loss.
c) Outdoor lighting
Outdoor lighting shall be through separate circuits controlled by timer-switch. Auto &
manual selector will be provided.
d) Maintenance power supply system
Maintenance power boxes will be provided in the whole power plant area, which will
be fed from MCC, PC or power distribution boards. 63A TPN welding sockets will be
provided for certain areas. For other service purposes 15A 3-pin GB standard sockets
will be provided.
e) Design codes and standards
The calculation and selection are in accordance with Chinese standard DL/T
5390-2007 Technical rule for designing auxiliary power system of fossil fuel power
plants.
3.4.11 Telecommunication system
The internal communication of the combined cycle power plant mainly included the

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following subsystems:
--Telephone system
--Paging system
3.4.11.1 Telephone system
The system consists of PABX (Private Automatic Branch Exchange) and the auxiliary
equipment, MDF (main distribution frame), distribution terminal equipment, cable
network and so on. In the project, the PABX have 20 trunk lines and 160 extension
lines.
3.4.11.2 Communication power supply
The power supply system consists of one set of 120A/-48V high frequency switch
power equipment and 300Ah/-48V maintenance-free batteries.
3.4.12 Cable and cable raceway
3.4.12.1 Cable
MV cables will be of copper conductor with XLPE insulation, protective sheath and
PVC external jacket. LV cables will be of copper conductors with XLPE insulation,
protective sheath and PVC external jacket. Control cables will be of copper
conductors with PVC insulation, protective sheath.
Main parameters of cable:
a) Power cable
Conductor material: copper
Core insulation: XLPE

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Sheath insulation: PVC
Max. conductor temp: 90 Degrees Celsius
The maximum conductor temperature during short-circuit will be met.
Rated voltage: 138kV, 13.8kV, 4.16kV, 0.48kV
Cable cross section 2.5 to 240 sq.mm
b) Control cable
Conductor material: copper
Cable cross section 1 to 10 sq.mm
Armored cables will be used under the following conditions: When cables are direct
buried.
3.4.12.2 Cable raceway
• General
The cable raceway system including conduits, flexible conduit, cable tray, cable
trenches will be installed and furnished with the requirements of power plant.
Cable trays, conduits and wire ways (including boxes) serve as a means of safely and
orderly routing the electric cables to various points around the power plant.
• Cable trays
The cable support system consists of hot dipped, galvanized ladder type cable tray
which will be used to support power and control cables. Power and control, cables will
be routed in separate tray systems.

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When cable trays are stacked above each other they will be arranged top to bottom in
the following order:
― Medium voltage power trays.
― Low voltage power trays.
― Control trays.
All cable trays will be installed so as to be electrically continuous. Power cable trays
(high, medium, and low voltage) should be grounded by bare ground conductor.
Cables will be fixed to the ladder/tray cable ties in adequate distances.
• Conduits
All metallic conduits will be electrically continuous and grounded at multiple locations
by means of their mechanical attachments to building steel or direct bonding.
Buried conduits shall be of HD PVC or steel pipes according floor load and it’s
location.
All exposed conduits will be galvanized steel with their corresponding fittings of the
same material.
Conduits will be used for indoor building services, such as lighting, ventilating, and
communications.
Flexible metal conduit of minimum practical length will be utilized between conduit and
equipment boxes for vibration protection, expansion considerations and equipment
removal.
Conduits exposed to chemicals will be either properly coated or made from chemical
resistant material.

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Directly Buried Conduits:
Heavy conduits will be used for direct burial in soil to withstand the soil pressure
forces.
The trenches in which the conduits are placed will be sloped to permit draining. a
grounding cable sized according to the system requirements will be run in the trench
to ensure a low impedance fault return path.
3.4.12.3 The cable fire-protection provision will be provided
The routes of cables will be arranged to have an adequate clearance from other
services. Cables will generally be routed to avoid hot or fire risk areas, and to
minimize the risk of damage.
All apparatus connections and cable installations will be designed and installed to
minimize the risk of fire and damage which may be caused in the event of fire.
Enclosed vertical runs of cables will be provided with fire stops to limit the spread of
fire, and will be sealed to prevent "chimney effects".
Fire will be blocked from one room to another room or outside. Fire will be blocked in a
limited direct distance in the trenches or at the branches of the trenches.
3.4.12.4 System automation
a) Supervision and control of CB
Supervision and Control of CB Sub-station will be realized by DCS system. The DCS
system will communicate with the Load Dispatch Center
HEI will discuss the interchange information with CELEC.
b) Tariff metering

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Tariff metering shall comprise both main and check as separate meters. Tariff main
and check meters shall be provided that shall provide two outputs per measured
quantity. Test terminals shall be provided to facilitate on Site tests.
Where main and check meters are required at the Power Plant, two sets of current
transformers are provided.
The current transformer windings and cables connecting such windings to main
meters shall be dedicated for such purposes and such cables and connections shall
be securely sealed. The current transformers supplying check meters are used for
other purposes provided that overall accuracy requirements are met.
Main and check meters shall be supplied via two voltage transformers or one voltage
transformer with two or more secondary windings. The voltage transformer winding
supplying main meters shall be dedicated to that purpose and such windings and
connections shall be securely sealed. The voltage transformer secondary winding
supplying check meters may be used for other purposes provided the overall burden
and accuracy requirements are met.
Meters shall be located on free-standing cabinets. The cabinets shall be equipped

with test blocks and all necessary UPS AC and DC supplies. Meters shall display their
output at all times, whether or not the voltage transformers are energized.
The following accuracy classes shall apply as per relevant metering point:
Current transformers 0.2s
Voltage transformers 0.5
Active energy meters 0.2
Reactive energy meters 2

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3.5 Chemical Part Description

3.5.1 General
3.5.1.1 Scope of work for chemistry system
The scope work of chemistry system:
 Demin-water supply system;
 Industry water system;
 HT & LT cooling water system;
 Nozzle cooling water system;
 Chemical dosing system;
 Water and steam sampling system;
 Oily water system;
 Domestic wastewater system;
 Laboratory, etc.
3.5.1.2 Water source and water quality
In this project, the demin-water source is the demin-water from plant 1; the industry
water for total plant is the water from plant 1; demin-water treatment system; domestic
water from city domestic water system.
•Demin-water quality
Method Title Test Result
PH@25℃ 5.5-6.5
Conductivity ( uS/cm) 0.6-1.0
SiO2 (ppm) 0.005-0.02

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3.5.1.3 Water and steam quality standard
We will adopt the Chinese Water and Steam Quality Standard (GB/T 1576-2008 Water
Quality for Industrial Boilers for generating unit and steam power equipment).
Overheated steam pressure MPa P≤1.0 P=0.7MPa

Items
Feeding water type Softened Demin-water Demin-water
Turbidity/NTU ≤5.0 ≤2.0 ≤2.0
Hardness/(mmol/L) ≤0.030 ≤0.030 ≤0.030
pH(25℃) 7.0～9.0 8.0～9.5 8.0～9.5

Feeding
water
Dissolved O2/(mg/L) ≤0.10 ≤0.10 ≤0.10
Ferric/(mg/L) ≤0.30 ≤0.30 ≤0.30
Conductivity(25℃)/(μS/cm) - - -
Superheater-Y 6.0～26.0 ≤10

Total
-
alkalinity/(mmol)
Superheater-N - -
Superheater-Y 4.0～18.0 ≤6.0

Phenolphthalein
-
alkalinity /(mmol)
Superheater-N - -
pH(25℃) 10～12 10～12 10～12

Boiler
water
Superheater-Y ≤4.0×103 ≤4.0×103
Dissolved
solids/(mg/L)
Superheater-N - -
3-
PO4 / (mg/L) - - -
3-
SO2 / ( mg/L) - - -
Alkalinity / (mmol) ＜0.20 ＜0.20 ＜0.20

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3.5.2 Demin-water supply system
The capacity of demin-water system will be designed & supplied to serve the following
consumers:
1. Boiler Feeding Water
2. HT & LT Cooling Water System
3. Nozzle Cooling Water System
4. Chemical Dosing Water System
The capacity of demin-water supply system will be: 5t/h.
3.5.2.1 Selection of demin-water supply system
According to the water quality requirement of the plant, the system process flow will be
designed as follows:
Demin-water Tank (plant 1) Demin-water Pump Demin-water Storage Tank (20m3)
Demin-water pump  to users
3.5.2.2 Description of main equipment
Demin-water supply system would be transport by two sets of pump controlled by

DCS system, normally the pump would be running all the time, one working and other
would standby; one set of motor control valve located at the demin-water pipeline, the
valve would controlled by demin-water tank (20m3), it would open when the level come
to low level, and stop when the level come to high level, the system process flow will
be designed as follows:

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3.5.2.3 Main specifics of demin-water system
Type IR50-32-250B
Fluid medium Demin-water
Flow 5m³/h
Working Temp. 28.3℃
Design Temp. 50℃
Head 20mH2O
Power 480V 3Ph 60Hz
Motor Shanghai Bangpu
3.5.3 Industry water system
3.5.3.1 Selection of industry water system
Industry Water System will provide the total industry water for the plant. The capacity of
the Industry Water System consists of flushing water for lube oil separator module,
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flushing for engine booster, flushing for fuel oil treatment devices etc.
The water source of industry water system is the fresh water from demin-water
treatment system of plant 1. The industry water system will be as follows:
Fresh water from plant 1  Industry Water Tank (20m3)  Industry Water Pump  to
users
Industry water system would be transport by two sets of pump controlled by local
control box, one working and other would standby; the industry water would be
transport to the industry water tank (20m3) in plant 2, the system process flow will be
3.5.3.3 Main specifics of industry water system
Industry Water Unit Value
PH / 6.5-7.5
Conductivity uS/cm 90-200

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Industry Water Unit Value
Total Hardness ppm 30-65
SiO2 ppm 22-32
Me ppm 10-30
Organic Matter ppm 0.17-0.36
Temp. ℃ 24-27
3.5.4 HT & LT cooling water module
Main Function
HT cooling water module was used to supply cooling water for air cooler stage 1, nozzle
cooler etc. Each module contains 2 sets of water pump, thermostatic valve, and inlet
valve, check valves and stop valve etc.
The capacity of HT cooling water module will be: 176m3/h; head: 45mH2O.
LT cooling water module was used to supply cooling water for air cooler stage 2, lube oil
heat exchanger, and sampling racks etc. Each module contains 2 sets of water pump,
thermostatic valve, and inlet valve, check valves and stop valve etc.
The capacity of LT cooling water module will be: 286m3/h; head: 27mH2O.
3.5.4.1 Selection of HT & LT cooling water module
HT cooling water module
Air radiator  HT cooling water pump  Air cooler stage 1  Nozzle cooler  Air

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radiator
LT cooling water module
Air radiator  LT cooling water pump  Air cooler stage 2  Lube oil cooler 
Sampling racks  Air radiator
HT cooling water module contains 2 sets of water pump, thermostatic valve, and inlet
valve, check valves and stop valve etc. All of the pumps would be controlled by DCS;
one pump would be running and another one standby during normally operation, the
system process flow will be designed as follows:
LT cooling water module contains 2 sets of water pump, thermostatic valve, and inlet
valve, check valves and stop valve etc. All of the pumps would be controlled by DCS;
one pump would be running and another one standby during normally operation, the
system process flow will be designed as follows:

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3.5.5 Nozzle cooling water module
Main Function
Nozzle cooling water system was used to supply cooling water for diesel engine
nozzles.
Each module contains water storage tank (1m3), cooling water pump 2 sets, cooler,
valves etc.
The capacity of nozzle cooling water system will be: 1.32m 3/h; head: 4.8mH2O
3.5.5.1 Selection of nozzle cooling water module
Nozzle cooling water module
Demin-water pipeline  Nozzle cooling water tank  Nozzle cooling water pump 
Engine  Nozzle cooling water tank
Nozzle cooling water heat exchanging module

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HT cooling water pump outlet  Nozzle cooling water heat exchanger  HT cooling
water pump inlet
Nozzle cooling water module contains 2 sets of water pump, one sets of storage tank,
feeding water valves and heat exchanger etc. All of the pumps, valves would be
controlled by DCS; one pump would be running and another one standby during
normally operation, the system process flow will be designed as follows:
3.5.6 Chemical dosing system
The chemical dosing system will supply the chemicals to the condensate water pump
outlet minimize corrosion and prevent scale formation.
Chemical dosing systems include following system:

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a. hydrazine dosing system
b. Trisodium phosphate dosing system
The equipment will be supplied as separate skid mounted units for each chemical
complete with all piping, valves and instrumentation for safe running and protection
against abnormal conditions.
The chemical conditioning philosophy proposed must have an extensive record of

successful application for similar operating parameters. The chemical dosing system
supplied will be compatible with maintaining this conditioning philosophy.
The systems will be complete with all necessary plant and control components
included.
The pump controls will be arranged to allow, as selected, the local start/stop of
individual pumps.
The equipment will be suitable in all respects to deal with the chemical solutions
normally used for conditioning feed water.
A demineralised water supply will be provided for stock solution dilution.
a) Hydrazine dosing system
The hydrazine dosing system is used to remove dissolved oxygen contained in the
condensate water and to control pH value in the feed water, to protect boiler internals,
etc., from rust during long term shutdown of the plant. The hydrazine will be injected
into condensate water of the unit and to the deaerator outlet.
One (1) set of dosing equipment will be set, it contains: one (1) set of solution tank,
two (2) sets of dosing pumps.
Relevant drawings (HDEG-JY211A-XT) show the proposed flow diagram of system.

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b) Trisodium phosphate dosing system
The trisodium phosphate dosing system is used to avoid deposits of hardness in the
boiler’s system
One (1) set of dosing equipment will be set, it contains: one (1) set of solution tank,
two (2) sets of dosing pumps.
Relevant drawings (HDEG-JY211B-XT) show the proposed flow diagram of system.
3.5.7 Water and steam sampling system
Water & steam sampling system monitors the chemistry of the water and steam in the
steam cycle in order to control the chemical additives to the water cycles to ensure
correct water and steam quality.
Adequate chemical laboratory monitoring instrumentation will be provided to

demonstrate the safe and reliable operation of the processes. The instruments will
provide adequate information for the detection of any deviations from defined chemical
control limits, so that appropriate corrective actions may be taken.
High temperature and high pressure rack consists of coolers, pressure reducing
devices, needle and flow control valves, shut off valves, pressure indicators, piping and
accessories.
Each sampling racks will be centralized with three (3) boilers.
Relevant drawings (YTQ-EG100-XT) show the proposed flow diagram of system.
3.5.8 Oily wastewater system
3.5.8.1 Selection of oily wastewater system
This system was made for the oily wastewater treatment of oil tank area, oil purification
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device, main building fuel supply module etc, and the system process flow will be
Relevant drawings (HY0315-001) show the proposed flow diagram of system.
3.5.8.2 Scope of oily wastewater system
The scope consists of a complete oily wastewater system, which meet the design data
requirements. Complete oily wastewater plant includes among others:
1) Belted oil scraper
2) Oil & water separator
Following manual start-up and operation manually, also you can view the equipment
operation status in DCS.
3.5.9 Domestic sewage system
3.5.9.1 Selection of domestic sewage system
This system was made for the main building, production, office building, canteen
discharge water etc. This project will build a new domestic sewage treatment module;
its capacity is 3m3/h.
Domestic sewage will be sent to wastewater regulation pool after collected in the septic,
by the booster pump come to Integration of sewage treatment plant, via the treatment of
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primary sedimentation tank, biological contact oxidation pond, secondary settling tank,
disinfection pool, row to the Teaone river.
The system process flow will be designed as follows:
Relevant drawings (HY0313-001) show the proposed flow diagram of system.
3.5.9.2 Scope of domestic sewage system
The scope consists of a complete domestic sewage system, which meet the design
data requirements. Complete domestic sewage plant includes among others:
1. Manual grille
2. Anoxic tank
3. Primary sedimentation tank
4. Secondary setting tank
5. Disinfection pool
Following manual start-up and operation manually.
3.5.10 Laboratory
A chemical laboratory will be provided for the plant including all the furniture,
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instruments, apparatus particulars, glassware and chemical-agents. The main

equipment will include water and fuel analysis instruments.
3.6 I&C Part Description

3.6.1 General
Esmeraldas II Project 12×8MW Thermoelectricity units located in Ecuador, the

coordinate of location of power plant is north latitude of 0°41'13'' and west longitude of
79º41'37''. Annual average atmospheric temperature is 28.3℃. Total installed capacity
of 12×8MW diesel engine-steam combined circulation units, the three host devices
are: the boiler from the No.3 703 Research Institute of CSIC, Diesel engine supply by
SXD of CSIC Co.,Ltd, Generator supply by ABB. The power station belongs to
CELEC.
The project of Esmeraldas II Thermoelectricity power plant installs twelve sets of

Diesel -steam combined cycle generating unit, each one unit includes one (1) Model
12PC-6B diesel engine, one (1) HRSG and one (1) generator.
3.6.2 Scope of work
3.6.2.1 Design scope
In order to assure safe, reliable and efficient operation, the work scope of instrument
and control (I&C) is to design and supply a set of complete, reliable instrument and
control system for the power plant that includes
twelve sets of Diesel-steam combined cycle generating unit , each one unit includes
one (1) Model 12PC-6B diesel engine, one (1) HRSG and one (1) generator and
associated auxiliary system, such as Transfer and step-up of heavy oil system,
Off-loading and Transfer of Diesel Oil System, etc.
3.6.2.2 Supply scope

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According to functional requirement of this project and meet with safety and economical
operation of the unit, the equipment of instrument and control device will be adopted
with the advanced, mature, reliable, practical technology.
The DCS, PLC, local measuring instruments, actuators, instrument valves, control
panels, consoles, cabinets, junction boxes, cables, installation material and cable tray
will be supplied according to requirement of plant systems.
3.6.3 Automation level
The centralized control for unit will be adopted. The operators in Central Control Room
(CCR) can complete start-up/shut-down control, supervise and control unit during
normal operation and complete emergency handling under unit abnormal operation.
During the unit starting, a small number of operators have to be in the field for looking
around. And the function groups will be automated.
Microprocessor-based Distributed Control System (DCS) will be adopted. It will perform

all the functions mentioned in the Contract documents including monitoring, control,
alarm, protection and interlock, diagnosing, accident treatment and maintenance
guidance of the unit to meet all requirements at various operation conditions, to assure
safe and economic operation of the unit. DCS will provide major and minor modulating
control functions, and sequence/on-off control function for unit and their auxiliary
system.
The auxiliary system such as transfer and step-up of heavy oil system, off-loading and
transfer of diesel oil system, transfer of lube oil system, compressed air, dematerialized
water and industrial water system, radiator system, and diesel engine system will be
controlled through microprocessor-based programmable logic controllers (PLC).
The PLC is exchange information with DCS by data communication and hard-wired
connection. Start up/ shut down, monitor, control for Diesel engine can be realized both
in the local control cabinet and the central control room.
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3.6.4 Control mode
Central control mode will be adopted for the control of whole power plant.
A Distributed Control System (DCS) will be adopted as control center of the control
network for the whole power plant. The operator can implement the centralized control
of the combined cycle unit and auxiliary systems through this control network. This
control network will contain all the necessary equipment such as servers, Engineering
Station, Operator Station, History Data Station, printers etc. The Operator Station will be
located in the Central Control Room (CCR), and other network equipment and control
cabinets will be located in DCS and I&C cabinets room.
The DCS will be equipped with special control devices, local conventional instruments
and control devices to form a complete C&I system. All Control and Instrumentation
systems will be latest field proven technology, high reliability by redundant system. All
plant control systems will be synchronized with master clock of DCS. Emergency
shutdown devices (hard wire push button) at central control room will be provided. In
the case of the DCS fault, the operator can shut down the unit safely through the
devices (indicators, emergency hardwired buttons etc.) on the auxiliary control panel or
consoles in CCR to ensure the safety of the equipment and personnel.
The Diesel engine can be controlled and monitored through PLC and also through
operator workstations of DCS system in CCR. PLC system is supplied with Diesel
engine. The PLC system will communicate with DCS through fiber optic redundant
communication interface and hardwired. Three operator stations supplied with IA will be
located in CCR, too.
The PLC system will be adopted to control some auxiliary system such as Compress air
system, Oily waste water treatment system, tank master system, heavy oil purification
system, diesel oil purification system.
3.6.5 I&C function

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3.6.5.1 DCS control function
The DCS will implement all the functions specified in the Contract documents including
Data Acquisition System (DAS), Modulating Control System (MCS), Sequence Control
system (SCS) and Electric Control System (ECS) to meet all kind of operation condition
and to ensure the unit safety high-effective operation.
3.6.5.2 Data acquisition system (DAS)
The Data Acquisition System (DAS) is a part of the DCS, which will be able to monitor,
display, alarm, calculate, record and have a operating guidance for all input/output data
that is required for plant process management as well as provided accurate information
for the operator so that safe and economic operation will be ensured.
The following is the function implemented in DAS:
a) Input signal processing
b) Alarm limit check and over-limit alarm
c) Display: includes operation display, process mimic diagram, group displays, bar
graphic displays, trending displays and alarm displays
d) List log: includes periodical log, Sequence of Events (SOE), trip log, etc.
e) Historical data storage and retrieve
f) Plant performance calculation; etc.
3.6.5.3 Modulating control system (MCS)
The Modulating Control System (MCS) will give load demand to HRSG and Radiator
and Common system according to the load requisition and status of unit to control the
unit through sub-loops. So as to ensure the unit operate steadily.
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The following is the function implemented in MCS:
a) Auxiliary steam head pressure control
b) Drum level of the HRSG control
c) Deaerator water level control
d) Deaerator pressure control
e) 2000m3 tank outlet pipe oil temperature control
f) 250m3 tank outlet pipe oil temperature control
g) 750m3 tank outlet pipe oil temperature control
h) The return oil header pressure control
I) The pressure of main pipe of diesel oil transfer pump outlet control
j) The liquid level of condensate water tank control
k) LT radiator No.1~No.8 fan control
l) HT radiator No.1~No.2 fan control
3.6.5.4 Sequence control system (SCS)
Sequence control system is composed of different function groups defined according to

process system. Each function group will achieve specified start-up/shutdown function.
3.6.5.5 Interlock and protection
Interlock and protection system includes following items:
a) HRSG subgroup
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b) Diesel engine system subgroup
d) Transfer and step-up system subgroup
e) Off-loading and transfer system of diesel engine subgroup
f) Off-loading and transfer system of lube oil subgroup
g) Compressed air system subgroup
h) Dematerialized water and industrial water system subgroup
i) Radiator system subgroup
j) LT/HT cooling water system subgroup
3.6.5.6 Master lock system
Master Clock System (GPS) is a part of DCS. The master clock will be located in DCS
and I&C cabinets room.
3.6.5.7 Diesel engine generator control system
Diesel Engine generator control network will be set up in this power plant. The control
of the diesel engine generators could be implemented through PLC provided with gas
turbine generators and also through gas turbine generator control network in CCR.
The functions of the PLC:
• Normal start-stop
• Emergency shut down
Peak load select

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• Status display: standby, start up, on-line, emergency shut down etc.
• Speed display
The following signal could be recorded, and be printed too.
-- Diesel engine lube oil inlet engine pressure
-- Diesel engine lube oil inlet engine temperature
-- Diesel engine lube oil outlet turbocharge pressure
-- Diesel engine HT water outlet engine temperature
-- Diesel engine main bearing temperature
-- Diesel engine speed
-- Diesel engine generator bearing temperature
-- Diesel engine temperature of generator stator
PLC will have the automation protection function to prevent the potential accident of
gas turbine generator, include following items:
-- Diesel engine lube oil inlet engine pressure low
-- Diesel engine lube oil inlet engine temperature high
-- Diesel engine lube oil outlet turbocharge pressure low
-- Diesel engine HT water outlet engine temperature high
-- Diesel engine main bearing temperature high
-- Diesel engine overspeed

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-- Diesel engine generator bearing temperature high
-- Diesel engine temperature of generator stator high
3.6.5.8 Clock system
A master clock system will be supplied and will be synchronized to satellite time. The
clock will be DC operated, complete with electronic type crystal control and being
self-compensating for variation in ambient temperature. The clock system will have an
accuracy of 1/100 seconds per day.
The clock system will also provide time signals to other plant and equipment requiring
synchronized timing, including the tariff metering, and will also operate a main wall
clock in the CCR.
3.6.5.9 Sequence of events recording system (SOE)
The digital input of SOE shall be shared with DCS. It will be event-triggered to initiate a
CRT display change and produce a hard log response. Each SOE point will have a time
resolution of one millisecond to support post event analysis. Events will be time-stamped,
place in the data archive and printed on dedicated alarm printer. The Diesel engine
generator SOE signals would be transmitted to DCS and display & printing of plant level
SOE would be possible on DCS, too.
3.6.5.10 BOP control system
The BOP control system is including Compressed air system, Diesel fuel supply
system, Industrial water system, Dematerialized water system, Air radiator system,
Condensate water system, Oily waste water system and so on. These systems are all
controlled by DCS.
a) Compressed air system
Compressed air system will supply dry, clean, and oil-less, water-less, dust-less air for
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air instrument and control. The control of the compressor and the dryer is
implemented by the manufacturer. The following signals will be monitored and
controlled:
• Pressure of the manifold of outlet of the compressor;
• Pressure of service compress air tank;
• Pressure of instrument compress air tank
b) Diesel fuel supply system
Diesel fuel supply system is designed for fuel supply of diesel engine. The following
signals will be monitored by DCS:
•Flow of the fuel;
• Level and temperature of the oil tanks;
• Pressure of the manifold
c) Industrial water system
DCS I/O cabinet will be used to control industrial water pumps, valves to supply
industrial water for the plant. The following signals will be monitored and controlled by
DCS:
• Level of industrial water tank;
• Main pipe pressure of Industrial water pump;
• Replenish water flow of industrial water;
d) Dematerialized water system

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DCS I/O cabinet will be used to control dematerialized water pumps, valves to supply
dematerialized water for the plant. The following signals will be monitored and
controlled by DCS:
• Level of dematerialized water tank;
• Main pipe pressure of dematerialized water pump;
• Temperature of dematerialized water;
• Replenish water flow of dematerialized water;
e) Air radiator system
Every three diesel generator matched a unit radiator, include 8 sets of LT cooling
water system and 2 sets of HT cooling water system. 12 sets of diesel generator all
putting into operation, the corresponding HT/LT cooling water system of the fan is all
in operation. HT/LT radiator of each table fan adopts full variable frequency control;
According to each column outlet temperature to automatic adjust this column fan
inverter frequency.
The following signals will be monitored and controlled by DCS:
• Radiator fan vibration
• LT radiator row inlet temperature
• LT radiator row outlet temperature
• HT radiator outlet temperature
• HT radiator inlet temperature
f) Condensate water system

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DCS I/O cabinet will be used to control condensate water pumps, valves to supply
condensate water for deaerator in the plant. The following signals will be monitored
and controlled by DCS:
• Level of condensate water tank;
• Main pipe pressure of condensate water pump;
g) Oily waste water system
DCS I/O cabinet will be used to monitor the condition of oily waste water system. The
following signals will be monitored and controlled by DCS:
• Operation condition of oily water pump;
• Operation condition of waste oil pump;
• Level of oil waste water basin;
3.6.5.11 Electrical control system
Electrical control system will include but not limited to as the following:
• Emergency diesel generators;
• Electrical protection relays;
• Metering system;
• UPS system;
• DC system;
• Others

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The electric control system will hardwired to DCS. The detail information will be shown
in electric part.
3.6.5.12 Auxiliary system
The control system for some auxiliary system (e.g. compressor air system, etc.) will be
based on PLC and be controlled and monitored on operator station in local control
room.
The operator stations of these PLC systems will be located in local control room. The
auxiliary system shall have one EWS and three OS.
As it is very important, several important signals of compressor air system such as

start/stop remotely etc. will be connected to DCS by hardwire. Other signals of
auxiliary system will be connected to DCS by redundant data link. So that operators
could monitor the auxiliary system in CCR.
3.6.6 I&C equipment
3.6.6.1 Distributed control system (DCS)
The “DCS” shall be advanced all over the world and shall be based on open architecture
standards; it also shall be demonstrated to have been field operational in similar
facilities.
The ratio of performance and price of “DCS” will be high.
The power supply of “DCS”, the operator workstations, data highways and controllers
will all be redundant.
The important signals for regulation and protection are three or two redundant.
3.6.6.2 Operator workstation / engineering workstation

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The “DCS” will include several operator workstations. They will be all located in CCR,
the control center of the whole plant.
The operator workstation shall include 21 color CRT (A minimum resolution
1280Hx1024V, TFT type) and general-purpose keyboard/special keyboard for
operators to monitor and control the unit. The operator workstation shall also include
one set multicolor printers and high-speed printer for alarm and report process, and one
set multicolor printers for log. In addition a multicolor screen printer could copy graphic.
Engineering workstation shall include 21 color CRT (A minimum resolution

1280Hx1024V, TFT type) and general-purpose keyboard to program the “DCS” system.
It shall also include laser printer to print program. A large capacity laser disc shall
storage historic data.
3.6.6.3 Data highway system
Data highway is used for linking the Operator station, Processing Unit and Engineering
/Programmers Station and other peripherals into a complete system and realizing data
communication among them.
The data highway will be redundant designed. Any nodes on data highway will be
directly connected through dual redundant communication modules.
A failure of any controller, processor or node on the data highway will not affect the
integrity of the data highway or communications between other healthy nodes on the
highway. Any communication failure will produce a system alarm and display a
diagnostic message indicating the component that failed.
3.6.6.4 Programmable logic controller (PLC)
PLC system will be a complete set and will including following items:
• Controller;
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• Memory;
• I/O modules;
• Interface module;
• Power supply;
All modules in the system will be of the plug-in type for easy field replacement.
The spare capacity of 10% will be foreseen in each I/O module.
3.6.6.5 Diesel engine generator controllers
A Diesel engine generator control network with operator stations will be set up in this
power plant. This control network will contain all the necessary equipment such as
operator stations, history data station, printers etc. to control, monitor, record and
protect diesel engine generator units. The operator stations will be located in the CCR.
The control of the diesel engine generators could be implemented through IA control
system provided with diesel engine generators and also through DCS system in CCR.
IA control system will contain all the necessary equipment to control, monitor, record
and protect the Diesel engine generator and auxiliaries. This equipment will be
housed in the control cabin located at the head of the diesel engine generator unit.
The data exchange between the diesel engine generator PLC and DCS will be
performed via communication and hardwired. The operator could supervise and
control the diesel engine generators in CCR.
3.6.6.6 Field instrument
a) Primary element for flow measurement
In general removable orifice plates with flanges will be used for differential pressure. It
will be square-edged, paddle type with concentric orifice. Flow nozzles may be used
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where high pressure and temperature steam, such as main steam.
b) Thermal sensor
For thermocouple inputs, the control system will provide reference junction
compensation and linearization for type K thermocouples as defined by IEC584
Standard. Thermocouples shall be with duplex elements.
Resistance Temperature Detector (RTD) will be of the three-wire type with 100-Ohm
platinum (Pt100) resistance elements. RTDs shall be with duplex elements.
c) Pressure gage
Pressure gauges are among the most often used instruments in a plant, and are used
to test pressure for water or steam and so on. Spring pipe is a key elastic sensor
element of pressure gage. The produce quality, percent of pass, accuracy and
working stability are greatly affected by its process quality.
d) Transmitter
Pressure and differential pressure transmitters will be of capacitance type, 2 wires,

and smart sensor. The transmitter will have oil filled bellows/diaphragm as measuring
element.
Differential pressure type will be provided complete with equalizing valve manifold.
Transmitters will have easily accessible span and zero adjustment facilities and the
accuracy will be less than +/-0.5% of span
All process transmitters will have LCD displays.
e) Process switch
Switches will provide safe and reliable electrical contract for alarm, interlocks and
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protection. Set point of the switches will be field adjustable or fixed as required by the
process.
Switch will act at the assigned point with accuracy within +/-0.5% of the adjustable
range, and will repeat to within 0.25% of the adjustable range.
f) Actuator
In general for regulating services pneumatic or electrical final control elements (valve
actuators/damper drives) will be used.
The command signal generated by the control system will be 4-20mA generally
corresponding with 0–100 % opening of the regulating services control elements.
For on-off and inching services electrical motorized actuators will be used.
Electrical motorized actuators will provide the following interface to the control system.
• Open/close/stop command signals shall be powered from the control system;
• Actuator is to include the appropriate interposing relays to accept open/close/stop

commands from the control system;
• Contacts in actuators are to provide (separately) at least the following status

feedback signals:
- Closed
- Opened
- Fault
- Remote/local
- In the case of inching valves: Actuator % position

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3.6.7 Power supply and air supply for I&C
3.6.7.1 Electrical power supply
a) General
Reliable DC and AC power supplies will be provided. For AC power supply, 480V AC
with three-phases, 120V AC with single-phase will be provided. DC power supply is
125V DC.
b) 480V AC power supply
480V AC power supply will provide power for motor driven valves, three phases motor
driven actuators and other three phases AC equipment.
In general, two loops of 480V AC power supplies from different phase of auxiliary low
voltage main bus will be supplied.
c) 120V AC normal power supply
The equipment, their power supply failure does not affect unit safe operation, will be
supplied with 230V AC normal power supply.
d) 120V AC UPS
The critical consumption, such as general power supply for I&C, DCS power supply
will be from two independent power sources, one from UPS, and another from
emergency diesel power supply. The equipment such as transmitters for DCS will be
fed from DCS power supply system.
e) 125V DC power supply
125V DC power supply is used for I&C protection system and the some control
equipment. Two loops of 125V DC from auxiliary 125V DC battery group will be

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provided for I&C control equipment.
3.6.7.2 Instrument air supply
Air supply air instrument and control will be special compressed air supply of dry,
clean, and oil-less, water-less, dust-less air. The pressure will be 3.5MPa. Air supply
for air tanks will be sufficient for the designed air consumption quantity for operation of
all pneumatic devices and will sustain supply for periods 10~15 minutes and longer
during the procedure for safe unit shutdown.
3.6.8 Cable channel for I&C
3.6.8.1 General
The main building cable channel layout will be four layers for the main cable channel, the
upper two layers are used for electrical cables, the lower two layers are used for power
cables for I&C. The cable channel design scope of I&C is that cable channels under the
floor of 12.6 of the turbine house and channels under the DCS/I&C cabinets room and
the central control room. The others design will be in the electric part and the main
manufacture. The connection to the other channels will be considered.
3.6.8.2 Fire fighting of the cable channel
Cable fire-proof block up material will be used where cables connect to the cabinets,
consoles, panels and junction boxes.
Cable fire-proof block up material will also be used in the holes where cable channels
pass the walls and the floors.
Fire-proof clapboard will be used around the junction of the cable channels.

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4 Plant Performance
4.1 General
A power plant, being a corporation, definitely concerns on the following indexes for a
purpose of higher profit and benefit.
- Efficiency
- Availability
- Reliability
- Productivity (Utilization)
All indexes mentioned above are related and affected for each other, therefore a
proper management including safety as a priority should be considered carefully in
order to make all activities in safe, proper and correct way to prevent any loss.
Regularly assessing and improving should be seriously regarded as an importance

way to solve the problems finding during actual implementation and target a higher
benefit.
Here comes to a typical distribution of costs over the life time, mainly operation &
maintenance occupies most proportion in the total costs.

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4.1.1 Operation
During the operations phase, the operator will perform all tasks necessary to operate
and maintain all units in accordance with an Operating Plan, approved procedures,
and prudent industry standards including:
Operations management:
- Schedules, shift routines, man loadings
- Plant operations and supervision
- Ongoing operations training
- Fuel management
- Plant chemistry control

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Quality administrative support and maintenance management systems are currently in

place at the plant and will continue to be used. These systems will be modified only
where necessary to incorporate Units. The existing operations management system
will be modified to incorporate the transition from operating Units. Details of the
operations management system are given below
Effective operations management will provide the planning, scheduling, and training
necessary for efficient and profitable operation of Units
Schedules, Shift Routines, Man loadings. Staffing plans for units are designed for
the ongoing operational and maintenance requirements of the facility. All periodic
testing, inspections and maintenance activities will be identified as well as those
operational and maintenance requirements that require specialized and extra
assistance at specific times during the maintenance cycle of the plant.
The staffing plan for Units includes a permanent staff that will be fully responsive to all
electrical and thermal load demands and will be responsible for the performance of all
preventive maintenance and routine repairs.
Associated technical and specialized vendor support will be subcontracted as needed

during planned outages, inspections, and overhauls
Plant Operations and Supervision. The operating plan will require the following:
Operate the facility in accordance with the operating plan, O&M manual, an approved
annual budget, and prudent industry standards.
- Perform and record periodic operational checks and test of equipment in accordance
with approved maintenance procedures, the equipment manufacturer’s specifications,
and applicable laws and regulations.
- Maintain operating logs, records, and reports for the facility.
- Coordinate scheduled shutdowns or other modifications in basic plant operations

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with expected dispatch.
Operation cost:
Following gives a typical operating cost in different parts, which is useful to operation
management for improvement.
Typical Operating Cost (%)
Cost category Typical Variations

10
0
Miscellaneous
Labour costs
Lube oil costs
Materials
Capital costs
Fuel costs
4.1.2 Maintenance
Maintenance management:
- Preventive maintenance
- Predictive maintenance
- Corrective maintenance

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- Outage management
- Spare parts inventory control
Maintenance
Corrective Preventive Predictive
Maintenance Maintenance Maintenance
Regular Scheduled Reliability

NDT
Inspection Maintenance centered
CM maintenance
manual ON-line Minor Major
Visual inspections Repair Overhaul

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Maintenance cost:
4.1.3 Administration
Administrative Support
- Administrative planning
- Computer systems and communications
- Budget and accounting controls
- Records management
- Plant safety program
- Plant security.
Quality administrative support and maintenance management systems are currently in

place at the plant and will continue to be used. These systems will be modified only
where necessary to incorporate units. The existing operations management system
will be modified to incorporate the transition from operating units. Details of the
operations management system are given below.
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Experience Effects Selection Methods Action
Small
Failure Cost Run to failure
consequence
analysis
Root Cause of Repair action

Failure
Fault history Time Which PM to ELDOC Regular PM

based use action
Cost history Periodic

relation Select CM
Condition
method
monitor
checks
Condition history Known
What FAKS On-line
fault measures diagnostics
CMM
S modes
Trouble
REMOTE On-line
Kind of assistance
EXPERT
shootin assistance
g
4.1.4 Safety
Safety as a priority is specially described in the figure below:
PPE Safety Meeting & Inspection
Personal Protective Equipment Permit to Work

Lock-out & Tag-out
Line Breaking
Safety Flags & Barricades
Job Hazard Analysis
Cutting & Welding
Safety First Aid
Confined Space
Performance Respiratory Protection
Electrical Safety Hot Work Hoists & Rigging Chemical Handling
Elements of Safety

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For more information, please go to chapter 5.
4.2 Efficiency
The importance of efficiency in reducing the unit cost of electricity can best be seen by
examining its relation to other factors affecting cost. What matters most to the utility
manager is the reduction of the total lifetime cost of the plant.
Definition
Where, GMC=gross maximum capacity

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PO=Planned outages hours
FO=Forced outages hours
FDF=Forced derating hours
PH=Period hours
4.3 Availability
This section discusses the expected facility availability, equipment redundancy, ability
to respond to varying utility needs for power, maintenance programs, fuel availability,
water availability, project quality control measures.
4.3.1 Facility availability
The Complex Plant will employ light diesel oil & heavy oil fuel diesel engines,
configured in a 1 on 1 combined cycle arrangement. Combined cycle generating
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plants of similar size have demonstrated operating equivalent availability factors

above 90 percent over several years.
Degradation in output from fouling and wear
All diesel engine degrade in output from their new and clean condition because of
fouling and wear. “Non-recoverable” degradation from equipment wear increases
rapidly in the first few thousand fired hours and then slows. Virtually all of the
degradation due to wear will be recovered during the major overhaul conducted at the
end of 6 years.
Summary of availability
All units of complex station are expected to provide high availability and be more
responsive to the needs of the system for power during periods of peak load. Outage
rates are expected to be low and scheduled outages will be planned for off-peak
periods.
4.3.2 Annual and lifetime capacity factors
The complex station will be operated as a merchant plant; as such, annual capacity
factors will vary based on market conditions (i.e., demand cycles and power
generation costs). An average annual capacity factor of 60-65 percent is generally
predicted over the 30-year projected lifetime of the facility.
Distributed control system
The distributed control system will be a redundant microprocessor-based system that

will provide control, monitoring, and alarm functions for plant systems and equipment.
The following functions will be provided
- Control the heat recovery steam generator and other systems in response to unit
load demands (the diesel engine has its own control system).
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- Provide control room operator interface.
- Monitor plant equipment and process parameters and provide this information to the
plant operators in a meaningful format.
- Provide visual and audible alarms for abnormal events based on field signals or
software-generated signals from plant systems, processes, or equipment.
- The DCS will have functionally distributed architecture comprised of a group of

similar redundant processing units linked to a group of operator consoles and an
engineering workstation by redundant data highways. Redundant processors will be
identically programmed to perform the specific tasks for control information, data
acquisition, annunciation, and historical purposes. Because of this redundancy, no
single processor failure can cause or prevent a unit trip. Experience with similar
systems has been that simultaneous malfunctions of two or more processors are very
infrequent. DCS failures that have occurred have almost always been in
communication between processors, or more importantly, between the DCS and the
controlled equipment
4.3.3 Fuel availability
The complex station currently receives light diesel oil & heavy oil from the oil storage
tanks.
4.3.4 Water availability
The dematerialized water & industrial water supply by phase I. Dematerialized water
supply for circulating cooling is the greatest water use constituting approximately 70
percent of the water usage. Most of industrial water is use to washing equipment.
4.3.5 Project quality assurance and control
This section summarizes the quality assurance and control program. The objective of
the quality control program is to ensure that all systems and components have the
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appropriate quality measures applied (during design, procurement, fabrication,

construction, and operation) to achieve facility safety, reliability, availability, operability,
constructability, and maintainability. System quality is ensured by applying controls to
various activities depending on the activity being performed. For example, the
appropriate controls for design work are checking and review, and the appropriate
controls for manufacturing and construction are inspection and testing. Appropriate
controls will be applied to each of the various activities for the project
1) Quality Assurance
For quality assurance planning purposes, the project activities have been divided into
nine stages that apply to specific periods of time during the project. As the project
progresses, the design, procurement, fabrication, erection, and checkout of each plant
system proceeds through these stages and the appropriate quality assurance controls
are administered.
The project stages are defined as follows:
- Conceptual Design – activities such as the definition of requirements and

engineering analyses.
- Detail Design – activities such as the preparation of calculations, drawings, and lists
needed to describe, illustrate, or define systems, structures, or components of the
power plant.
- Procurement Specification Preparation – activities necessary to compile and

document procurement specifications’ contractual, technical, and quality provisions for
plant systems, components, or services.
- Manufacturers’ Control and Surveillance – activities necessary to ensure that the

manufacturers conform to the procurement specification provisions.
- Manufacturer Data Review – activities required to review manufacturers’ drawings,

data, instructions, procedures, plans, and other documents to ensure coordination of

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plant systems and components and conformance to procurement specifications.
- Receipt Inspection – inspection and review of products during manufacture at the

time of delivery to the construction site.
- Construction/Installation – inspection and review of construction, storage, equipment

and component installation, cleaning, and initial testing of systems and components at
the plant site.
- System/Component Testing – documented controlled testing, commissioning and

operation of plant components in a system to ensure that the performance conforms
to specified requirements and all guarantees.
- Plant Operation – the actual operation of the plant system.
2) Quality Control Records
The following quality control records will be maintained as a minimum for review and
reference:
- Approved Environmental Permits
- Project Procedures Instruction Manual
- Design Calculations
- Project Design Manual
- Quality Assurance Audit Reports
- Piping and Instrument Diagrams
- Conformance to Construction Records Drawings
- Procurement Specifications (Contract Issue and Change Orders)
- Manufacturers’ Quality Assurance Program Manuals
- Construction Test Records
- Historical Operating and Maintenance Data.

Dept. Page:
O&M 113 / 124
For procured component purchase orders, a list of qualified suppliers is developed.

Before contracts are awarded, supplier capabilities are evaluated. The evaluation
considers the supplier’s personnel, production capability, past performance, and
quality assurance program.
Supplier quality assurance capabilities are reviewed with special consideration given
to the program description, implementation procedures, and the suppliers’ quality
performance history. Before contracts are awarded, the suppliers’ facilities may be
surveyed to verify that their quality assurance program is effective and applicable to
the materials, equipment, and services supplied.
Each procured component has adequate contractual requirements to ensure quality

assurance. During construction, field quality assurance activities are accomplished
during the last four stages of the project: receipt inspection, construction/installation,
system/component testing, and plant operations. Suppliers will be contractually
responsible for performing the work in accordance with the quality requirements
specified by contract. Quality compliance will be surveyed through inspection, audit,
and administration of independent testing contracts.
4.4 Reliability
Reliability is expressing that the preventive maintenance activities have been made in
a correct way
A low reliability will also indicate that there are improvements to be made on the
maintenance side, or that the purchased equipment is a low quality.
The importance of reliability
Reliability is every bit as important to the economic success of a plant as the capital
and operating expenditure (CAPEX and OPEX). The cost of electricity (COE) was
calculated for a base case (100%) and then sensitivities for the efficiency, the CAPEX
Dept. Page:
O&M 114 / 124
and the availability performed. The efficiency has been plotted as heat rate and the
availability as outage so that all plots have a positive slope.
4.5 Productivity (Utilization)
Utilization is expressing the amount of hours the engine totally has been in use over a
certain time period.
A low utilization degree can either indicate that the engine has been in stand-by
frequently or that the outage hours have been high.
5 Safety
5.1 Introduction
The present safety section is designed to provide safety recommendation information,

advice and guidance to the user.
The machine/plant has been built in accordance with state-of-the-art standards, the
latest recognized safety rules and the applicable regulations and standards quoted in
the contract. Nevertheless, its use may constitute a risk to life and limb of the user or
of third parties, or cause damage to the machine and to other material property.
The machine/plant must only be used in technically perfect condition in accordance

with its designated use and the instructions set out in the operating manual, and only
by safety-conscious persons who are fully aware of the risks involved in operating the
machine/plant. Any functional disorders, especially those affecting the safety of the
machine/plant, should therefore be rectified immediately.
In addition to the instructions mentioned in this document, maintenance staff must

respect security instructions mentioned in the operation & maintenance
documentation related to each piece of equipment, and also instructions in force in the

Dept. Page:
O&M 115 / 124
power station.
5.2 User Responsibilities
The instructions set out in this Manual assume that operators already have a general
understanding of the requirements for safe operation of mechanical and electrical
equipment in potentially hazardous environments involving liquid fuels at the site
concerned. These instructions therefore should be interpreted and applied in conjunction
with the safety rules and regulations applicable at the site and the particular
requirements for operation of other equipment at the site.
It is the user’s responsibility to supplement the operating instructions by instructions

covering the duties involved in supervising and notifying special organizational features,
such as job organization, working sequences or the personnel entrusted with the work.
It is the user’s responsibility to check - at least from time to time - whether the personnel
is carrying out the work in compliance with the operating instructions and paying
attention to risks and safety factors.
5.3 Operator Adequate Training & Skills
Any work on and with the machine/plant and equipment must be executed by trained,
instructed or authorized staff under the supervision of experienced persons.
Personnel entrusted with work on the machine must have read the operating
instructions and in particular the chapter on safety before beginning work. This applies
especially to persons working only occasionally on the machine, e. g. during setting up
or maintenance.
The equipment supplied is a complex set of machinery, which is intended for use only
by professionally trained operators. The owner/user should therefore ensure that all
operators are properly trained for the operation of the equipment assigned to them. All
Dept. Page:
O&M 116 / 124
operators and maintenance staff must have ready access to a copy of this Manual.
5.4 General Safety Instructions
Safety instructions before operation
The user should take into account different aspects before operating any equipment:
- Check that the signaling and lighting systems are fully functional.
- No works in progress on equipment, no work permit or access permit in progress.
- Fire detection and protection fully operational.
- Ensure that safety instructions and warnings attached to the machine are always
complete and perfectly legible.
- No alarm on the control cabinets.
During operation
During start-up and shut-down procedures always watch the indicators in accordance
with the operating instructions.
The operators should operate the machine only if all protective and safety-oriented
devices, such as removable safety devices, emergency shut-off equipment, sound
-proofing elements and exhausters, are in place and fully functional.
It is the user’s responsibility to check the machine/plant at least once per working shift
for obvious damage and defects and report any changes (incl. changes in the
machine’s working behavior) to the competent organization/person. In the event of
malfunctions, stop the machine/plant and lock it. Have any defects rectified
immediately.

Dept. Page:
O&M 117 / 124
The operators shall adhere to intervals specified in the operating instructions for
routine checks and inspections, and those prescribed by relevant regulation(s).
Maintenance & repair
Before beginning any operation or maintenance activities on a piece of equipment read

the relevant drawings and documents.
For the execution of maintenance work, use the appropriate tools.
Always tighten any screwed connections that have been loosened during maintenance
and repair.
Any safety devices removed for set-up, maintenance or repair purposes must be refitted
and checked immediately upon completion of the maintenance and repair work.
Coupling guards, fan guards or other devices protecting personnel contact with rotating
or moving parts that were removed for maintenance shall be reinstalled following the
maintenance activity to ensure adequate protection has been restored.
Never make any modifications, additions or conversions which might affect safety. This
also applies to the installation and adjustment of safety devices and valves.
After maintenance activities have been completed, residual oils, coolants and other
slippery material may still be present in the compartments and care should be taken to
eliminate such hazard.
Genuine parts
It is important that owners/users should only replace components with spare parts, which
are identical to the original or contain modifications. When ordering spare parts always
quote the model and serial number of the unit of equipment concerned.
Parts must comply with the technical requirements specified by the manufacturer and
Dept. Page:
O&M 118 / 124
conform to applicable statutory requirements.
Ensure that all consumables and replaced parts are disposed safely and with minimum
environmental impact.
Cleaning
Equipment shall permanently remain in clean state to allow easy detection of any
trace of fluid and safe access for personnel. Any defects found must be rectified
without delay in accordance with applicable regulations.
Keep all handles, steps, handrails, platforms, landings and ladders free from dirt,
snow and ice. Floors, platforms and other walkways should be kept free of oil, grease,
water, and other slippery materials. Stairways, aisles, exits, walkways and work areas
should be kept free of remains and other obstructions.
Lifting
Use only appropriate means of transport and lifting gears of adequate capacity.
To avoid the risks of accidents, individual parts and large assemblies being moved for
replacement purposes should be carefully attached to lifting tackle and secured. Use
only suitable and technically perfect lifting gear and suspension systems at adequate
lifting angle with appropriate lifting capacity. Never work or stand under suspended
loads.
The fastening of loads and the instructions of crane operators should be entrusted to
experienced persons only. The foreman giving the instructions must be within sight and
sound of the operator.
Drain all modules/skids before attempting to lift.

Dept. Page:
O&M 119 / 124
5.5 Access Permit & Work Permit
The end user shall ensure that site safe work practices integrate access permit and work
permit procedures. Permit to access inside enclosure or inside confined space as well
as permit to work both issued by the end user Safety Office is the only way to guaranty
the safety of the worker and the information link to the Operation Office.
Access permit is an expressed/authorized permitting to enter an enclosure or a confined

space of all personnel to perform data collection or similar activities. Access permit
guarantees safe access regarding explosive or flammable fluids, noise, asphyxiating,
CO2 release, low oxygen concentration, permanent communication link with a second
person stationed immediately outside.
Work permit is an expressed/authorized permitting to perform works on any system.

Work permit guarantees safe access on the relevant system at zero energy level. Zero
energy level means fluid system effectively locked out and drained out, control system
locked out, electrical supply system racked out and locked out and preventing
inadvertent release of stored or residual energy whether mechanical, electrical,
hydraulic, (spring, capacitor, automatic fire fighting). Lock out and tag out (LOTO) is a
process to support the work permit.
Safety precautions for personnel
Lock out/Tag out (LOTO) is a process of isolating or controlling or safeguarding any

machinery or source of hazardous energy that any operator/employee/user may
encounter while operating, maintaining, or re-commissioning of the machinery. Lock out
is the process where the isolating device, valve, breaker, main switch, are isolating the
corresponding circuit and locked with a single key locking device to make certain the
isolating device guarantees the safety of the workers during the whole length of the
worker’s activities. Tag out is the process of notifying all affected employees that a
machine or equipment is shut down and locked to perform servicing or maintenance.

Dept. Page:
O&M 120 / 124
Tagging is performed using appropriate tag attached to the locked equipment.
The work permit issued by the Safety Office to the worker lists, one by one, all the
activities performed to establish working safe condition. It is also a support to ensure the
equipment will operate safely and correctly after the worker has signed the document to
confirm end of work and returned it to the Safety Office.
5.6 Personal Protective Equipment
Personal Protective Equipment (PPE) is defined as “all equipment designed to be

worn or held by the worker to protect him against one or more hazards likely to
endanger his safety and health at work, and any addition or accessory designed to
meet this objective. This excludes normal working clothes, equipment for emergency
and rescue, PPE for military, police or other public order agencies, and equipment as
such”.
An employer, who requires employee/personnel to perform routine maintenance

and/or servicing on a machine, must provide employee safeguarding and PPE.
Various country specific regulatory documents require personal protective equipment

to be used when the risks cannot be avoided or sufficiently limited by technical means
of collective protection or by measures, methods or procedures of work organization.
All PPE should conform to the more stringent of either local or national safety
standards. The employer must enforce strict policies that should be followed by all
personnel at site. The PPE must be rated accordingly to the severity of the hazard and
must follow industry standards.
Typical PPE recommendations are:
Eyes: Protective eyewear (spectacles, goggles, X-ray goggles, etc.)
Head: Protective headwear (helmets, caps, etc.)

Dept. Page:
O&M 121 / 124
Feet: Protective footwear (safety boots, insulating shoes, ankle boots, etc.)
Clothing: Protective clothing of appropriate design to resist flame or high heat

exposure
Hands: Protective gloves of appropriate design to resist injury to hands
Ears: Hearing protection (earmuffs, ear plugs, etc.)
Fall: Fall protection equipment, safety harness, etc.
5.7 Management of Hazards
Main hazards are listed below to identify the risk and the relevant main precautions.
The objective is to prevent occurrence of hazards and minimize their consequences.
5.7.1 Hazard due to potentially explosive atmosphere
The hazardous areas are identified on the Hazardous Areas Layout. Any ignition
source is prohibited in this area during operation.
5.7.2 Hazard due to chemical substances
Chemical substances may be corrosive, flammable, toxic… Any chemical product

must be handled and used according to its Material Safety Data Sheet Chemical
products must be used and stored away from any source of heat and in ventilated
areas. Products and packing must be destroyed according to local environmental
regulations.
5.7.3 Hazards due to fire
Fire is mainly due to any combustible agent like lube oil or fuel oil spillage, in presence
of air and hot point. User shall maintain hot surfaces clean of flammable contaminants
Dept. Page:
O&M 122 / 124
at any time. Especially before carrying out any work generating spark or heat, ensure
this has been expressly authorized, clean the machine/plant and its surroundings from
dust and other flammable substances. Smoking shall be limited to smoking areas.
After a fire, it is the final user's responsibility to conduct a Root Cause Analysis and an
assessment by experts of the effects of the fire on any equipment and system
potentially affected by it. The assessment may lead to replacement and
re-commissioning before putting the affected equipment and systems back into
service.
5.7.4 Hazards due to hot surfaces
Hot surfaces could be provoked by heat transfer, ignition sources, fire, solar ray… Any
insulation and other safeguards on any hot surface such as piping, valves, casings,
should be reinstalled after completion of the maintenance activities to ensure
adequate protection has been restored.
5.7.5 Hazard due to pressurized equipment
Pressurized equipment may cause injury in case of leakage or burst. Always use the
equipment inside the limits for which it is designed.
Check pressure relief valves setting periodically following O&M instructions.
5.7.6 Hazard due to spillage
Spillage may cause soil pollution and injury (chemical injury, burn, fall…). Pressurized
connections may give way to high-pressure leaks that may not be visible or audible to
personnel.
Operators shall take proper precautions while performing their duties where high
pressure hazards may exist. They should frequently inspect for absence of leaks.

Dept. Page:
O&M 123 / 124
5.7.7 Hazard due to noise level
High noise level may cause hearing problem.
During operation, all acoustic enclosures doors must be kept closed.
The end user shall put warning sign in noisy area and provide personnel protection as
applicable by the local regulations.
5.7.8 Hazard due to electricity
Electricity presents four kinds of hazards: electrification, electrocution, burns, eye

injury (by UV rays from electrical sparks).
Access to energized system must be forbidden or restricted. Permit to work and LOTO
(Lock out / Tag out) are the best practices to guaranty safety. Only authorized person
shall have access to electrical areas. High voltage electrical lines and switch gears
induces large electrical field where access need to be strictly controlled.
5.7.9 Hazard due to work at height
Work at height may present hazards of fall, crushing, fracture...
Operator shall use adequate PPE (Personnel Protective Equipment)
For carrying out overhead assembly work, always use specially designed or otherwise
safety-oriented ladders and working platforms. Never use machine parts as a climbing
aid.
5.7.10 Hazard due to confined space
Confined space present hazards of asphyxia due to low oxygen concentration and/or
intoxication due to presence of toxic materials.

Dept. Page:
O&M 124 / 124
Best practice to guaranty safety is access permit associated with the relevant safety
precautions regarding explosive or flammable fluids, noise, asphyxiating, CO 2 release,
low oxygen concentration and permanent communication link with a second person
stationed immediately outside.

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O&M Harbin Huitong Electric Power Engineering Co., Ltd.

Ecuador Esmeraldas II Thermoelectricity Project General

Jiang Peng Zhou Shugang Tie Sijia

2014-01-01 Operation Regulation

Harbin Huitong Electric Power Engineering Co., Ltd

1 User’s Guide ................................................................................................................................ 3

Serial No.：HTP-ER-OM-A-0 R e v. 0 Issued Date:01/01/2014

This user’s guide is basically established to:

- describe the structure of O&M manual

- explain how to use this O&M manual

- establish the ways to find necessary information for management, operation,

1.2 Brief Description about O&M Structure

- Operation & maintenance Manual

- Systems & OEM (Original Equipment Manuals)

1.2.1 General introduction

- Plant Overall Description

- Basic introduction of main equipment and systems

Serial No.：HTP-ER-OM-A-0 R e v. 0 Issued Date:01/01/2014

1.2.2 Operation manual

In general, the operation manual covers the following content.

- Device and Settings

1.2.3 Maintenance manual

This section generally covers maintenance considerations, recommendations or

The following content could be found in this manual.

- General Maintenance description and procedures on main equipment

1.2.4 System & OEM

- OEM (original equipment manuals)

Serial No.：HTP-ER-OM-A-0 R e v. 0 Issued Date:01/01/2014

1.3 Outstanding Documents

- Civil & Erection

1.4 Instruct to Operation Staffs

1.4.1 Management of power plant

Regulations and recommendation are written in section 1 (general introduction),

Comparing with other kinds of plant, giving an example, as a method is also

1.4.2 Operation management & efficiency

Those documents are described in section 2 of Operation Manual

1.4.3 Operation staffs

The following information is supplied to operation staffs

Serial No.：HTP-ER-OM-A-0 R e v. 0 Issued Date:01/01/2014

- Routine Test recommendation in Operation Manual

- Recommended operation regulations necessary for Thermoelectricity plant in

- Useful settings including in Operation Manual

- System description in Systems & OEM

1.5 Instruct to Maintenance Staffs

1.5.1 Maintenance management & planning

Those documents are described in Maintenance Manual

1.5.2 Maintenance staffs

The following information is supplied to maintenance staffs

- Routine Test and periodic inspection recommendation in maintenance Manual

- Recommended maintenance procedures of main equipment in maintenance

- System description and instruction book in Systems & OEM

1.6 Instruct to Safety Staffs

Serial No.：HTP-ER-OM-A-0 R e v. 0 Issued Date:01/01/2014

Esmeraldas II Project 12×8MW Thermoelectricity units located in Ecuador, The

The project of Esmeraldas II Thermoelectricity power plant installs twelve sets of

Start compressed air is used for diesel engine start-stop.

2.2 Configuration of Combined Cycle Power Plant

 Twelve (12) identical HRSGs, HRSG is type of single-pressure, horizontal duct,

 Power and auxiliary transformers.

 Instrumentation and control system configured to enable operation from a

 Low voltage house service

 HT&LT cooling water system

 Nozzle cooling water system