Part 3 Power plant Volume I.pdf

Khabat Thermal Power Plant Units 1&2 and Bazyan 400kV Substation

EPC/TURNKEY BIDDING PACKAGE Bidding No. :

PART 3 Volume I Technical Specification for Power Plant

CONTENTS LIST OF ABBREVIATIONS VOLUME I 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

TECHNICAL SPECIFICATION

PROJECT DESCRIPTION PLANT DESIGN CRITERIA SCOPE OF WORK GENERAL REQUIREMENTS SITE DETAILS AND SAFETY REQUIREMENTS MECHANICAL PLANT AND SYSTEMS ELECTRICAL CONTROL, INSTRUMENTATION AND COMMUNICATIONS CIVIL WORKS QUALITY CONTROL, INSPECTION AND TESTING COMMISSIONING, START-UP AND TESTING

VOLUME II

SCHEDULES

A. B. C1. C2. C3. C4. D.

Site Particulars Dates of Despatch, Delivery to Site and Completion Manufacturers Guarantee Particulars Mechanical Schedules Electrical Schedules Control and Instrumentation Schedules Suppliers of Materials, Manufacturers, Places of Manufacture Testing and Inspection E. Drawings and Documentation F. Variations from Specification G1. General Tests and Inspections G2. Tests in Manufacturer’s Works G3. Site Tests H. List of Spare Parts and Consumables J. List of Special Tools and Equipment VOLUME III APPENDICES 1. PLOT PLAN 2. GENERAL ARRANGEMENT 3. SYSBOL & LEGEND 4. FLOW DIAGRAM 5. SINGLE LINE DIAGRAM 6. CONTROL SYSTEM CONFIGURATION DRAWING 7. BASIC PLANT OPERATION SCHEME ON PCS

(i)

LIST OF ABBREVIATIONS %

per cent

°C

degrees Celsius

A

ampere

ac

alternating current

AFFF

aqueous film forming foam

AGI

above ground installation

AGMA

American Gear Manufacturers Association

ANSI

American National Standards Institute

API

American Petroleum Institute

ASME

American Society of Mechanical Engineers

ASTM

American Society for Testing of Materials

AVR

automatic voltage regulator

AWS

American Welding Society

AWWA

American Water Works Association

barg

bar gauge

BCSA

British Construction Steelwork Association

BMS

Building Management System

BoP

balance of plant

BS

British Standards

C&I

control and instrumentation

C/H

(C/H ratio)

CCCW

closed circuit cooling water

CCGT

combined cycle gas turbine

CCR

central control room

CCTV

closed circuit television

CCW

closed cooling water

CD

compact disc

CD Rom

compact disc read-only memory

CEMS

continuous emissions monitoring system

CFD

Computational Fluid Dynamics

CO

carbon monoxide

CPU

central processor unit

Cr

chromium

CT

current transformer

( ii )

CV

flow coefficient

CV

curriculum vitae

CW

circulating water

dB

decibel

dB(A)

decibel (A weighted)

dc

direct current

DEH

digital electro-hydraulic

demin

demineralization

DFR

design flow rate

DGP

data gathering panels

DLT

digital linear type

EHV

extra high voltage

EMC

electromagnetic compatibility

EN

Euro Norme

EPA

Environment Public Authority

EPC

engineer, procure, construct

EPR

ethylene propylene rubber

EWS

engineer’s workstation

FAT

Factory Acceptance Test

FCAW

flux-cored arc welding

FD

Fire Department

FGD

flue gas desulphurization

FM GMAW

gas metal arc welding

GMT

Greenwich mean time

GPS

global positioning system

GRP

glass reinforced plastic

GSC

gland steam condenser

GT

gas turbine

GTAW

gas tungsten arc welding

H&S

health and safety

HAZID

hazard identification

HAZOP

hazard and operability

HCFC

single hydrochlorofluorocarbon compound

HEI

Heat Exchange Institute

HMI

human machine interface

( iii )

HP

high pressure

HRSG

heat recovery steam generator

HV

high voltage

HVAC

heating ventilation and air-conditioning

Hz

hertz

I/O

input/output

I/P

input

IBC

intermediate bulk containers

IBM

International Business Machines

IEC

International Electrotechnical Commission

IEEE

Institute of Electrical and Electronics Engineers

IP

intermediate pressure

IP

International Protection

IPB

isolated phase busbar

ISDN

integrated service digital network

ISO

International Standards Organisation

kg

kilogram

KKS

Kraftwerk Kennzeichen System

km

kilometre

kN

kiloNewtons

kV

kilovolt

kW

kilowatt

LAeq

equivalent steady sound level in dB (a) containing the same acoustic energy as the actual fluctuating sound level over a given period

LAN

local area network

lb

pound

LCV

lower calorific value

LP

low pressure

LSF

low smoke and fume

lub

lubrication

LV

low voltage

m

metre

m

metre

m/s

metres per second

m2

metres squared

( iv )

m3

metres cubed

mA

milliampere

mb

millibar

MCB

miniature circuit breaker

MCC

motor control centre

MCC

motor control centre

MCR

maximum continuous rating

MED

multiple effect distillation

mg

milligram

mg/l

milligram per litre

MI

mineral insulated

MIG

metal inert gas

mm

millimetre

mm2

millimetre squared

MMA

manual metal arc

MOV

Motor Operated Valve

MPI

Magnetic Particle Inspection

MSS

Manufacturers Standard Society

MTBF

mean time between failure

MTTR

mean time to repair

MV

medium voltage

MVA

megavolt ampere

MVAr

megavolt-ampere reactive

MVArh

megavolt-ampere hours

MW

megawatt

MWe

megawatts electrical

MWh

megawatt-hour

NB

nominal bore

NDE

non-destructive examination

NDT

non-destructive testing

NFPA

National Fire Protection Agency

Nm3

normal metres cubed

NOx

oxides of nitrogen

NPHR

net plant heat rate

NPO

net power output

NPSH

net positive suction head

(v)

O&M

operation and maintenance

O/P

output

O2

oxygen

OCGT

open cycle gas turbine

ONAF

oil natural air forced

ONAN

oil natural air natural

P&ID

piping and instrumentation diagram

PA

public address

PABX

private automatic branch exchange

PCS

plant control system

PD

Pressure Directive

pH

index of acid concentration

PLC

programmable logic controller

PN

nominal pressure

ppm

parts per million

PSS

power system stabilizer

PSTN

public switched telephone network

PTFE

polytetrafluoroethylene

PTZ

pan-tilt-zoom

PVC

polyvinyl chloride

QC

Quality Control

QCC

Quality Control Certificate

QCR

Quality Control Record

RH

relative humidity

rms

root mean square

rpm

revolutions per minute

RSO

recurrent surge oscillogram

RTD

resistance thermometer detector

SAW

submerged arc welding

SCADA

Supervisory Control and Data Acquisition

SF6

sulphur hexafluoride

SFC

static frequency converter

SMACNA

Sheet Metal and Air Conditioning Contractor National Association

SMAW

shielded metal arc welding

SO2

sulphur dioxide

( vi )

SOE

sequence of events

SPN

single phase neutral

ST

steam turbine

TEMA

Tubular Exchanger Manufacturers Association

TEWAC

totally enclosed water cooled

TIG

tungsten inert gas

TPN

three phase neutral

TV

television

UHF

ultra high frequency

ULSS

stainless steel

UPS

uninterruptible power supply

UV

ultra violet

V

volt

VCR

video cassette recorder

VDE

Verband Der Elektrotechnik Elektronik Informationstechnik e.V

VDU

visual display unit

VOC

volatile organic compounds

VT

voltage transformer

VWO

valve wide open

WB

World Bank

WHO

World Health Organization

WTP

water treatment plant

XLPE

cross linked polyethylene

( vii )

VOLUME I

TECHNICAL SPECIFICATIONI

1. PROJECT DESCRIPTION 1.1 1.2 1.3

General Site Description Target Project Start and Completion

2. PLANT DESIGN CRITERIA 2.1 2.2 2.3

General Unit Rating Site Layout

2.4

Plant Operating Philosophy 2.4.1 2.4.2 2.4.3 2.4.4

2.5 2.6

Seismic Design Performance Criteria 2.6.1 2.6.2

2.7

Condition of Service Site Conditions Fuel/Water Supplies Grid Conditions

Output and Heat rate Plant Start -Up

Environmental criteria 2.7.1 2.7.2 2.7.3 2.7.4 2.7.5

Noise Emissions to Air

Ambient Air Quality Aqueous Emissions Visual Impact

3. SCOPE OF WORK 3.1 3.2

Summary of Main Scope and Services Terminal Points 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7

Fuel Supplies Water Supplies Cooling Water System Electrical Connections Communications Drainage Security Fencing and Access Roads

(i)

4. GENERAL REQUIREMENTS 4.1

Project Management 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 4.1.7 4.1.8 4.1.9

4.2

Programs and Progress 4.2.1 4.2.2

4.3 4.4

Drawings Enclosed with the Specification Schedules Drawings and documents to be submitted by the Tender Drawings and documents to be submitted by the Bidder Drawings and document format Drawing sheet numbers Drawing and document revision Drawing and document status

Operating and maintenance instructions HAZOP studies Places of manufacture, testing and inspection Packing and marking on packages Training 4.9.1 4.9.2

4.10 4.11 4.12

Program Requirements Progress Reporting

Design and Standardization Drawings and Documents 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6 4.4.7 4.4.8

4.5 4.6 4.7 4.8 4.9

Overall Scope Organization Operation of Computer system for project management Project Management Plan Health, Safety and Environmental Management Plan Environmental Protection Project Quality Plan Training Plan for MOE personnel Project Control Procedures

General Content of training

Spare parts Special tools and lifting devices Warranty engineer

5. SITE DETAILS AND SAFETY REQUIREMENTS 5.1 5.2 5.3

Location of Site, access and use of Site Site facilities Site services during construction period 5.3.1 5.3.2 5.3.3

5.4

Site construction electricity supplies Water supplies Other services

Health and safety at work

( ii )

5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.4.7 5.4.8 5.4.9 5.4.10 5.4.11 5.4.12 5.4.13 5.4.14 5.4.15 5.4.16 5.4.17 5.4.18 5.4.19 6.

Risk assessment Specific risks produced by Bidder activities Documents Bidder 's safe systems of working Training Safety equipment Assistance to Owner Confined spaces Land owned by third parties Temporary electricity supply Fire precautions Compressed gases Access, fencing and safety barriers Site rules First aid and medical facilities Emergency evacuation of the Site Safety management Cranes, hoists, lifting equipment and scaffolds, etc Electrical safety conditions

MECHANICAL PLANT AND SYSTEMS 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15 6.16 6.17 6.18 6.19 6.20 6.21 6.22 6.23 6.24 6.25 6.26 6.27 6.28 6.29 6.30 6.31

Boiler and its accessories Fuel Supply and Storage System Electrostatic Precipitator Ash Handling System Turbine Generator and Accessaries Condensate System Feedwater System Main and Reheat System Feedwater Heater, Extraction , Drain and Vent System Auxiliary Steam System Closed Cooling Water System Circulating Water System Compressed Air System Water Supply and Treatment System Chemical Feed and Sampling System Auxiliary Boiler Diesel Generators Service Gas System Fire Protection and Detection System Crane and Lifting Equipment Laboratory Equipment Workshop and stores Equipment General Plant Requirements Painting and Protection against Corrosion Packing and marking on packages Flue gas Desulfurization system Waste water treatment system Sewage water treatment system Sump pump Piping Elevators

( iii )

7.

ELECTRICAL 7.1

General 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.1.6 7.1.7 7.1.8

7.2

Generators 7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6 7.2.7 7.2.8

7.3

Function Major components Design criteria

Transformers 7.6.1 7.6.2 7.6.3

7.7

Function Major components Design criteria

Generator circuit breaker 7.5.1 7.5.2 7.5.3

7.6

Rectifier Excitation transformer Control equipment Field suppression Connections Monitoring and protection

Generator main connections and neutral earthing 7.4.1 7.4.2 7.4.3

7.5

General Rating and capability Generator cooling Gas systems Demineralized water system Terminals Sliprings and brushgear Instrumentation and metering

Excitation system and equipment 7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6

7.4

Nominal voltage ratings Electrical equipment enclosure Control and selector switches Switchboards, panels and cubicles Indicating lamps and fittings Panel wiring and terminal boards Current transformers Voltage transformers

Function Major components Design criteria

Switchgear 7.7.1 7.7.2 7.7.3

Function Major components Design criteria

( iv )

7.8

DC supplies system 7.8.1 7.8.2 7.8.3

7.9

Uninterruptible power supply equipment 7.9.1 7.9.2 7.9.3

7.10

Function Major components Design criteria

Function Major components Design criteria

Electrical control system 7.10.1 General 7.10.2 Design criteria

7.11

Electrical protection 7.11.1 General 7.11.2 Design criteria

7.12

Synchronizing

7.13

Motors 7.13.1 General 7.13.2 Design criteria

7.14

Earthing and Lightning Protection 7.14.1 General 7.14.2 Design criteria

7.15

Cabling 7.15.1 7.15.2 7.15.3 7.15.4 7.15.5 7.15.6 7.15.7 7.15.8 7.15.9 7.15.10 7.15.11

General Medium voltage cables Low voltage cables Control and instrumentation cables Optical fiber cables Telephone cables High temperature cables Thermocouple and compensating cables Intrinsically safe cables Mineral insulated cables Cable installation

7.16

Cathodic Protection System

7.17

Variable speed drives

7.18

Electrical equipment for hazardous areas

(v)

8. CONTROL, INSTRUMENTATION AND COMMUNICATIONS 8.1

Introduction

8.2

Scope of supply

8.3

Objectives

8.4

Operational philosophy

8.5

Control and monitoring of plant 8.5.1 8.5.2 8.5.3 8.5.4

8.6

Steam generator Steam turbine Generator Auxiliary plant

Plant control system 8.6.1 8.6.2 8.6.3 8.6.4 8.6.5 8.6.6

General system design Operator’s facilities Engineer’s workstation System response times Spare capacity Software

8.7

Metering

8.8

Condition monitoring

8.9

Plant performance monitoring

8.10

Emissions monitoring

8.11

Station clock system

8.12

Load dispatch

8.13

Fire detection and alarm system

8.14

Gas detection system

8.15

Private automatic branch exchange (PABX)

8.16

Public address system (PA)

8.17

Closed circuit television, intruder detection and site access control Systems

8.18

Weather station

8.19

General requirements 8.19.1 Introduction 8.19.2 Environmental requirements 8.19.3 Hazardous areas

( vi )

8.19.4 8.19.5 8.19.6 8.19.7 8.19.8 8.19.9 8.19.10 8.19.11 8.19.12 8.19.13 8.19.14 8.19.15 8.19.16 8.19.17 8.19.18 8.19.19 8.19.20 8.19.21 8.19.22 8.19.23 8.19.24 8.19.25

Insulation and isolation Electromagnetic compatibility (EMC) Identification Installation Flow measurements Level measurements Pressure measurements Temperature measurements Position measurements Quality measurements Vibration measurements Control valves and actuators Motorized valves Manual valves Pneumatic actuators/positioners Cubicles and racks Testing Training Documentation Support tools and calibration equipment Spare parts Instrument and electrical test equipment

9. CIVIL WORKS 9.1

General requirements for civil works 9.1.1 9.1.2 9.1.3 9.1.4 9.1.5 9.1.6

9.2

The site specific data 9.2.1

9.3

General The Bidder’s enabling works Scope of main civil engineering and building works

Design of the works 9.4.1 9.4.2 9.4.3 9.4.4

9.5

General

Scope of civil engineering and building works 9.3.1 9.3.2 9.3.3

9.4

General Civil program and method statements Planning and building permits/approvals Site investigations Ground contamination Design and construction

General Preferred structural design concept Materials Civil design parameters

Specific building and architectural requirements 9.5.1 9.5.2

Cladding and decking Metal doors and frames

( vii )

9.5.3 9.5.4 9.5.5 9.5.6 9.5.7 9.5.8 9.5.9 9.5.10 9.5.11 9.5.12 9.6

Materials and workmanship 9.6.1 9.6.2 9.6.3 9.6.4 9.6.5 9.6.6 9.6.7 9.6.8 9.6.9 9.6.10 9.6.11 9.6.12 9.6.13 9.6.14 9.6.15 9.6.16 9.6.17 9.6.18 9.6.19

9.7

Scope of works Lighting systems Small power installation Distribution system Cables and wiring Lightning protection system

Mechanical building services 9.8.1 9.8.2 9.8.3 9.8.4 9.8.5

9.9 9.10 9.11

Codes and Standards Materials Certification of materials Storage of materials Construction plant and equipment Concrete Setting out and monitoring Earthworks Roads, hardstandings, car parks and paths Piling Structural steelwork Surface water drainage and buried pressure pipelines Building drainage Brickwork and blockwork Builder’s work Access Fencing Landscaping Laydown area

Electrical building services 9.7.1 9.7.2 9.7.3 9.7.4 9.7.5 9.7.6

9.8

Internal doors and frames Internal vision panels External walling Internal masonry walling Suspended ceilings Damp proofing Stairs Sanitary ware Finishes Flat roof waterproofing systems (if required)

Scope of works Design information Quality control Domestic hot and cold water services HVAC systems

Sub-bidders Functional requirements Record drawings

( viii )

10. QUALITY CONTROL, INSPECTION AND TESTING

10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8

General Extent of work Document submission Inspection notification and right of access Inspection and tests Non-conformances Quality control records, certificates and certificates of conformance Specific tests and inspections

11. COMMISSIONING, START-UP AND TESTING 11.1

General 11.1.1 Staffing

11.2

Pre-commissioning 11.2.1 11.2.2 11.2.3 11.2.4 11.2.5 11.2.6 11.2.7 11.2.8 11.2.9 11.2.10 11.2.11 11.2.12 11.2.13

11.3

Commissioning 11.3.1 11.3.2 11.3.3 11.3.4 11.3.5 11.3.6 11.3.7 11.3.8 11.3.9 11.3.10 11.3.11 11.3.12

11.4

Boiler Turbine Generator Condenser Control and instrumentation installation and pre-commissioning Turbine governing equipment Protective relaying Switchboards, cubicles, relay panels, marshalling boxes, enclosures and ancillary electrical equipment Low voltage switchgear Motors Electrical equipment for hazardous areas 1-30 kV XLPE cable and accessories Auxiliary multicore cables

Oil supply systems Boiler Generator Excitation system Generator main and neutral earthing connections Current transformers Voltage transformers Control and instrumentation installation and Commissioning Turbine governing equipment Turbine Pumps Site acceptance tests

Testing 11.4.1 11.4.2 11.4.3 11.4.4

Tests on completion Performance guarantee tests Reliability tests Environmental tests

( ix )

11.4.5 11.4.6 11.4.7 11.4.8 11.4.9 11.4.10

Reporting of test results Performance worse than guaranteed Rejection of plant Liquidated damages Taking over Defects after taking over

(x)

1

PROJECT DESCRIPTION

1.1

General This Specification is intended to assist the Bidder for the design, manufacture, delivery, off-loading at Site, erection, painting, setting to work, testing and attention to defects of the Khabat oil fired power plant units 1&2, to be located in Kurdistan region, which is 30km west of Erbil, Iraq. The station will be constructed on a turnkey basis and shall include all equipment, work and services in order to render the power plant fully complete and functional for safe, reliable and commercial operation under all conditions and respects.

1.2

Site Description The site is in a hilly area in the Khabat District, about 30km west of Erbil, 3.5km north of the village of Khabat, about 1.7km from the Great Zab River. Heavy and large equipment will be unloaded in harbor (if available) and transported through the national highway to site by trailer. Light weight equipment and construction materials can be unloaded on site by truck or trailer. In case that the bridge or underground facility on access way has insufficient strength to bear heavy load, it shall be reinforced for the protection of the existing facilities under Bidder’s responsibility. The Bidder shall be responsible for surveying all routes and obtaining any necessary permits to ensure that all equipment, particularly oversized and heavy loads, can be transported to their required destination.

1.3

Target Project Start and Completion The Works are expected to commence on April 16, 2010, and the plant shall be complete and ready for Operational Acceptance having successfully completed all the tests on completion as defined in Section 11 by December 31, 2012 for Unit 1 and April 30, 2013 for Unit 2.

1-1 KHABAT TPP UNITS 1&2 - VOLUME I

2

PLANT DESIGN CRITERIA

2.1

General This Specification requires a steam generation power plant design that is modern, well proven, safe, and economically attractive both in capital cost and running cost and offering a high availability with low forced outage rate. The plant shall be fully automated and require minimum operator intervention for normal operation. The Bid shall comply with the Specification unless compliance would for any reason put at risk safety, reliability and economy due to deviation from standard practice of the Bid. However, the intent of the Specification shall always be complied with. Any deviations from the Specification shall be clearly identified in Schedule [F], which shall be completed and returned as part of the Bid. The meaning of all terms is as defined in the [EPC Contract Document]. Equipment shall be designed and selected to ensure high reliability and availability of the complete plant with low forced outage rates and minimal maintenance over the lifetime of the power station, which shall be defined as 25 years. An appropriate level of redundancy shall be included in each system; the Works shall be designed so that no single auxiliary plant failure shall result in the total loss of the unit generating capability. In this context, it is required that with agreed exceptions, all unit auxiliaries will be provided with at least one installed spare (N+1). For the station auxiliaries, no single equipment failure shall result in any loss of station generating capability. Prototype plant will not be acceptable, and plant that is offered with limited operating experience must be fully supported by manufacturer’s warranties and indemnities.

2-1 KHABAT TPP UNITS 1&2 - VOLUME I

2.2

Plant performance guarantees The Bidder shall meet the followings plant performance guarantees associated with Khabat Thermal Power Plant.

2.2.1

Plant output and heat rate guarantees Description

Fuel oil Operation

Guaranteed Steam Generation Base load 150,000 < Net plant output [GNPO] (kW) Guaranteed Steam Generation Base Load Net plant heat rate [GNPHR] (kJ/kWh)

38% <

[based on LHV of the fuel] Net plant output is measured at the tariff meter on the HV side of the main transformers The net plant heat rate is defined as: mf [LHV15 + (tf − 15) *cp ] GNPHR = 3600 --------------------------kJ/kWh GNPO where

Description average specific heat capacity of fuel in the temperature range

Cp= 15°C to tf (kJ/kg°C) LHV15=

lower heating value of fuel at 15°C,

mf =

mass flow of fuel (kg/s)

tf =

fuel temperature at delivery point (°C)

2.3

Unit Rating

2.3.1

Maximum guaranteed rating (MGR) Maximum guaranteed rating is a maximum continuous rating guaranteed by the Bidder. The turbine generator shall be designed for an Net Plant Output 2-2 KHABAT TPP UNITS 1&2 - VOLUME I

no less than 150MW measured at the tariff meter, located on the HV side of the step up transformers. The MGR is based on the following condition ; A.

Generator terminal output, kW

[160,000]

2

B.

Main steam pressure, kg/cm gage

169

C.

Main steam temperature, ℃

538

D.

Reheat steam temperature, ℃

538

E.

Number of extraction stage

7

F.

Design Wet Bulb temperature, ℃

25

G. Approach temperature at cooling tower, ℃

[5]

H.

Circulating water temperature rise, ℃

[12]

I.

Exhaust Pressure, mmHgA

[81]

J.

Feedwater makeup, %

0.0

K.

Turbine speed

3,000

L.

Generator rated power factor, lagging

0.85

leading

0.95

M. Generator rated voltage, kV N.

[15]

Short circuit ratio

not less than 0.5

O. Excitation system response ratio * Note : [

2.3.2

not less than 1.0

] value shall be decided by Bidder.

Capability rating (CR) Capability rating is a continuous capable rating at the worst cycle condition. The turbine generator shall be designed for an output not less than that of MGR under the following conditions : A.

Design Wet Bulb temperature, ℃

30

B.

Feedwater makeup, %

3.0

Other conditions such as steam conditions, design wet bulb temp, etc. shall be the same as MGR conditions.

2-3 KHABAT TPP UNITS 1&2 - VOLUME I

2.3.3

Valve wide open (VWO) Valve Wide Open rating is a maximum continuous rating calculated with all steam control valves wide open. At the inlet, boundary conditions specified in paragraph 2.2.1, the turbine generator shall be designed for an output with no less than 105% main steam flow rate at MGR or no less than main steam flow rate at CR, which is bigger.

2.3.4

Boiler maximum continuous rating (BMCR) Boiler Maximum Continuous Rating is a maximum rating specified and guaranteed by Bidder. It shall be designed on the basis of main steam flow at HP turbine stop valve inlet at VWO plus auxiliary steam flow including minimum 20 % margin.

2.3.5

Maximum continuous rating with top heater out-of-service(MCR & THO) MCR & THO is a maximum continuous rating with top heater out-of-service. At the conditions specified in paragraph 2.2.2, the turbine shall be designed for continuous operation, with an output equal to that of Bidder's MGR at the generator terminals and top heater out of service.

2.4

Site Layout The Bidder shall provide a layout generally in accordance with the conceptual site layout provided in Volume 3, conversant with good operating practice, so that maintenance access is fully available to any part of the plant. The layout shall be based on an ‘outdoor’ type boiler installation. The site layout, including plant, buildings, roads, gates, laydown areas, etc. shall take into consideration the requirement for heavy vehicles and cranes required for installation and future maintenance of the plant to access to carry out the necessary work. The site layout shall be subject to approval of the KNOC.

2.5

Plant Operating Philosophy The Plant shall be designed for base load and two shifting operation. The intended operating regime for the immediate future will be base load, operating 8000 to 8150 hours per annum equating to a typical annual availability of 91 to 93 per cent. In addition, the plant shall also be capable of operating on a two-shift operating regime, based on one start per day. Plant normal start-up and shutdown will be initiated from the central control 2-4 KHABAT TPP UNITS 1&2 - VOLUME I

room. All the works shall be operated primarily from the PCS in the central control room. The plant shall be automated to reduce the manual intervention required by operations staff. The boilers shall be capable of start-up, shutdown and continuous operation on the fuels as defined in Schedule A, and each block shall have cold and hot start up capability and be able to operate either individually or in parallel with the other blocks. The plant shall be provided with a black start capability. 2.5.1

Condition of Service

2.5.1.1 Operation capability The Boiler and steam turbine-generator shall be capable of ; A.

Achieving the peak load of valve wide open rating at rated steam temperatures of 538℃/538℃(Turbine) and operate at this overload capacity without any time limitation when as required.

B.

Start up Time Light off~ Steam to turbine

Steam to Turbine ~ MGR

Cold Start Warm Start Hot Start C.

When supplied with steam at the temperature stated in the Contract, the load variations at a rate of minimum 10% of MGR per minute between 50% and 100% MGR, and at a rate of minimum 3% of MGR per minute between 30% and 50% MGR.

D.

Operating at no load. Any time limitation, if applicable, shall be stated by the Bidder.

E.

Accepting 10% MGR load step change within 10 seconds when the unit is operating in the load range of 50% to 100% MGR. After each occurrence of load step change, the turbine shall enter a stabilizing period for the power plant.

2.5.1.2 Normal operation The steam turbine-generator shall be designed to be operated as follows ; A.

Constant pressure operation

2-5 KHABAT TPP UNITS 1&2 - VOLUME I

The main steam pressure remains constant at the rated condition, through all of the operation range, while the load is controlled by either throttling main steam flow with the designed control valve(s). B.

Governor Regulating Operation Between 50% and 100% MGR, the load is regulated by governor within ±5% instantaneous load variation with response to the network frequency fluctuation.

2.5.1.3

Abnormal operation The steam turbine-generator shall be capable of uninterrupted continuous operation under the following conditions ; A. With circulating water shut off from one section of the condenser. B. When the circulating water flow to condenser is reduced to 1/2 normal flow due to pump limitations. C. With full load when one of high pressure feedwater heaters trips out of service. D. With one Air or Hydrogen cooler out of service at 80% rated capacity. E. At approximately full load with system frequencies between [48.5] and [51.5] Hz.

2.5.2

Site conditions Equipment shall be designed and installed to enable safe and flexible operation of the Works over the entire range of operating modes and conditions as defined in this Specification and shall operate safely and reliably over the full range of site ambient conditions listed in this Specification. The Bidder shall be responsible for sourcing all site meteorological data to facilitate the design of the plant, including such air sampling on site as is necessary to ensure the correct design of the boiler air intake filters.

2.5.3

Fuel/water supplies Indicative analyses of the fuel and water supplies to the plant are provided in Schedule A for information. However, the Bidder is responsible for obtaining sufficient data regarding the fuel/water supply conditions, including analyses as

necessary

for

his

design

of

fuel/water

treatment

plant

and

handling/storage facilities, in order to ensure that the required quantity and 2-6 KHABAT TPP UNITS 1&2 - VOLUME I

quality of fuel/water is supplied to the Plant. 2.5.4

Grid conditions The voltage variation on the transmission system will normally remain within the limits stated in Volume 2, Schedule A. The frequency of the transmission system will be nominally 50 Hz, and will normally be controlled within the limits stated in Volume 2, Schedule A. Each generation unit shall have, as a minimum, the following capabilities:




operate continuously maintaining its active power pro rata to transmission system frequencies within the range [48.5] Hz to [51.5] Hz;




remain synchronized to the transmission system at transmission system frequencies within the range [47.5] Hz to [52] Hz for a duration of [60] minutes;




remain synchronized to the transmission system at transmission system frequencies within the range [47] Hz to [47.5] Hz for a duration of [5] seconds required each time the Frequency is below 47.5 Hz;




remain synchronized to the transmission system during rate of change of transmission system frequency of values up to and including [0.5] Hz per second;




sustained operation at the specified minimum stable generation within the range [49.8] Hz to [51] Hz.

For requirements regarding the design of the generators, refer to Section 7.2. 2.6

Seismic Design Iraq is an area of relatively high seismicity and all plant items shall therefore be designed to resist seismic loads. This Project site should be considered to be UBC Zone 3. The United Nations Development Program provides a seismic design code of UBC 97, Zone 3.

2.7

Performance Criteria

2.7.1

Output and heat rate 2-7 KHABAT TPP UNITS 1&2 - VOLUME I

The Bidder shall guarantee the corrected net electrical power output (NPO) and corrected net plant heat rate (NPHR) at the base reference conditions as specified in Volume 2, Schedule [C, Part 1], based on the following definitions: Net electrical power output:

The net plant output is the total plant net

output measured at the tariff meter, located on the HV side of the step up transformers, net of all site auxiliary loads, and transformer losses, corrected to base reference conditions. Net plant heat rate: shall be based on the lower heating value of the fuel and corrected to the base reference conditions The Bidder shall also provide the undernoted curves necessary for correcting power output and specific heat rate from the test conditions to the guarantee base reference conditions in his bid:

2.7.2

A.

Variation in ambient temperature

B.

Variation in barometric pressure

C.

Variation in relative humidity

D.

Variation in fuel LCV and C/H ratio

E.

Variation in grid frequency

F.

Variation in steam temperature and pressure to turbine

Plant start up The Bidder shall guarantee and demonstrate the time for each block to reach full load, and for the steam generator to reach full load from cold, warm and hot starting conditions. Start up curves for the plant shall be provided in the Bid.

2.8

Environmental Criteria The plant shall conform as a minimum with the current World Bank guidelines, the requirements of the local environment authorities in Iraq and with all other relevant consents and regulations.

2-8 KHABAT TPP UNITS 1&2 - VOLUME I

2.8.1

Noise

2.8.1.1 General The facility shall be designed and constructed such that construction workers and operators are exposed to a minimum level of noise. The Bidder shall take appropriate steps to minimize noise exposure through equipment attenuation and procurement of inherently quieter equipment. All noise limits specified in this document are to be evaluated as LAeq levels. This is the energy weighted average of measured noise level as averaged over a specified time period. All sound levels are expressed in terms of decibels as referenced to a sound pressure level of 20 micropascals. The absolute limit of any measured sound pressure level anywhere in the work area shall not exceed 85 dB(A). In locations where it is necessary for operational attendants to make routine examinations closer than 1 m to an accessible part of a running machine which is between 80 and 85 dB(A), the KNOC will wish to adopt hearing protection aids. Therefore the Bidder is required to draw specific attention to portions of the plant where this situation may be encountered and fix appropriate warning labels or signs. Noise within buildings shall comply with the limits specified in Section 9 Civil. 2.8.1.2 Construction noise The maximum noise level caused by construction noise outside the nearest window of the nearest occupied house shall be: Daytime

70 dB(A)

Evening

60 dB(A)

Night

40 dB(A).

Noise levels at all time periods during public holidays shall not exceed 40 dB(A). Noise levels shall be limited to 80 dB(A) or lower at a distance of 1 m from all 2-9 KHABAT TPP UNITS 1&2 - VOLUME I

construction equipment and activities to the fullest extent feasible. If a noise level exceeding 85 dB(A) is likely to occur in any area, warning signs shall be predominantly displayed in that area, indicating that a noise hazard exists and hearing protection must be worn. Any area where noise levels could exceed 90 dB(A) shall have controlled access to prevent unprotected personnel from entering the areas. Peak or intermittent noises such as those resulting from pile driving shall occur during daytime periods only and maximum noise levels shall not exceed 70 dB(A) at the nearest inhabited dwelling. 2.8.1.3 Far field noise during operation The Bidder shall identify the location of the nearest residential, institutional or educational location and establish the background noise level. The noise level including background and contribution from the plant during operation shall either (a) raise background noise level by a maximum of not more than 3 dB(A) at the nearest receptor location off-site or (b) not exceed the following limits, consistent with the new updated version of the EHS Guidelines, replacing the Pollution Prevention and Abatement Handbook 1998: One Hour LAeq (dB(A)) Receptor Residential, institutional,

Daytime

Night time

(07:00 to 22:00)

(22:00 to 07:00)

55

45

70

70

educational Industrial, commercial

A noise test procedure shall be submitted by the Bidder, outlining the proposed method of noise testing, to demonstrate compliance with the stated environmental noise limits. The on-site and environmental noise levels shall be assessed by the Bidder in order to comply with the site requirements relating to noise emissions. The noise level shall not exceed 85dB(A) of overall sound pressure level at a distance of one(1) meter from each equipment. And the maximum noise level at the plant boundary shall be maintained below 65dB(A). Parts of the boilers and the steam turbines shall be enclosed in acoustic enclosures to ensure noise limits are achieved. The Bidder shall ensure that

2-10 KHABAT TPP UNITS 1&2 - VOLUME I

noise emissions are minimized, not only for steam generation plant, but also for the balance of plant equipment. 2.8.2

Emissions to air

2.8.2.1 Emissions during construction The Bidder shall ensure that suitable site practices are employed to ensure that atmospheric dust contamination generated by the construction works do not exceed levels which could constitute a health hazard or nuisance to those persons working on the site or living nearby. 2.8.2.2 Emissions during operation The World Bank has set emission limit for NOx, SO2 and particulate matter from boiler of thermal power plant in July 1998. On April 30, 2007, IFC published new updated versions of the EHS Guidelines, replacing those previously published in the Pollutant Prevention and Abatement Handbook 1998. According to the updated version of the EHS Guidelines for thermal power plants (December 19, 2008), the maximum emission limits for each pollutant of boiler using the liquid fuel are as follows. Parameter

Maximum value 400 mg/Nm3

Nitrogen oxides *

1,500 mg/Nm3

Sulfur dioxide *

50 mg/Nm3

Particulate matter

* The emission limits are referenced to 3% O2, dry flue gas. (Plant > 50MWth to < 600MWth) Continuous monitoring of NOx, SO2, CO, O2 and H2O to correct to dry flue gases shall be made from the main stacks of each boiler and displayed on the PCS. Any exceedances of limit values shall be alarmed. Sampling points and safe access adjacent to the monitoring points shall be included. Any natural gas vent stacks required shall be at a height sufficient to ensure that the concentration of gas at ground level is significantly less than the explosive limit. Emissions of volatile organic compounds from the fuel oil tanks shall be 2-11 KHABAT TPP UNITS 1&2 - VOLUME I

limited by installation of appropriate VOC removal plant, such as active carbon filters. 2.8.3

Ambient air quality The World Bank (WB) has set ambient air quality guidelines for nitrogen dioxide (NO2) and SO2. The guide values from the WB are set out below. World bank air quality guide values (micrograms/cubic meter) Parameter

Reference period

Recommended ground level concentration guide value

Nitrogen dioxide

Sulfur dioxide

Short term exposure (24 hour mean)

150

Long term exposure (annual average)

100

Short term exposure (24 hour mean)

150

Long term exposure (annual average)

80

The plant shall not lead to either the airshed dropping into the category of poor air quality or an increase of more than 5 mg/m3 in the annual mean level of particulates and/or SO2 for the entire airshed. For the purposes of bidding, the minimum height for the main stacks shall be considered as 130 meters, however the Bidder shall be responsible for suitable stack design of sufficient height, temperature and velocity to ensure that the above ambient air quality guidelines are not exceeded in combination with all other contributing sources in the vicinity of the proposed plant. The Bidder shall be responsible for the assessment of the existing background air quality through monitoring data, or where none is available through a modeling exercise. 2.8.4

Aqueous emissions The discharge of any effluents during construction, including site drainage, shall be the responsibility of the Bidder who shall reach agreement with the regulatory authorities and the local sewerage authorities with regard to the detailed methods of disposal. Operational aqueous emissions from the plant shall be treated and 2-12 KHABAT TPP UNITS 1&2 - VOLUME I

discharged in accordance with the following quality limits, consistent with the new updated version of the EHS Guidelines, replacing the Pollution Prevention and Abatement Handbook 1998: Effluent guidelines of waste water Parameter

Maximum, mg/l (except pH and temperature)

pH

6

to 9

COD *

20

TSS

50

Oil and grease

10

Total residual chlorine

0.2

Chromium

0.5

Copper

0.5

Iron

1.0

Zinc

1.0

Lead

0.5

Cadmium

0.1

Mercury

0.005

Arsenic

0.5

Temperature increase at the edge of

3°C

the mixing zone * Not included in the EHS Guidelines Effluent guidelines of sewage water Parameter

Maximum, mg/l (except pH and total coliform bacteria)

pH

6 to 9

BOD

30

COD

125

Total nitrogen

10

Total phosphorus

2

Oil and grease

10

TSS

50

Total coliform bacteria

400 MPN/100ml

2-13 KHABAT TPP UNITS 1&2 - VOLUME I

Aqueous discharges shall be segregated into storm drains, process effluent and domestic sewage streams. Each shall be provided with an appropriate monitoring and treatment system to ensure that the discharge limits are not exceeded. The waste water originating from the power plant shall be treated by waste water treatment facility before discharge to the river. The water treated with physical and chemical method shall be suitable for the conditions of the effluent guidelines. Any areas of the plant that may be subject to oil spillage shall be drained to an oil interceptor and the clean water discharged with the surface water drainage system. A sewage treatment facility shall be installed for the operational phase, sized for the number of operating and maintenance personnel. All fuel oil lubricating storage tanks and chemical storage tanks shall be bunded to contain 110 per cent of the contents of the largest tank. 2.8.5

Visual impact All reasonable measures shall be taken to minimize visual impact of the plant. Structures and buildings shall meet the standards generally accepted for a facility of this type and shall be in accordance with all applicable local and national consents relating to appearance. Final architectural arrangements shall be submitted for approval to the KNOC.

2-14 KHABAT TPP UNITS 1&2 - VOLUME I

3

SCOPE OF WORK

3.1

Summary of Main Scope and Services This Contract provides for the design, manufacture, construction, supply, testing in works, packaging for export, shipping, transport, delivery to Site, unloading at Site, complete erection, health and safety management, painting, commissioning and putting into operation, performance and reliability testing on completion, instruction of the KNOC’s personnel and obligations for the defects liability period of the steam generation power plant. The station shall be constructed on a full design and build, turnkey basis, and it will be the responsibility of the Bidder to ensure that all equipment, scope of work and services are provided in order to render the power plant fully complete and functional for safe, reliable and commercial operation under all conditions and respects. All material, plant and equipment shall be new and fit for the purposes of a steam generation power station. Equipment shall be selected to ensure high reliability and availability of the complete plant with low forced outage rates and minimal maintenance. Permanent, safe access to all items of plant as necessary shall be provided for inspection, operation and maintenance activities. Unless specifically excluded from the scope of work, interconnecting cabling, pipework etc between items of equipment and plant described in this specification shall all be included under this contract, as shall the installation, testing and commissioning of the same. The quantity of equipment shall be based on one (1) unit unless otherwise specified as a common facility. All necessary auxiliary equipment and systems including, but not limited to, the following: Generally, the main supply will include but not be limited to the following (refer to specific sections for further details):

3-1 KHABAT TPP UNITS 1&2 - VOLUME I

3.2

Mechanical Plant and Systems

3.2.1

Boiler and its accessaries A.

Boiler proper and accessories

1) Furnace 2) Drum 3) Superheater 4) Reheater 5) Economizer 6) Structural steels 7) The following boiler proper accessories as required ; a) Attemperators b) Soot blowing system c) Two(2) long retractable furnace thermocouple probe assemblies including cooling system complete with electric operators and position transmitters d) Safety valves and power relief valves including one(1) set hydraulic jack with discharge pipe, common silencer, start-up vent with silencer. e) Refractories and brick. f) Casing. g) Buckstay, lugs and clevises and hanger rods. h) Blowdown tank and/or flash tank, miscellaneous tanks. i) HP bypass system and its attemperator system. j) All drain and vent piping. k) Connections for the required blanking off, hydrostatic testing and chemical cleaning including nozzles, double valves and caps. l) Required

thermocouples

for

monitoring

drum/tube

metal

temperatures brought out to, and including a common junction box covering steam drum, superheater and reheater tubes. m) Required measuring device for monitoring the thermal stress and life expenditure of superheater header, reheater header and other boiler pressure parts. n) Necessary furnace observation ports and/or access ports and/or doors for good direct viewing of all the fires, furnace interior, soot

3-2 KHABAT TPP UNITS 1&2 - VOLUME I

blowing, superheater and reheater, and economizer area and ducting, as well as access as required. o) Remote furnace flame and stack smoke monitoring system including cameras, color monitors and all accessories. p) Drum level monitoring system including electronic level indicators, level and pressure transmitters. B.

Draft system

1) Forced draft fans with inlet silencers and drivers. 2) Combined Induced draft fans and drivers. 3) Gas recirculation fans and drivers, if required. 4) Scanner cooling air fans and drivers. 5) Sealing air fans and drivers. 6) Regenerative air preheaters and drivers. 7) Steam coil air heaters, drain tank with accessories. 8) Required air and gas ducts complete with expansion joints, dampers and

actuators,

all

necessary

auxiliaries

and

associated

instrumentation and controls C.

Fuel burning system

1) Fuel oil burning system with accessories 2) Fuel oil burner atomizing steam system with accessories 3) Light oil burning system with accessories D.

Fuel oil supply system

1) In-line service tank suction heater, heavy oil heaters with accessories. 2) Fuel oil supply system including fuel oil burning pumps and motors, flow meter and integrator, accumulator, all required piping, valves and instrumentation. 3) Fuel oil return pipings including flow meter and integrator, all required valves. 4) Light oil supply system including light oil burning pumps and motors, flow meter and integrator, all required piping, valves, actuators and instrumentation. E.

The following miscellaneous items ;

1) All required thermal insulation and lagging materials. 2) Complete lubricating oil system and cooling water system, as required.

3-3 KHABAT TPP UNITS 1&2 - VOLUME I

3) Set of connections, orifice flanges, and all other items, required for the ASME Performance Test. F. 3.2.2

Instrumentation and controls

Fuel oil system Fuel oil supply system shall consist of the following equipment as a common facility for 2 units.

3.2.2.1

Fuel oil supply system A.

Fuel oil booster pumps and motors

B.

Fuel oil service pumps complete and motors

C.

Clean fuel oil sump pumps and motors

D.

Fuel oil storage tanks with its accessaries

E.

Fuel oil emergency storage tank with its accessaries

F.

Fuel oil in-line suction heaters, fuel oil heaters and fuel oil emergency inline suction heaters

G. Heating coil for fuel oil storage tanks and fuel oil emergency tank H.

Filtering systems

I.

Fuel oil supply system including heat tracing, flow meter and integrator, accumulator, all required piping, valves, drains, vents, fittings, and instrumentation etc.

3.2.2.2 Light oil supply system A.

Oil service pumps complete and motors

B.

Light oil storage tank with its accessaries

C.

Flow meter and integrator, all required piping, valves, actuators and instrumentation

3.2.2.3 Steam converter system A.

Steam converter with accessories

B.

Fuel oil heater converter feed tank with accessories

C.

Steam converter feed pumps and motors

D.

Drain receiver tank with accessories

E.

Drain cooler with accessories

F.

Blowdown tank with accessories

G. Steam converter system including all necessary piping, valves and instrumentations

3-4 KHABAT TPP UNITS 1&2 - VOLUME I

3.2.3

Electrostatic precipitator including A.

All mechanical equipment, structural components and accessories

1) Ash hoppers with vibrators and heaters on each hopper, and exterior siding for hopper area enclosure. 2) Precipitator roof including penthouse and handrail around entire precipitator roof. 3) Gas distribution plates or equivalent at the inlet and outlet sides of precipitator. 4) Collecting electrodes and discharge electrodes. 5) Automatic rapping system for collecting and discharge electrodes and for the gas inlet and the outlet distribution devices. 6) Permanent washing system including chemical(NaOH) tank, pumps, nozzles, pipe for drain between precipitator hopper and air lock valve, drain piping, gate valves and fitting, blinded dummy pipe, supports, expansion joints, spectacle flanges, gaskets, bolts, nuts, instruments and controls, etc. 7) Gas flow control devices in the upstream duct of EP inlet nozzle. 8) Access and inspection doors to precipitator shell, hoppers and top housing, hoisting facilities for maintenance on the roof, and access platforms, walkways, handrails, stairs and ladders 9) Support structures for all equipment, platforms, stairs, walkways and enclosure including bottom enclosure. 10) Access platforms and stairways for level switch, aeration pad and vibrator of hopper and air lock valve. B.

Complete set of electrical, instrumentation and control apparatus and control devices.

C.

The following miscellaneous items ;

1) Piping, valves, fittings and pipe support. 2) Drain pipe and gutter for roof drainage. 3) All flanges, gaskets, bolts and nuts including counter flanges for flanged connections. 4) Thermal insulation and lagging. 5) Hoisting facility to handle the equipment from EP roof to ground. 6) Instruments and test connections for conducting performance tests. 7) Dust concentration monitoring system.

3-5 KHABAT TPP UNITS 1&2 - VOLUME I

3.2.4

Ash handling system A.

The following ash transport system and accessories ;

1) Transport piping 2) Air intake valves 3) Ash intake valves 4) Line select valves 5) Unit select valves 6) Steam air heaters 7) Seal air fan and drivers 8) Electric heater for seal air fan 9) Non-return valves 10) Hot air select valves B.

The following vacuum system and accessories ;

1) Vacuum pumps with drivers, air-water separators, etc for 2 units. 2) Vacuum breakers. 3) Vacuum transmitters. C.

The following ash storage silo and accessories for 2units common facilities.

1) Ash storage silo. 2) Aeration air steam heaters. 3) Cyclone separators with air lock valves(upper and lower),

equalizing

valves, etc. 4) Pulse-jet bag filters with air lock valves(upper and lower), equalizing valves, etc. 5) Dust hopper with valves(upper and lower), equalizing valves, etc. D.

The following ash discharge devices and accessories for 2units common facilities ;

1) Dry unloaders. 2) Outlet hopper with gate dampers. 3) Rotary unloaders/table feeders. 4) Dustless unloaders. E.

Complete set of electrical equipment including related control equipment and accessories.

F.

All heaters, instruments and accessories.

G. All Instrumentation and controls

3-6 KHABAT TPP UNITS 1&2 - VOLUME I

3.2.5

Steam turbine/generator and auxiliaries A.

Tandem compound, single reheat, two(2) flow, regenerating and condensing steam turbine.

B.

The following turbine accessories:

1) Control and protective valve systems including main steam stop valves, reheat stop and intercept valves, and steam control valves. All actuators for these valves shall be supplied. 2) Gland steam sealing system including GSC. 3) Exhaust hood spray system. 4) Complete lubricating oil system including purification, storage and transfer, and fire protection. 5) Complete hydraulic and control oil system. 6) Rotor turning gear with manual and automatic engagement, complete with lubrication system and controls. 7) LP bypass system and devices for turbine startup and protection. 8) Complete prewarming system including piping and valve, if required by design. 9) Protective devices such as exhaust casing relief diaphragms, vacuum breaker, low vacuum alarm switches and transmitter, low oil pressure switches for alarm and trip, thrust bearing wear detector, exhaust hood alarm thermostat, and dump valve (blowdown valve). C.

The following miscellaneous items:

1) Piping and valves including power operated valves, safety valves and relief valves, root valves for instruments, motorized and control valves hangers and supports for all the systems. 2) HP turbine exhaust non-return valves. 3) Set of connections, orifice flanges, and all other items, required for the ASME Performance Test. 4) All pumps required for equipment. 5) A portable lube oil centrifuge (one common to four(4) units) 6) H2 and CO2 gas bottles, bottles rack and manifolds including connecting tube between manifolds and bottles 7) Drain and vent pipe relation with steam seal including connection with condenser for dump drain and lube oil system. 8) Special thermal insulation and lagging materials for turbine. 9) Embedded material (Fixators) 3-7 KHABAT TPP UNITS 1&2 - VOLUME I

10) Electro-hydraulic control oil for flushing until complete commissioning, initial fill, and two(2) years operation. 11) Lubricating oil and seal oil for flushing until complete commissioning, initial fill. 12) Strainer for EHC and lube oil flushing during commissioning. 13) Steam blowdown cover plate for MSV, CRV and HP turbine exhaust non-return valves. 14) Servo Motor mechanism 15) Special welding rods 3.2.6

Condensate system A.

Single shell type condensers

B.

Condensate pumps and motors

C.

Condenser vacuum pumps and motors, heat exchangers

D.

Heaters 1) Low pressure feedwater heaters (No. 1, 2, 3) and external drain cooler for heater No 1 2) The following miscellaneous items : a)

All heater supports including support rails

b)

Tube and shell side safety relief valves, and orifices, as specified herein.

c)

Orifices including gaskets, bolts and nuts, both flanges for pipe line.

d)

A sufficient number of plugs for each tube material and tube size furnished for unit as specified herein.

e)

All valves, level gauges, temperature and pressure instruments, thermowells including heater isolation MOV's

f)

Connections

for

gauge

glasses,

level

and

pressure

instrumentation, and for vents, drains, as required 3) Platform and stairway for the heaters(No. 1, 2, 3 feedwater heater) for inspection and operation 4) Two(2) test samples of tubing of each material, size and thickness supplied. Test pieces shall be 2m in length E.

Stand pipes for the drain of the HP/LP heater relief valves

F.

All associated piping, valves, instrumentation and controls between condenser and inlet deaerator, demi & condensate storage tank, makeup water line to miscellaneous systems, minimum flow recirculation line, condensate rejection line, deaerator level control. 3-8 KHABAT TPP UNITS 1&2 - VOLUME I

3.2.7

Feed water system A. Deaerator and accessories 1) Deaerator including vent condenser with internal spray distribution system and tray banks. 2) Horizontal feedwater storage tank. 3) Connecting downcomers and pressure equalizing pipe between deaerator and feedwater storage tank. 4) Deaerator/feedwater storage tank unit supports. 5) The following miscellaneous items: a) Safety relief valves and orifices b) Feedwater storage tank section with a vortex breaker c) Necessary manholes and access doors d) Pressure relief doors in the tray enclosure e) Platform and stairways around on deaerators/feedwater storage tanks necessary for operation, inspection, maintenance and access f)

Screen for pump suction

g) Deaerator pressure control valves and level control valves B. Boiler feed water pumps 1) Horizontal, centrifugal, double suction, barrel type boiler feed pumps with electric motors and completed with the following accessories: a) Complete Lube oil systems for each boiler feed pump and motor drive b) Shaft seals with complete external and internal cooling water system for each boiler feed water pump c) Vibration monitoring devices for each boiler feed water pump and motors d) Balance drum leak-off water system including pipe work and the relevant gauges e) Warm-up system including flow restriction orifices, piping and temperature measurements with terminal boxes(E-type, dual) f) Cone type flow measuring elements with all accessories, including root valves for each pump. The services of these elements are minimum flow control, pump protection and feedwater flow control g) Temperature detectors for the each boiler feed pumps and motor drives h) Flexible couplings and coupling guards i) Suction basket strainers including fine elements for start-up, coarse 3-9 KHABAT TPP UNITS 1&2 - VOLUME I

elements for normal operation, pressure differential indicating switches and five(5) way valve manifold for startup and normal operation. A five(5) way valve manifold shall be installed between the sensing lines and PDIT 2) The following miscellaneous items : a) Barrel blanking off plates b) Suction and discharge pressure gauges including root valves, pipes, etc c) Redundant pressure transmitters for pump discharge d) Complete reverse rotation detecting system with sensors and signal condition devices e) Instrumentation for boiler feed water pump C. HP Feedwater Heaters and accessories 1) Complete, 100% capacity, U-tube, high pressure, horizontal closed feedwater heaters with integral drain cooling zone and desuperheating zone for each No. 5, 6, 7 HP feedwater heater. 2) The following miscellaneous items : a)

All heater supports including support rails

b)

Tube and shell side safety relief valves, and orifices, as specified herein

c)

Orifices including gaskets, bolts and nuts, both flanges for pipe line

d)

A sufficient number of plugs for each tube material and tube size furnished for unit as specified herein

e)

All valves, level gauges, temperature and pressure instruments, thermowells including heater isolation MOV's

f)

Connections

for

gauge

glasses,

level

and

pressure

instrumentation, and for vents, drains, as required 3) Platform and stairway for the heaters(No. 5, 6, 7 feedwater heater) for inspection and operation 4) Two(2) test samples of tubing of each material, size and thickness supplied. Test pieces shall be 2m in length D. BFP minimum flow control valves and accessories E. Boiler feedwater control valves and accessories F. Instrumentation and controls for feedwater system G. All required complete piping and valves including hangers, supports for feedwater system 3-10 KHABAT TPP UNITS 1&2 - VOLUME I

3.2.8

Main and reheat system A.

Main and reheat steam system is composed with piping and accessories. The main steam system is from the steam generator superheater outlet to the turbine-generator main stop valves. The cold reheat steam system is from turbine exhaust steam to the steam generator reheater inlet. The hot reheat steam system is from the steam generator reheater outlet to the turbine-generator combined reheat valves.

B. The following miscellaneous items : 1) Dump drain and vent Automatic valves for operating and maintenance 2) Pressure and temperature instrument such as transmitter, thermowells, thermocouple 3) Blind flanges, special flanges, blanks and spacers for hydrostatic testing, cleaning and system flushing 4) PQR material for field welding 5) Access holes, half couplings and plugs for radiographic inspection of pipe field welds 3.2.9

Feedwater heater extraction, drain and vent system A. MOVs for extraction line B. One(1) non-return valve for each extraction heaters and two(2) non-return valve for deaerator C. Heater cascading and dump drain control valves D. Safety relief valves and blow off stand pipe for the drain of the HP/LP heater relief valves E. Pressure and temperature instruments such as transmitters, thermowells, thermocouples F. Automatized drain valve & piping for exdtraction line G. Instrumentation and controls H. All required complete piping and valves including hangers, supports for feedwater heater extraction, drain and vent system

3-11 KHABAT TPP UNITS 1&2 - VOLUME I

3.2.10

Auxiliary steam system A. Auxiliary steam headers B. Control valves and desuperheaters for Auxiliary steam C. Instrumentation and controsl

3.2.11

Closed cooling water system A. CCW heat exchangers B. CCW pumps and motors C. CCW header tank with its related pipe work, valves and fill water connection. D. Chemical pot feeders complete with inlet and outlet isolation valves, drain valve, vent valve and charging valve E. Instrumentation and controls F. CCW Sampling system

3.2.12

Circulating water system A. Circulating water pumps B. Cooling tower including blowdown system C. Circulating cooling water pumps D. CW sampling systems E. Condenser tube cleaning system F. All associated piping and valves G. Instrument and cntrols

3.2.13

Compressed air system A. Instrument air system B. Service air system C. Air compressors including intercoolers, aftercoolers, filters, sand seperators. etc D. Capacity Air dryers E. Instument air receivers and service air receivers 3-12 KHABAT TPP UNITS 1&2 - VOLUME I

3.2.14

Water treatment system The following raw water supply system shall consist of the following equipment as a common facilities for 2 units A. Raw supply system and accessories 1) Raw water pumps 2) One(1) 100% Raw water storage tank 3) Intake equipment a) Travelling screen b) Stop gate c) Trash rake d) Screen wash pumps 4) All associated piping, valves, instrumentation and controls B. Raw water system and accessories 1) Cooling tower make-up pumps 2) Raw water transfer pumps 3) Clarifier and agitator 4) Sludge transfer pumps 5) Gravity filters 6) Filter backwash pumps 7) Demi. water supply pumps 8) All internal facilities of clarifier 9) Chemical feed system a) Alum dissolving tank and agitator b) Alum feed tank c) Alum feed pumps d) Caustic mixing tank and agitator with electric heater e) Caustic feed pumps f)

Alum aid dissolving tank and agitator with electric heater

g) Alum aid feed tank h) Alum aid feed pumps C. The following potable water and service water systems and accessories: 1) Potable water pumps 2) Service water pumps 3) Potable water Hydropneumatic water tank 3-13 KHABAT TPP UNITS 1&2 - VOLUME I

4) Service water Hydropneumatic water tank 5) Sodium hypochlorite feed tank and agitator 6) Sodium hypochlorite feed pumps 7) Activated carbon filters for potable 8) Integrating flow meter D. The following makeup demineralizer systems and accessories: 1) Activated carbon filters 2) Cation exchangers 3) Degasifiers, air blowers and silencers 4) Degasified water transfer pumps 5) Anion exchangers 6) Mixed bed ion exchangers 7) Resin traps 8) Regeneration systems a) Acid day tank with visual indication of tank liquid level and acid injection pumps b) Caustic day tank with visual indication of tank liquid level and caustic injection pumps c) Gas scrubber and mixing tees d) Caustic and acid bulk storage tanks with visual indication of tank liquid level e) Caustic unloading & transfer pumps f)

Acid unloading & transfer pumps

g) Regeneration water pumps h) Steam water Heater i)

Electric heaters for caustic storage tanks and day tank

j)

Steam traps

E. The following demi. water transfer system and accessories 1) Demi. water make-up pump for 1 unit 2) Demi. water storage tank for 1 unit F. The following FGD make-up water system and accessories G. The followings shall be included in 1) Connections for sampling 2) Design and supply of piping, valves, fittings and pipe supports 3-14 KHABAT TPP UNITS 1&2 - VOLUME I

3) All piping for acid and caustic unloading and transfer 4) Design and supply of support accessories such as sole plates, sub-sole plates, shims, wedges, foundation anchor bolts and nuts 5) Initial charge of media and chemicals for all filters, exchangers and chemical tanks 6) All flanges, gaskets, bolts and nuts including counter flanges for flange connections. 7) Safety showers and eye washers. 8) Instrumentations and controls. 9) Steps, platforms, ladders or stairs for monitoring and maintenance. 10) Lube oil and/or grease for initial charge of rotating elements. 11) All control components such as current to pneumatic converters, air regulators with filters and gauges, impulse piping and fitting, air tubing and bulkheads, instrument box, tube raceway, etc., all instrument installation materials as required 3.2.15

Chemical feed and sampling system A. The following hydrazine injection system and accessories for main system 1) High density hydrazine tank 2) Low density hydrazine tank 3) Hydrazine feed pumps 4) Graduated gauge glass 5) Agitator and low level switch for each tank 6) Hydrazine metering cylinder 7) Air operated dispensing pump B. The following aqua-ammonia injection system and accessories for main system 1) Ammonia feed pumps 2) Ammonia tank 3) Fume scrubber for each tank 4) Graduated gauge glass 5) Agitator and low level switch for ammonia tank 6) Concentrated ammonia metering cylinder 7) Air operated dispensing pump C. The following phosphate injection system and accessories for main system 1) Phosphate tanks with basket strainer 2) Phosphate feed pumps 3-15 KHABAT TPP UNITS 1&2 - VOLUME I

3) Graduated gauge glass for each tank 4) Agitator and low level switch for each tank D. The following sulfuric acid system and accessories for cooling water system 1) Sulfuric acid tanks 2) Sulfuric acid feed pumps 3) Graduated gauge glass for each tank 4) Agitator and low level switch for each tank E. The following sodium hypochlorite system and accessories for cooling water system 1) Sodium hypochlorite tanks 2) Sodium hypochlorite feed pumps 3) Graduated gauge glass for each tank 4) Agitator and low level switch for each tank F. The following inhibiter system and accessories for cooling water system 1) Inhibiter tanks 2) Inhibiter feed pumps 3) Graduated gauge glass for each tank 4) Agitator and low level switch for each tank G. Instrumentation and controls H. All required complete piping and valves including hangers, supports for the chemical feed system 3.2.16

Auxiliary boiler Auxiliary boiler shall be of the following common facility for 2 units A. Auxiliary boiler feedwater pumps with electric motor drivers B. Auxiliary boiler deaerator and storage tank C. Condensate make-up pumps with electric motor drivers D. Light oil feed pumps with electric motor drivers E. Blowdown tank F. Forced draft fan with driver G. Firing system composed of oil burner and windbox, ignitor, scanners, and local panel H. Air duct with air foil type ventrt meter, flue gas outlet breeching and outlet I.

Long retractable sootblower and rotary sootblowers

J. All instrumentation, control and safeguards, including control panels and all installation materials and including instrumentation and control and sample line covering upto insulatio for freeze protection within Bidder scope 3-16 KHABAT TPP UNITS 1&2 - VOLUME I

K. Flow nozzles and root valves for water analyzing at boiler feed pump discharge, superheater outlet and boiler water L. Insulation of the pipes and equipment and place and steam bracing all feed oil line for freeze protection system within Bidder scope M. Steel stack N. Desuperheater O. Monorail with steel structure fot forced draft fan maintenance 3.2.17

Black start diesel generator including

3.2.17.1Black start diesel generator A. Diesel engine unit B. Combustible air intake system for diesel engine including filter, air cooler C. Exhaust gas system including turbo charger, silencer, expansion joint D. Fuel oil system including pumps, filter(s), day tank, level gage and switches for day tank E. Lubricating oil system including L.O cooler, filters, pumps, preheater, priming L.O pump with one(1) stand-by pump and potable electric L.O pump F. Cooling system including radiator, radiator fans, duct, expansion tank(s), jacket water heater, pump(s) G. Starting air system including air compressor with one(1) stand-by compressor, air receiver H. Small generator sets including cell motor starting device using battery starting I.

Generator unit including exciter

J. Generator neutral earthing resister cubicle K. Steel structure and support for all tanks L. All required instrumentation and accessories including local instruments, control panel, panel instruments and annunciators including motor starter(if required). M. All

required

electric

equipment

and

accessories

including

AVR,

synchronizing equipment with auto synchronizer, meters, control switches N. Programmable microprocessor type protection relay. O. Internal cables mounted on equipment 3.2.17.2The following miscellaneous items : A. Design and supply of measuring instruments within the terminal points as described herein 3-17 KHABAT TPP UNITS 1&2 - VOLUME I

B. Design and supply of support accessories such as base plates, shims, wedges, foundation bolts and nuts, grouting material for engine/generator C. All flanges, gaskets, bolts and nuts including counter flanges for flanged connections D. Grease for initial charge E. Consumable parts and/or materials required for storage, installation and startup testing F. Earthing pads with clamps or studs G. Lift lugs for equipment maintenance H. Fire fighting system for fuel oil day tank 3.2.18

Heating, ventilation and air conditioning systems Heating, ventilation and air conditioning systems for the complete plant and buildings, including air handling units, chiller system, split air conditioner(w/ humidifier), supply or exhaust fans, hot water generator and all equipment and accessories relevant HVAC system.

3.2.19

Fire protection and detection Fire protection and detection system shall consist of the following common facility for 2 units. Fire protection and detection systems for the complete plant and buildings, including fire pumps, buried hydrant system, hydrant outlets, sprinkler systems, deluge water spray system, foam/water deluge /spray systems, hose reel and equipment cabinets, portable extinguishers, alarm panels and control system. Electronic/electrical panel room shall be designed by fire protecting gas system

3.2.20

Cranes and lifting equipment.

3.2.20.1

Cranes

A. Steam turbine building overhead crane and auxiliary hoist, all necessary equipment and accessories B. Raw water pump house overhead crane and auxiliary hoist, all necessary equipment and accessories C. Workshop crane overhead crane with all necessary equipment and accessories D. Boiler Feed Pumps Underhung cranes with all necessary equipment and accessories E. FGD pump room per unit 3-18 KHABAT TPP UNITS 1&2 - VOLUME I

F. Cooling water pump house overhead crane and auxiliary hoist, all necessary equipment and accessories 3.2.20.2

Hoist

A. Monorail hoist as the common facility for the water/waste water treatment building B. Monorail hoist as the common facility for the air compressor C. Monorail hoist for Emergency Diesel Generator D. Monorail hoists for FD Fan E. Monorail hoist for CID Fan. F. Monorail hoist for Air preheater. G. Monorail hoist for Closed Cooling Water Pump H. Monorail hoist for Sealing Air Fan I.

Monorail hoist in absorber area

J. Monorail hoist in GGH area K. Monorail hoist for equipment of limestone slurry preparation building L. Monorail hoist for vacuum belt filter, pump and conveyor in gypsum dewatering building M. Monorail hoist for pump and dehydrator in FGD waste water treatment building N. All Monorail hoist shall be including trolley and lifting devices with all necessary accessories. 3.2.20.3

Miscellaneous item Each crane shall be supplied complete with all equipment and accessories necessary for safe, efficient and reliable operation including the following but not limited to, as applicable.

A. Crane bridge complete with cross travel rails, walkways and access ladders and stairs to operator's cab and to the walkways along the travel rails. B. The travel rails and their accessories C. Wireless remote pendant. Back up shall be hard wired pendant control. D. Automatic audible alarm, when crane is in operation. E. End stops. F. End carriages. G. Traversing cab incorporating the independently driven hoists and the cab traversing gear H. Maintenance platforms and access ladders, where applicable 3-19 KHABAT TPP UNITS 1&2 - VOLUME I

I.

The main lifting gear complete with ropes and hook fittings

J. The auxiliary lifting gear(where required) complete with ropes and hook fittings K. Slings and shackles 3.2.20.4

Electrical equipment

A. Electrically operated thrust or other type electro-magnetic brakes B. Slip-ring or other type variable speed hoist, long travel and traverse driving motors C. Speed control equipment for motions D. Crane electrical equipment protection panel E. Crane electrical equipment and control cubicles complete with contactors, timers, resistance, rotor acceleration relays, limit switches, cables, wiring, anti-condensation heaters, etc. F. Crane lighting, rood lights, warning lights, plugs and sockets complete 3.2.21

Laboratory equipment Laboratory equipment shall consist of the following common facility for 2 units. Refer to the Vol.1 Technical specification para. 6.21

3.2.22

Services gas system Service gas system shall consist of the following common facility for 2 units. A. Nitrogen Gas Cylinders B. H2 Gas Cylinders, if necessary C. CO2 Gas Cylinders, if necessary D. Pressure Regulators E. All necessary pipework and valves, including insulation, cladding and trace heating (if necessary) for all services.

3.2.23

Workshop equipment Workshop equipment shall consist of the following common facility for 2 units. A. Large Lathe B. Medium Lathe C. Radial Drill Machine D. Flore Drill Machine E. Universal Milling Machine F. Band Sawing Machine G. Metal Cutting Sawing Machine 3-20 KHABAT TPP UNITS 1&2 - VOLUME I

H. 1 x GTAW (200a), 1 x SMAW (150a) 1 x GMAW (300a) welding machines & accessories.

Standard tools sets of for all disciplines shall be supplied. (10

Sets for each discipline: welder, elect, inst, mech, controls). 3.2.24

Elevators A. Boiler area B. FGD absorber area

3.2.25

Flue gas desulfurization system A. Absorber system and accessories ; The following equipment shall consist per unit. 1) Absorbers with reaction tank including internal structure 2) Reaction tank agitators and drivers 3) Absorber recirculation pumps and motors 4) Spray headers and internals 5) Spray nozzles 6) Mist eliminators 7) Mist eliminator washing headers and nozzles 8) Gypsum bleed pumps and motors 9) Absorber slurry sump pumps and agitator 10) Density meter pumps and motors with accessories 11) Absorber off-load cleaning system The following equipment shall consist of the common facility for 2 units. 1) Mist eliminator washing water pumps and motors 2) Mist eliminator washing water tank 3) Oxidation air blowers and motors with humidifiers 4) Emergency storage tank with agitator 5) Emergency storage pumps and motors B. Flue gas system and accessories ; The flue gas system shall consist of the following equipment per unit. 1) Gas-gas heater(GGH)s with complete accessories 2) Flue gas ductworks 3) Expansion joints 4) Dampers with drivers and seal air systems 5) Emergency quenching system 6) Purge air fan 3-21 KHABAT TPP UNITS 1&2 - VOLUME I

7) GGH washing water sump agitator & pumps C. Limestone slurry preparation system and accessories The limestone slurry preparation system shall consist of the following equipment as a common facility for 2 units. 1) Limestone powder storage silos with bag filters 2) Screw feeder 3) Limestone solution tanks and agitators 4) Limestone slurry transfer pumps and motors 5) Limestone slurry storage tanks and agitators 6) Limestone slurry feed pumps and motors 7) Limestone slurry preparation area sump pumps and agitator 8) Limestone unloading air compressors with air dryer D. Gypsum dewatering system and accessories The gypsum dewatering system shall consist of the following equipment as a common facility for 2 units. 1) Gypsum dewatering feed tanks with agitators 2) Gypsum dewatering feed pumps and motors 3) 1st stage hydrocyclone 4) Vacuum belt filters with complete accessories 5) Filtrate tanks and agitators 6) Filtrate return pumps & motors 7) 2nd stage hydrocyclone feed pumps and motors 8) 2nd stage hydrocyclone 9) Gypsum dewatering area sump pumps and agitator 10) FGD wastewater blow down tank and agitator 11) FGD wastewater blow down pumps and motors E. FGD waste water treatment system and accessories The FGD waste water treatment system shall consist of the common facility for 2 units. 3.2.26

Waste water treatment system The waste water treatment system shall consist of the following equipment as a common facility for 2 units. A. Normal and abnormal waste water treatment systems and accessories 1) Neutralized water transfer pumps 2) Abnormal waste water pumps 3) Surface aerators for neutralization pond 3-22 KHABAT TPP UNITS 1&2 - VOLUME I

4) Surface aerators for abnormal waste water pond 5) lnternal facilities of clarifier 6) Clarified water pumps 7) Activated carbon filters 8) Filter backwash pumps 9) Sludge pumps 10) Internal facilities of thickener 11) Thickened sludge transfer pumps 12) Dehydrator package with cake hopper 13) Pump room sump pumps 14) Agitator for final pH adjust pond 15) Agitator for thickened sludge storage pond 16) Final disposal channel and accessories 17) Exhaust fan B. Oily waste water treatment system and accessories 1) Pipe skimmer for API oil separator 2) Oil separated water pumps 3) CPI C. Chemical injection system 1) C-Polymer injection tank for dehydrator with dissolving basket, electric heater and agitator 2) C-Polymer injection pumps for dehydrator 3.2.27

Sewage water treatment system The sewage water treatment system shall consist of the following equipment as a common facility for 2 units. A. Sewage water treatment system with accessories B. Final disposal pump C. All associated piping, valves, instrumentation and controls

3.2.28

Sump pump The sump pump shall consist of the following equipment as a common facility for 2 units. A. Sewage water sump pumps 1) Workshop BLDG. sump pumps 2) Administration BLDG. sump pumps 3) Security gate house sump pumps 3-23 KHABAT TPP UNITS 1&2 - VOLUME I

4) FGD control BLDG. sump pumps 5) Operation & maintenance management BLDG. sump pumps 6) Water & waste water treatment BLDG. sump pumps 7) FGD waste water treatment BLDG. sump pumps 8) Unloading entrance gate sump pumps 9) Chiller BLDG. sump pumps 10) Guard tower sump pumps for No. 1, 2, 3 B. Waste water sump pumps 1) Chemical Water Sump Pumps a)

Unit 1 boiler area sump pumps

b)

Unit 2 boiler area sump pumps

c)

Chemical storage area sump pumps

2) Oily water sump pumps a)

Unit 1 turbine BLDG. sump pumps

b)

Unit 2 turbine BLDG. sump pumps

c)

Unit 1 transformer area sump pumps

d)

Unit 2 transformer area sump pumps

e)

Fuel oil storage tank area sump pumps

f)

Fuel & light oil pump house sump pumps

g)

Fuel oil emergency tank sump pumps

h)

Light oil storage tank area sump pumps

i)

Workshop BLDG. sump pumps

j)

Emergency diesel BLDG. sump pumps

k)

Aux. boiler area sump pumps

3) Other sump pumps a) 3.2.29

Raw water intake canal area sump pumps

Plant design and pipings All required complete piping and valves including hangers, supports for Boiler, turbine-generator and all auxiliary system .

3.3

Electrical Equipment A. Totally enclosed, cylindrical rotor type, 3000 rpm synchronous generator B. Excitation system. C. 132 kV air insulated switchgear For specification of these devices, refer to Part 4 Volume 1 Section 4 D. Generator main connections 3-24 KHABAT TPP UNITS 1&2 - VOLUME I

E. Generator circuit breakers F. Main step up transformers G. Unit aux. transformers H. MV/LV transformers I.

Unit and station power supplies, including 6 kV switchgear, LV switchgear, MCCs and building services sub-distribution boards

J. DC supply system including batteries and UPS systems K. Electrical control system and protection L. Earthing and lightning protection M. MV and LV power, control and instrumentation, telephone and emergency cabling systems N. Lighting and small power systems O. Cathodic protection system 3.3.1

All Interface devices to SCADA system master station located at the national control centre (NCC) such as follows: -

Remote terminal unit of SCADA

-

Protection signaling equipment, if req.

-

Microwave radio link equipment

-

Optical Fibre Based PDH/SDH Equipment For specification of these devices, refer to Part 4 Volume 1 Section 10

3.4

Control and Instrumentation

3.4.1

Complete control, protection and monitoring systems for the steam turbine generator and auxiliary.

3.4.2

Complete control, protection and monitoring systems for the steam generator and auxiliary.

3.4.3

Control, monitoring and protection systems for the fuel supply and storage system, condensate system, feedwater system, main and reheat system, feedwater heater extraction, drain & vent system auxiliary steam system, closed cooling water system, circulating system , etc.

3.4.4

Control, monitoring and protection systems for the electrostatic precipitator, ash handling system, FGD system, sootblowing system, condenser tyube cleaning

system,

auxiliary

boiler,

compressed

air

system,

make-up

3-25 KHABAT TPP UNITS 1&2 - VOLUME I

demineralizer system, chemical feed system, water & waste water treatment system, chemical dosing system sampling system HVAC, etc. 3.4.5

Control, monitoring and protection systems for the station electrical systems Plant control system

3.4.6

Distributed Digital Control System(DCS) based Plant Control System (PCS)

3.4.7

Turbine Control System including Digital electronic governor systems, automatic run-up and loading system, turbine stress evaluator, turbine supervisory system, turbine trip system, generator control and monitoring system, generator gas systems.

3.4.8

PLC(Programmable Logic Controller) based the package control systems including LCD station

3.4.9

Central control room/computer room equipment including operator desks, chairs, printers, large screens, digital indicators, clock, CCTV monitors, furniture, etc.

3.4.10 Emergency shut down systems for safe plant running, shut-down and protection. 3.4.11 Interfaces between the PCS and packaged control systems including TCS via hardwired or redudant communication 3.4.12 Condition monitoring equipment for major plant and auxiliaries. 3.4.13 Plant performance system 3.4.14 Instrumentation with accuracy suitable for tariff metering 3.4.15 Gas and water emissions monitoring equipment 3.4.16 Water and steam sampling equipment 3.4.17 Local instrumentation 3.4.18 Instrument power and air distribution systems 3.4.19 Telecommunications systems 3.4.20 Closed circuit television and perimeter security system 3.4.21 Weather station 3.4.22 Fire and gas detection systems 3.4.23 Public address system 3-26 KHABAT TPP UNITS 1&2 - VOLUME I

3.4.24 Electrical and instrument test equipment 3.4.25 All required control and instrumentation for safe, reliable and efficient operation of the plant. 3.4.26 Others as specified in para. 8 “control, instrumentation and communication”.

3.5

Civil Works All civil works associated with the above equipment and facilities, including but not limited to:

3.5.1

Geo-technical and topographical surveys of the site, the raw water intake and discharge area including ground pollution report.

3.5.2

Hydraulic model study report and hydrological survey including water level data in consideration of the seasonal changes in Greater Zab River.

3.5.3

Route survey along the raw water pipe and discharge pipe.

3.5.4

Data collection including verification of design data provided in the tender documents

3.5.5

Enabling works with regard to existing services, earthworks, dewatering and demolitions

3.5.6

Access roads, site roads, paved hardstanding areas (for car parking, concrete slab laydown areas, gravel covered sterile areas, pathways, street lighting and landscaped areas

3.5.7

Utilities pipework

3.5.8

Acoustic attenuation where required to meet noise limits

3.5.9

Storm, sewage, oily and plant drainage systems

3.5.10 Utilities and underground services 3.5.11 Security works during construction and operational phases 3.5.12 Permanent Perimeter fence from concrete block wall with additional security camera system and security lighting. 3.5.13 Heavy duty, large rolling type security gate(s) for road access and small personnel access gate. 3.5.14 Hard landscaping 3-27 KHABAT TPP UNITS 1&2 - VOLUME I

3.5.15 Concrete slabs for miscellaneous pipe supports 3.5.16 Exterior & interior equipment support foundation and foundation accessories such as sole plates, counter flanges with bolts, nuts, gaskets, packing, channel base, sub-sole plates, shims, wedges, foundation anchor bolts, anchor frame and nuts, and grout and embedded materials 3.5.17 Piling works and/or ground improvement 3.5.18 Site services, (i.e., power, water, sewage and telephone,etc.) for the Bidder and KNOC office accommodation during the construction period 3.5.19 Building contents (ironmongery, fixtures and fittings, internal finishes, furniture, office computer equipment, fire and safety equipment) 3.5.20 Mechanical and electrical building services 3.5.21 Builder’s work associated with building services installation 3.5.22 Office accommodation during the construction period for the Bidder, and the KNOC Building works, foundations, structures and associated facilities: 3.5.23 Interfaces with associated contracts 3.5.24 Design, preparation of detailed construction drawings, bar bending schedules and all drawings and documents necessary for completion and maintenance of the works, 3.5.25 Preparation of as-built documentation 3.5.26 Buildings, structures, foundation and compounds to be included as a minimum, in the civil works as follows:


Turbine building




Central control building




Boiler and electrostatic precipitator




Stack




Absorber foundation




Fan foundation




Clean & dirty lube oil tank foundation with dike




Fuel oil & fuel oil emergency, light oil storage tank foundation and dike




Raw water storage tank foundation




Demi. water storage tank foundation 3-28 KHABAT TPP UNITS 1&2 - VOLUME I




Ash silo foundation




Limestone slurry storage & emergence storage tank foundation




Gypsum dewatering feed & filtrate tank foundation




Chemical storage tank and pump foundation with dike




Transformer foundations and compounds (with fire walls and bund walls)




Switch yard area facilities foundation




Raw water supply system complete with raw water intake canal and pump house, pump foundation and piping




Circulating water system structure complete with cooling tower and cooling water pump station




Discharge basin




Sewage treatment facilities foundation




Waste water treatment facilities foundation with pond




Truck scale foundation




Parking




Pipe rack foundation




Play ground




Aux boiler house




Electrical building




Administration building including toilets, small cafeteria




Operations & maintenance management building




Dining facility building




Prayer facility building




First aid center with 2 rooms




Raw water pump house included electrical facilities




Foam tank house




Fire brigade station




Fuel & light oil pump house




Service gas storage house




Workshop building




Warehouse building




Chiller building




Water & waste water treatment building




Security gate house with 2 rooms




Unloading entrance gate house with 2 rooms 3-29 KHABAT TPP UNITS 1&2 - VOLUME I




Sun shades and rain screens




Black start/emergency diesel generator building




Construction office




Gypsum dewatering building




Limestone slurry preparation building




FGD waste water treatment building




FGD pump rooms




FGD control building




Guard towers with personal amenities

Building services, including air conditioning of the local control rooms, central control building, special storage areas, toilets and mess rooms, prayer and cafeteria buildings. Foundations and associated works for:


All buildings, structures and compounds listed above




Steam turbine generators




Transformer compounds




Black start/emergency diesel generator




Fuel oil storage tanks and handling equipment




Service/fire water, potable and demineralized water storage tanks




Fire fighting foam equipment




Compressed air equipment




Miscellaneous plant and equipment




Service ways, silos, ducts and trenches, pipe racks and bridges




All necessary supports, access ladders, stairways, platforms, walkways, sunshades, handrails, etc., for the safety of personnel during plant operation and maintenance




Bunded areas for all lubricating and other oils and chemicals




Rain shelters over all bunded areas




Sump pumps




Sewage water treatment system

3.5.27 General services All necessary services associated with the above scope, including, but not limited to the following: A. Quality control inspection and testing Painting and finishing 3-30 KHABAT TPP UNITS 1&2 - VOLUME I

B. Spare parts C. Tools, lifting tackle and special appliances D. Contract documents and drawings E. Quality Control, inspection and testing F. Operation and maintenance manuals G. Training of the KNOC’s staff in the operation and maintenance of the Works H. Local lifting beams and manual hoists I.

Special tools and maintenance equipment for all plant and equipment

J. All flushing facilities and flushing oils K. All required insulation and lagging materials supply L. Welding rods required for the interconnecting piping and other parts within the Bidder's scope as well as welding specimens required for welder qualification tests and special welding rods M. All instrument nozzles, connections, root valves, sensing lines and their installation materials complete with instrumentation to measure and indicate all fluid conditions N. Enclosures for required systems. These include sound, personnel protection, weather and any other enclosures necessary to ensure a complete operating system O. Safety showers and eye washers P. Stairs and ladders, walkways, handrails, platforms and supports for monitoring, operation and maintenance of all equipment, and tanks, instrumentation, valves, etc. Q. Connections for sampling R. Sump and trench cover plate S. Strainers T. All accessories of concrete pond : walkway, stairway, ladder, polyethylene coated piping sleeve and handrail etc. U. First charge of all chemicals, lubricating oils, lubricants and filters V. Consumable spare parts up to end of the defects liability period The Contract shall include the whole of the aforementioned work which is described in or implied by the Specification and all matters omitted from the Specification which may be inferred to be necessary for the safe, reliable and efficient operation, stability and completion of the Works shall be deemed to be included in the Contract Price. All plant, equipment, materials and works shall

3-31 KHABAT TPP UNITS 1&2 - VOLUME I

be provided to complete the installation ready for commercial operation whether or not specifically called for herein.

3.6

Provision for KNOC Costs -

The Contractor shall provide Funitrue for Admin. Building, Operation & Maintenance Management Building. Furniture will be based on standard office equipment for the number of persons to be accommodated at the site.

-

The Contractor shall provide transportation (air, sea, and inland) and Hotel accomodation for KNOC to carry out the Manufacturing Testing.

The Contractor is requested to apply a ceiling amount of US$ 1,500,000 (one million and five hundred thousand United States Dollars) in the proposal.

3.7

Transfer of resposibilities The Plant shall be handed over to the O&M team on successful completion of performance verification tests. In order to guarantee a smooth and seamless transition of operations and maintenance responsibilities for the Plant from the contractor to the O&M Team it is essential that a detailed “Responsibility Transfer Plan” is developed by the Contractor and jointly agreed with the O&M Team. The success of the transfer process will be heavily influenced by the quality and duration of the training provided to the O&M staff assigned to the Plant. The “Responsibility Transfer Plan” should include the requirement for monitoring and reporting on the progress of the O&M staff assigned to the Project. In addition to the transfer of responsibility in terms of O&M personnel, the overall transfer process should define the process for documentation handover as a part of the overall start up and commissioning of the Plant. Such process must ensure that all relevant documentation and document management systems are fully transferred to the O&M team before the Contractor demobilizes from the site. The Contractor shall have full responsibility for the Plant from design up to final commissioning and handover to the O&M team. It is required that following handover of Plant responsibility to the O&M team, the Contractor shall maintain at site a core team of plant O&M

3-32 KHABAT TPP UNITS 1&2 - VOLUME I

specialists to provide ongoing support to the O&M staff. This support period is expected to last for one month. Responsibilities Chart The contractor shall develop “Responsibility Transfer Plan” including the following contents, but not limited


Overall method and responsibilities




Organization for commissioning and start-up




Support organization during initial operation




Critical design list need of the O&M staff’s review




Factory test process including the O&M staff’s witness of main plant item




Main system list need supervision of the O&M staff




Method and process of the O&M staff’s supervision




Start-up test procedure and handover document list (Drawings, results, O&M Manual)




3.8

As-Built document list

Terminal points The Bidder shall be responsible for the provision of sufficient data regarding the interface conditions for the plant, to ensure the appropriate design of the plant to ensure safe, efficient and reliable operation within the environmental limitations, under all operating modes and climatic conditions as defined in [Section 2]. The Bidder shall assess the proposed termination points for all services and shall agree with the KNOC an appropriate tie-in point and tie-in schedule. The location and schedule shall, where applicable, be designed to minimize inconvenience to other users of the systems.

3.8.1

Fuel supplies The Bidder shall be responsible for the connection of the fuel supplies to agreed termination points located adjacent to the site boundary. The exact location of these termination points will be finalized after award.

3-33 KHABAT TPP UNITS 1&2 - VOLUME I

An indicative analysis of the fuels is included in [Volume 2, Schedule A] for information. However, the Bidder shall be responsible for the provision of sufficient data regarding the fuel supplies for the plant, including analyses as necessary to ensure the appropriate design of treatment and handling/storage facilities to provide the requisite flow and quality of services as required by the boilers and other users within the site. 3.8.2

Water supplies The Bidder shall be responsible for supply the water to the plant from the Great Zab river. An indicative analysis of the raw water is included in [Volume 2, Schedule A] for information. However, the Bidder shall be responsible for the provision of sufficient data regarding the water supplies for the plant, including analyses as necessary to ensure the appropriate design of treatment and handling/storage facilities to provide the requisite flow and quality as required within the site.

3.8.3

Electrical connections Electrical power from each generator shall be exported to, and be compatible with, the electrical connection provided by the MOE. The MOE will supply the connection between 132kV AIS and First Transmission Tower supplied by the MOE. Bidder’s terminal point shall be up to the gantry towers of transmission line sides. Terminal point of OPGW(optical fiber ground wire) shall be same as main connection. The Bidder shall establish communication protocols and liaise with the Ministry of Electricity to ensure that all appropriate safety requirements are fulfilled.

3.8.4

Communications All connections to the public telephone network shall be the responsibility of the Bidder. The Bidder shall ensure that all communication systems used during construction and operation of the Site meet appropriate regulations and do not cause interference with any communication or electrical equipment on the surrounding site.

3.8.5

Drainage The drainage systems shall be sub-divided into surface water, sewage water, chemical and oily water systems.

3-34 KHABAT TPP UNITS 1&2 - VOLUME I

The surface water, sewage water, chemical and oily water treated by each treatment system shall be discharged to river through discharge basin. 3.8.6

Security fencing and access roads The Bidder shall provide site security fencing, access roads and a main site access gate. The Bidder shall also ascertain the requirements of the [Ministry of Electricity] and gas Bidder and provide additional security fencing, access roads and access gates to the gas supply compound and for electrical equipment compound. The detailed requirements of nominated gas Bidder and the [Ministry of Electricity] shall be determined by the Bidder in discussions with the two organizations. Details of the civil engineering work requirements on fencing and access road are provided in Section [9]. The alarm, surveillance and security requirements are detailed in Section [8].

3-35 KHABAT TPP UNITS 1&2 - VOLUME I

4

GENERAL REQUIREMENT

4.1

Project Management

4.1.1

Overall scope The Bidder shall implement and maintain plans, procedures necessary and appropriate for the performance of the work in accordance with the agreement.

4.1.2

Organization The Bidder shall establish and maintain project management team for the proper execution of the project.

4.1.3

Operation of computer system for project management The Bidder shall develop and operate project management computer system to control the detail status which occurs in the course of schedule control, material control, drawing and document control, etc. efficiently. Project management computer system shall be established of networked computers, integrated

software

applications,

organized

databases,

and

web-based

communications. The Bidder shall provide related information to KNOC in timely manner 4.1.4

Project management plan No later than two (2) months after receipt of written Notice to Proceed form KNOC, The Bidder shall submit the Project Management Plan to KNOC for approval. The project management plan shall be described the management approach and philosophy for the project implementation. The project management plan shall be contained detail procedures for the engineering, delivery, subcontract plan, interface coordination, permits, administration, correspondence and other plans The project management plan shall also contain the following a. Project organization - Project organization in terms of participating companies and key individuals - Project organization in terms of each phase of the project(engineering, procurement, construction, commissioning) 4-1 KHABAT TPP UNITS 1&2 - VOLUME I

b.

Engineering management plan - Review and approval category of engineering deliverables - Coordination between KNOC and Bidder (Incl. coordination between Bidder and subBidder) - Interface management with other Bidder’s design - Guidelines for Engineering control procedure - Engineering deliverables and document control - Others (change control, etc.)

c.

Procurement management plan - Material procurement strategy (including subcontracting strategy and qualified subBidder list - Guidelines for Material control procedure (purchasing, expediting and inspection) - Others (Material transportation plan, etc.)

d.

Construction and commissioning management plan - Subcontract management - Use and removal temporary facilities - Detailed construction method statement - Guidelines for material control and handling at site - Plan and schedule for obtaining various statutory permits - Responsibility transfer plan

e.

Project change control plan - Types of change - Change control process - Change control related forms

f.

Risk management plan - Risk definition and concepts

4-2 KHABAT TPP UNITS 1&2 - VOLUME I

- Risk management process - Integration with project management - Risk closure - Opportunity management process - The contractor shall develop the Risk management plan and operate in accordance with the clause 4.13 “Risk management guideline” . g.

Meetings - PRM(Project Review Meeting) The PRM shall be held to review and evaluate the project status and progress, identify the problem areas and establish plans for corrective actions. The contractor shall conduct the meetings. Meeting Frequency: Once a month, in principle, KNOC decides on meeting schedule based upon discussion with the participants. Meeting Place : in Iraq, in principle, KNOC will determine the final selection of the meeting location.

- SRM(Status Review Meeting) The SRM shall be held for the same purpose as the PRM, but its purpose is limited to the entities of a specific contract, or a group of related contracts. In the latter case, the SRM shall be participated by all organizations involved in the group of related contracts. The following SRMs are foreseen:  Engineering status review meeting  Equipment supply status review meeting  Construction status review meeting Meeting Frequency: As needed basis Meeting Place: The participants will take turns hosting the meeting as approved by KNOC in advance.

4-3 KHABAT TPP UNITS 1&2 - VOLUME I

h.

Communication plan - Types of communication - Contact points - Communication matrix - Correspondence forms

i.

Other plans - Document review and approval - Documents Distribution, - Record managements, - etc.

4.1.5

Health, safety and environmental management plan The Bidder shall establish comprehensive plan to identify and manage safety, health, environmental and operational risks in connection with the execution of the Work. The Bidder shall submit the HS&E management plan to KNOC for approval in accordance with schedule E of technical specifications.

The HS&E Management

plan must maximize: a.

Safety and accident prevention

b.

Plant and equipment integrity

c.

Pollution prevention

d.

Energy conservation

e.

Personal, occupational and environmental health

f.

Physical security

g.

Others(HS&E training of EPC Bidder workforce, HS&E Coordinator, Incidents, etc)

The HS&E Management plan shall comply with internationally recognized standards and legislation. The HS&E Management plan shall emphasize “no accidents, no harm to people and no damage to the environment.” The Bidder shall prepare and submit to KNOC a monthly HS&E report covering the activities at site. This report shall contain the following

4-4 KHABAT TPP UNITS 1&2 - VOLUME I

a. A list of all significant hazards observed at the site during the reporting period and a description of risk assessment and corrective actions taken to prevent recurrence of the same type of incident. b.

A list of all injuries/occupational health issues at the work site.

c.

Information showing the number of all injuries, illnesses, lost workday cases, and the number of workdays per month at the site.

d.

4.1.6

Spills/leaks and other Environmental Incidents.

Environmental protection The Bidder shall submit to KNOC within 10 days after his mobilization to the site an environmental protection plan for approval. The Bidder shall maintain vigilance with regards to environmental issues and contingencies and shall follow the provisions of the environmental protection plan as submitted to and approved by the KNOC. Spill prevention, drainage, disposal, pollution, etc. shall be covered by the environmental plan and the Bidder shall execute due care and diligence with regards to environmental protection.

4.1.7

Project quality plan The Bidder shall submit the project quality plan to KNOC for approval in accordance with schedule E of technical specifications. The Bidder shall establish an independent and professionally staffed QA/QC function within the project management team. The Bidder shall develop a QA/QC plan for the engineering, procurement and fabrication, installation phase work.

4.1.8

Training plan for MOE personnel No later than three (3) months receipt of written Notice to Proceed form KNOC, The Bidder shall submit the training plan to KNOC for approval in accordance with training requirements described in Clause 4.9 of technical specifications.

4.1.9

Project control procedures

4.1.9.1 Schedule control procedure

4-5 KHABAT TPP UNITS 1&2 - VOLUME I

No later than one (1) months after receipt of written Notice to Proceed form KNOC, the Bidder shall submit schedule control procedure to KNOC for approval.

The

Schedule Control Procedure shall set forth the procedure for controlling the engineering, procurement and manufacturing, construction and start-up, including sub-contracting, in accordance with the programme and progress described in Clause 4.2 of technical specifications.

The Schedule Control Procedure shall also

contain the following: a.

Organization

b.

Development and operation

c.

Progress measurement

d.

Update and reporting.

4.1.9.2 Material control procedure No later than two (2) months after receipt of written Notice to Proceed form KNOC, the Bidder shall submit the material control procedure to KNOC for approval. The Material Control Procedure shall set forth the procedure for controlling the material status from material purchase request to site storage and installation.

The Material

Control Procedure shall also contain the following. a.

Overview for material control

b.

Responsibility and role

c.

Detail procedure for material control

d.

Providing information and reporting.

4.1.9.3 Project numbering procedure No later than two (2) months receipt of written Notice to Proceed form KNOC, the Bidder shall submit the Project numbering procedure to KNOC for approval. The Bidder shall develop detail project numbering structure based on KKS(Kraftwerk Kennzeichen System). All entities shall use it for numbering of equipment, piping, valves, cable, instrumentation and spares. Plant and equipment items will be identified by a nomenclature system. Project Numbering Procedure shall also contain the following. a.

Work Breakdown Structure

b.

Numbering structure for drawing and document

c.

Numbering structure for equipment and component 4-6 KHABAT TPP UNITS 1&2 - VOLUME I

d.

Activity numbering structure for schedule control (Engineering, Procurement, Construction, Start-up)

e.

Cost control code of account

f.

Others

4.2

Programmes and Progress

4.2.1

Programme requirements The programmes supplied by the Bidder will be used by KNOC to monitor the overall progress of the project. Primavera project management software shall be used for all programmes for the duration of the Contract.

The programmes supplied by the

Bidder as part of this Project shall fully interrelate design, procurement, manufacture, erection and commissioning activities.

Key events shall be clearly identified on all

programmes and be integrated into the program logic. The Bidder shall provide primavera software (version 6.2.1 , 5 licenses) for project management. [ Include training (Intermediate level of competence) of KNOC/MOE’s staff in Iraq ] All programmes issued throughout the Project by the Bidder shall be provided electronically in Primavera format, to allow full interrogation by KNOC.

Print or plot

files will not be acceptable. The approved programme shall be adhered to by the Bidder and shall not be changed except as agreed by KNOC.

If at any time during the execution of the

project it is found necessary to modify the approved programmes, the Bidder shall inform KNOC and submit the modified programmes for his approval.

Any approval

or changes to the approved programmes shall not constitute approval of an extension of the guaranteed completion date, nor any approval of claims for increases in the EPC price. 4.2.1.1 Bidder programme during proposal The Bidder is requested to prepare the Bidder programme considering KNOC’s proposed project milestone schedule The Bidder submission shall be supported by a Bidder programme (bar chart format, level I) conforming with the outline project programme included in this Specification 4-7 KHABAT TPP UNITS 1&2 - VOLUME I

and in sufficient detail to indicate the Bidder’s intention for executing the Works, and must cover major items relating to design, procurement, manufacture, delivery, erection, setting to work and commissioning. shown.

The critical path shall be clearly

Long lead manufacturing items and the dates for placing the main

subcontracts shall be identified. Activity Resources in schedule should also include requirements for special items of plant/equipment such as mobile cranes, oil treatment equipment, welding preheat/post heat equipment, laser alignment equipment etc. to ensure sufficient level of equipment. Contractual Key dates and periods, programme and interface events shall be identified in the Bidder programme, including dates for access data and release of terminal points, that involve the KNOC or other Bidders. Key dates of despatch, delivery to site and completion shall be identified in Schedule B. The Bidder programme shall be resourced with the site labour requirements segregated into trade categories to meet the Bidder Programme. 4.2.1.2 Contract programme during after award The Bidder Programme shall be updated to include any modifications negotiated and agreed during the period up to award of contract and shall have the detail further expanded and developed prior to being submitted for approval by KNOC

within

[30] days after receipt of Notice to Proceed. The programme shall be of at least level 2 detail, resourced and capable of producing manning histograms for each phase of the works, covering design, procurement, manufacture, construction, erection and commissioning.

Activities of

over eight weeks duration are unacceptable and shall be broken down in detail to acceptable sub-tasks.

Following approval by KNOC, this programme shall become

the contract programme, and following the creation of a baseline, shall be used as the basis for measuring and reporting progress throughout the project timescale. The approved contract programme shall be adhered to by the Bidder and shall not be changed, except as agreed by KNOC. If, at any time during the performance of the contract, the Bidder has failed or is seen to be failing to perform the works in accordance with the contract programme, then KNOC may direct the Bidder in 4-8 KHABAT TPP UNITS 1&2 - VOLUME I

writing to allocate additional resources or accelerate the works at the Bidder’s cost. The Bidder shall be instructed to maintain his programme to reflect the current status of progress and to issue the required updated bar charts and associated reports etc, ‘S’ curves and histograms with each monthly progress report. ‘S’ curves shall be directly produced from the contract programme and be based on appropriate quantitative information.

This may include, but not be limited to:

a.

Number of design documents

b.

Quantity of procurement components

c.

Quantity of received materials

d.

Proportion of contract price for each plant area or construction activity

e.

Metres of pipework erected

f.

Metres of cables installed

g.

Number of cable terminations completed

h.

Commissioning packages.

4.2.1.3 Design schedule The Contract Programme shall incorporate design activities that identify the sequence of work for the project and the submission of drawings, studies and reports etc.

The Design Schedule shall be electronically extracted from the

Contract Programme and shall contain all major documents and drawings to be submitted for review by KNOC, their submission dates and durations for review as specified by KNOC, and shall meet the requirements of the Bidder and other Bidders engaged on the project. 4.2.1.4 Procurement and manufacturing schedule The Contract Programme shall incorporate a Procurement and Manufacturing Schedule, which identifies as a minimum: a.

Details of suborders and target dates for placing subcontracts

b.

Any detailed design required within the manufacturing period

c.

Long delivery items.

d.

Information to be supplied by the KNOC submission dates.

The Procurement and Manufacturing Schedule shall be electronically extracted from 4-9 KHABAT TPP UNITS 1&2 - VOLUME I

the Contract Programme and shall be in sufficient detail to enable the work to be adequately progressed.

This schedule shall meet the requirements of the Bidder

and other Bidders engaged on the project. 4.2.1.5 Preliminary Construction Schedule The Contract Programme shall incorporate a preliminary construction schedule, which should identify in sufficient detail the Bidders intended construction strategy. The programme shall satisfy the following criteria: a.

Contain full details of all civil/mechanical/electrical terminal point release requirements.

b.

Identify when services are required for commissioning purposes.

c.

Include an outline setting to work and commissioning schedule.

The Preliminary Construction Schedule shall be electronically extracted from the Contract Programme. 4.2.1.6 Construction schedule Within 60 days after receipt of Notice to Proceed, the Contract Programme shall incorporate a detailed level 3 Construction Schedule, expanding the detail in the Preliminary Construction Schedule and be electronically extracted from the Contract Programme.

In addition to the detail outlined in 4.2.1.5, this schedule shall be in

sufficient detail as agreed by KNOC, to enable the work to be adequately progressed and monitored.

This to include long duration activities of over 30 days

to be broken down into sub-tasks of no more than 30 days duration.

This schedule

shall meet the requirements of the Bidder and other Bidders engaged on the project. 4.2.1.7 Commissioning schedule During the progress of the works, the Bidder shall develop the outline setting to work and commissioning schedule into a detailed level 3 Commissioning Schedule, in sufficient detail to enable the work to be adequately progressed. Activities of over two weeks duration are unacceptable and shall be broken down into acceptable subtasks.

This schedule shall be electronically extracted from the Contract Programme

and submitted to KNOC for approval 3 months prior to the start of any commissioning activities and shall be approved not later than 1 month before the start of any commissioning activities.

This schedule shall meet the requirements of

the Bidder and other Bidders engaged on the project, and shall be integrated with 4-10 KHABAT TPP UNITS 1&2 - VOLUME I

the contract programme. 4.2.2

Progress reporting Monthly progress reports shall be produced by the Bidder and submitted to the KNOC from the commencement of the Contract.

The format is to be approved by

KNOC. They shall be submitted within one week of the report cut-off date to be agreed during negotiations.

The report shall address design, procurement,

manufacturing, construction, setting to work and commissioning issues.

The

reports shall include but not be limited to the following: a.

Executive summary.

b.

Schedule of forecast and actual key events.

c.

Three month look-ahead programme (extracted from the Contract Programme).

d.

Progress to date in narrative format.

e.

Areas of concern and details of corrective action being taken.

f.

Actual resources against planned.

g.

Updated ‘S’ curve.

h.

Issue Register update

i.

Critical Items Report

j.

Contract programme updated to show progress achieved. Programme progress updates

shall also be provided in the form of a fully working Primavera

electronic file, which will allow analysis by KNOC.

Electronic print or plot file

are not acceptable. k.

Planning and consents.

l.

Safety issues and industrial relations.

m. Colour photographs of progress in digital format. Each set shall comprise a total of 20 colour photographs, individually marked with the date taken, a description of the subject and the direction of view. n.

Contract financial status.

The Bidder may be required to include additional schedules and charts considered necessary by KNOC to adequately monitor the Contract. Hard copies of progress reports are to be issued to the KNOC in accordance with Schedule E. An electronic copy shall also be submitted to the KNOC. Following mobilization at site, the Bidder’s site office shall submit weekly progress reports to KNOC in accordance with Schedule E. The report shall summarize site 4-11 KHABAT TPP UNITS 1&2 - VOLUME I

activities, indicate numbers of the various classes of workmen employed on site, the plant and equipment on site and record any areas of concern and details of corrective action being taken.

Daily activity reports shall also be provided

summarizing the main activities to be undertaken each day, noting any special activities that require witnessing, together with full particulars and details of all obstructions, modified or additional work, incidents and the number of men employed in each of the several portions of the work in progress, in accordance with Schedule E. Access to the Bidder’s or subBidder’s works shall be granted to KNOC at any reasonable time for the purposes of ascertaining progress. KNOC shall also have access to the Bidder’s daily activity reports. The Bidder shall provide more frequent updates of schedule as required by KNOC if deemed necessary. KNOC may request the Bidder to provide additional reports when in his opinion they are warranted. Where there is an agreement to pay by time and material rates, the Bidder shall keep records of labour, materials and equipment.

Such records shall be valid only

when signed by both parties. For work of a disputed or uncertain nature, sheets shall be signed by both parties as an agreed record of work done.

The sheets shall be annotated “For record

purposes only” and shall not imply any commitment concerning payment. 4.3

Design and Standardization The Works shall be designed to ensure satisfactory operation in which continuity of service is the first consideration and to facilitate inspection, cleaning and repairs. All equipment supplied shall be designed to ensure safe and satisfactory operation under the atmospheric conditions prevailing at the Site, and under such variations of load and pressure as may be met with under working conditions. In doing so the Bidder shall be responsible for and shall carry out HAZOP studies or other studies deemed necessary by KNOC as part of the design process.

The Works and all

equipment and materials forming part of this Contract shall comply in all respects with any relevant statutory regulations, by-laws or orders currently in force where the 4-12 KHABAT TPP UNITS 1&2 - VOLUME I

Plant is to be erected. Although the Works shall generally comply with international standards, any instruction in this Specification that a particular aspect of the Works shall comply with a named code or standard shall take precedence, and that particular aspect of the Works shall comply with the named code or standard.

International standards

are those standards such as BS, IEC, ISO, ANSI/ASME, API, NFPA, JIS, TRD, DIN and EN which are in common use throughout the world for this type of application. In the event of any conflict in standards, the hierarchy of standards shall be as follows, with the standards occurring first in the list taking precedence over any standards later in the list: a.

Standards named in the Specification

b.

International Standards

c.

Other standards approved by KNOC.

The Bidder may offer Works which comply with international standards, or internationally recognized codes or standards, which differ from those specified. However the Bidder may offer Works which comply with the different standards or codes only if he is able to demonstrate to KNOC’s satisfaction that the Works offered are equal or superior to that which would have resulted had the specified code or standard been used. This substitution of codes or standards for those specified will only be acceptable if the manufacturing organization in question has extensive experience with the alternative code or standard offered.

If requested to do so by

KNOC, the Bidder shall supply to KNOC, at his own cost, two copies in English of the relevant code or standard which he proposes to substitute for that specified. The Bidder shall be responsible for ensuring that all standards used are current, the use of superseded or obsolete standards is unacceptable. The ruling date for current standards are those in place at the time of Contract signature. The Bidder shall be responsible for submitting all statutory calculations for the third party verification and for all other calculations required by KNOC. The International System of Units (SI) shall be used in connection with this Contract 4-13 KHABAT TPP UNITS 1&2 - VOLUME I

and the provisions of ISO 31 and ISO 1000. All materials, fittings, components, items of plant and equipment supplied for incorporation in the Works shall be standardized accordingly. If, after making diligent enquiries, the Bidder is unable to obtain an item standardized in SI units, written approval shall be obtained from KNOC to supply non-standard material. The principal units shall be as follows: Parameter

Units

Pressure

Remarks

bar absolute

All calculations relating to plant performance

bar gauge

All pressure gauges

millibar Temperature

Gauges below atmospheric pressure

°C

Volume

l

(m3)

litre

Mass

kg

(t)

(metric tonne)

Flow – mass

kg/s

(t/h)

Flow volume

l/s

(m3/h)

Flow – gas

kg/s

(Nm3/h)

Rotational speed

rpm

Power

kW

Enthalpy

kJ/kg

Vibration

mm

Head

m of H2O

Heat rate Emissions level

(measured at 0°C 1.013 bar a)

(MJ/Nm3) (amplitude peak to peak) (mm Hg)

kJ/kWh mg/m3

Alternative units indicated in brackets, may be used with the agreement of KNOC. SI units shall be used in all correspondence, documentation, calculations, drawings, measurements etc. If reference has to be made to non-standard items, the SI units shall be quoted followed by the non-standard units in brackets. The Bidder shall standardize mechanical and electrical equipment as well as instrumentation. Corresponding parts shall be made to gauge and shall be interchangeable wherever possible. When required by KNOC the Bidder shall prove this quality by actually interchanging the various parts.

4-14 KHABAT TPP UNITS 1&2 - VOLUME I

Particular attention must be paid to internal and external access in order to facilitate inspection, cleaning and maintenance. The Works shall be arranged such that each major item, plant, or group of minor plant items, can be safely isolated from all hazards for maintenance, if necessary, whilst the remainder of the plant remains in service. The design shall conform to the best current engineering practice.

All plant shall be

of the manufacturer’s standard design, provided that this design is in general accordance with the Specification and shall use components proven to be satisfactory by previous experience. The design dimensions and materials of all parts shall be such that they will not suffer damage as a result of stresses under the most severe service conditions. The materials used in the construction of the Plant shall be of the highest quality and selected particularly to meet the duties required of them. designed and constructed to minimize corrosion.

The plant shall be

Workmanship and general finish

shall be of the highest class throughout. All equipment shall be designed to minimize the risk of fire and damage which may be caused in the event of fire. The equipment shall also be designed to prevent ingress of all vermin, accidental contact with electrical live parts and minimize the ingress of dust and dirt. The Bidder shall provide the services of an approved Classification Society or Insurance Inspection Company subject to KNOC’s approval and which shall include: a.

the certification of designs and drawings and the checking of scantlings of the components of pressure and vacuum containing parts

b.

the certification of designs and drawings of lifting equipment and any other items of plant and equipment which in the opinion of KNOC requires insurance inspection

c.

the inspection and certification that all such components and plant items are manufactured, constructed and tested in accordance with the accepted standards

4-15 KHABAT TPP UNITS 1&2 - VOLUME I

d.

the inspection and certification of pressure or vacuum containing parts, lifting equipment, welding and associated non-destructive testing of such welding, during erection and commissioning on Site.

All certificates shall be distributed in accordance with the requirements of this Specification.

4.4

Drawings and Documents

4.4.1

Drawings enclosed with the Specification A list of the drawings to be read in conjunction with the Specification is given in Volume 3.

The drawings issued by KNOC with the Tender Specification and

forming part of the documents for tendering purposes are intended to be descriptive of the character of the Works and used in conjunction with the requirements of the Tender Specification and shall in no way limit the responsibility of the Bidder to supply all plant and equipment and services necessary to provide for a complete and functional complex. Any omission from either drawings and/or the Tender Specification or express reference to any detail or work necessary and obviously intended shall not relieve the Bidder of his responsibility to include that detail or work. The sizes of the buildings shown on the Tender Specification drawings are approximate, since the actual size will depend on the size and shape of the plant, equipment and materials forming the Bidder’s Works and the space required for installation, maintenance, lay down, storage, access, etc. When measurements are affected by conditions already established, the Bidder shall take and be responsible for field measurements notwithstanding any information given on the Tender Specification Drawings. 4.4.2

Schedules The following technical schedules, contained in Volume 2, have been prepared on IBM compatible computers using Microsoft Word and Excel, and are available via CD ROM. Schedule A

Site particulars 4-16 KHABAT TPP UNITS 1&2 - VOLUME I

Schedule B

Dates of despatch, delivery to site and completion

Schedule C

Manufacturer’s technical particulars

Schedule D

Suppliers of materials, manufacturers, places of manufacture, testing and inspection

Schedule E

Drawings and documentation

Schedule F

Deviations from Conditions of Contract or from Specification

Schedule G

Tests and inspections

Schedule H

List of spare parts and operational consumables

Schedule J

List of special tools

The Bidder is required to complete the required technical schedules (including prices, where applicable) and return these via CD ROM with the completed schedules of their Tender.

A signed print out of the schedules shall be used as original.

The

completed schedules have precedence over the disks. The details provided in Schedule C1 – Manufacturer’s Guarantee Particulars shall take precedence over any other technical information provided in the Tender. Schedule F (Deviations from Conditions of Contract or from Specification) has been prepared on Microsoft Excel on the CD ROM. Bidders are required to complete and return all Comments and Deviations on a CD using the format as provided, ensuring that all items are referenced to the relevant Volume/Section and Page of the Specification, and are uniquely numbered. Unless a specific variation is detailed in Schedule F, the Bidder shall be deemed to comply fully with the requirements of the Specification. 4.4.3

Drawings and documents to be submitted by the Tender A list of the drawings and documents to be included within his Tender is included in Schedule E.

4.4.4

Drawings and documents to be submitted by the Bidder A list of the drawings and documents to be submitted by the Bidder during the Contract implementation stage is specified in Schedule E. The Bidder shall also submit any further drawings or documents as may be reasonably required by KNOC, 4-17 KHABAT TPP UNITS 1&2 - VOLUME I

during the design and construction of the Works.

The Bidder shall prepare and

submit to KNOC review drawings (including dimensioned general arrangement, layout and detailed design drawings), and documents (including schematics, Process and Instrumentation Diagrams (P&IDs), data sheets, descriptions, plans and schedules) of all the plant and equipment specified in the Specification. Drawings and documents already submitted by the Bidder and reviewed by KNOC, and such drawings and documents as shall be thereafter submitted by the Bidder and reviewed by KNOC, shall not be departed from without the written instructions of KNOC. Copies of each drawing, calculation and data shall be submitted in accordance with the programme given in the Schedule of Contract Drawings. If the Bidder requires early review of any drawing or document to avoid delay in the delivery of the Contract Works, he shall advise KNOC to such effect when submitting the drawing or documents.

The sequence of submission of items shall be such that all

information necessary for assessing each item is available at the time when received. In all cases, the drawings or documents shall be submitted in sufficient time to permit modifications to be made if such are deemed necessary by KNOC without delaying the delivery of the Contract Works. As soon as practicable, and not later than 20 working days after receipt, KNOC will advise the category of the drawing as “Reviewed”, “Reviewed as Noted”, or “Returned for Correction”, as may be appropriate. The categories “Reviewed” and “Reviewed as Noted” authorize the Bidder to proceed with manufacture of the equipment covered by such drawings subject to the corrections, if any, indicated thereon.

Where prints of drawings have been “Returned for Correction”, or

“Reviewed as Noted” the Bidder shall make the necessary revisions on the drawings and submit further copies for approval in the same procedure as for the original submission of drawings. Drawings shall be submitted for review at all stages of revision. The Bidder shall supply copies of each drawing for revision as detailed in the appropriate Schedule. Following review, additional copies shall be provided for use at Site as required by KNOC.

4-18 KHABAT TPP UNITS 1&2 - VOLUME I

All dimensions marked on drawings are to be considered correct, although measurements by scale may differ there from. Detailed drawings reviewed by KNOC are to be acted upon where they differ from the general drawings. Drawings showing the physical location of all devices and a plot plan showing the location of all equipment shall be provided. Drawings shall not be “typical” but shall actually represent the equipment provided. Drawings shall be corrected to “as built” before final unit acceptance. “Review” of drawings shall not relieve the Bidder of any of his obligations under the Contract. All legends and notes on drawings provided by the Bidder shall be in the English language. All drawings shall be dimensioned in millimetres (or metres) and drawn to one of the preferred scales quoted in Table 7 of BS Publication PD6031 and on paper of the appropriate size from the International series of A sizes. 4.4.5

Drawings and document format Each drawing and document shall bear a unique drawing/document number. Individual items of equipment forming a part of a drawing shall be clearly identified by means of tables or other approved methods. Each drawing shall incorporate the following information: a.

Location.

b.

Drawing title (shall contain no abbreviations).

c.

Original drawing sheet size ie A0, A1, A2, A3 or A4.

d.

Drawing status.

e.

Drawing number with provision for sheet and revision suffixes.

f.

Drawing date.

g.

Identity of persons carrying out the draughting, checking and approval.

h.

Scale or not to scale.

i.

Project/contract number.

j.

Revision.

k.

North point on geographically related drawings.

KNOC’s information shall be in the form of KNOC’s Drawing Information Box.

This

box shall be located at the bottom right-hand corner of the drawing. 4-19 KHABAT TPP UNITS 1&2 - VOLUME I

Documents submitted for review or approval shall incorporate the following information:

4.4.6

a.

Document title (shall contain no abbreviations)

b.

Document status

c.

Document number

d.

Identity of person carrying out the preparation, checking and approval

e.

Project/Contract number

f.

Revision.

Drawing sheet numbers All drawings shall have a two digit sheet number. Where only one sheet exists the sheet number shall be 00, where more than one sheet exists the sheets shall be numbered from 01 to 99 accordingly.

4.4.7

Drawing and document revision All drawings and documents shall have a two digit revision number and all changes shall be clearly indicated by the addition of the following: appropriate revision number, revision date; identity of persons carrying out the draughting, checking and approval; concise details of the modification. First issues have a revision status of 00, subsequent changes shall increase the revision status from 01 to 99 accordingly. The change of drawing status shall result in a revision increase of one, whether there are changes to the drawing or not.

4.4.8

Drawing and document status Status definitions shall be used on all drawings and documents. not be part of the drawing or document title. a.

For approval

b.

For review

The status shall

The definitions are as follows:

4-20 KHABAT TPP UNITS 1&2 - VOLUME I

c.

For information (for non-project/contract drawings)

d.

For tender purposes

e.

For construction (includes manufacturing)

f.

As built and records.

All revisions of drawings shall be submitted in the following formats as detailed below: a.

A contract drawing list giving the Contract number, manufacturer’s number, sheet number, revision and title of each drawings.

b.

Paper prints of each drawing - full size.

c.

Paper prints of each drawing - A3 size.

d.

AutoCAD ACAD 2000 drawing file.

e.

Drawings in PDF format.

The Contract drawing list shall be submitted by the Bidder for review by KNOC who will indicate thereon KNOC’s requirements. On completion of commissioning, all drawings shall be updated and marked ‘as built’. These shall be supplied as final record drawings. The AutoCAD ACAD 2000 drawing files referred to above shall be imported and exported on media such as Digital Linear Type (DLT) or CD.

Each media shall be

clearly labeled and accompanied by a transmittal sheet showing all file details. Where the file format is restricted, the transmittal sheet shall clearly show how filenames relate to drawing numbers. 4.5

Operating and Maintenance Instructions The Bidder shall supply complete and detailed Operating and Maintenance manuals in English covering the operation and maintenance of the plant and equipment as required by the Contract. The contents of the operating and maintenance instructions, together with all drawings, illustrations and diagrams shall refer specifically to the plant and equipment being supplied under the Contract, and shall be specially prepared where necessary.

General instructions referring to a range of equipment is not acceptable. 4-21 KHABAT TPP UNITS 1&2 - VOLUME I

Operating instructions shall detail all integrated plant normal pre-start checks, starting up, running and shutting down procedures, for the various modes of operation of the plant from cold, warm or hot conditions, emergency operating procedures and any precautions recommended to prevent plant deterioration during periods of non-operation. Operating instructions shall cover local/remote and manual modes of operation and shall also include action on receipt of alarms. The Bidder shall prepare a comprehensive commissioning schedule for each plant item and check lists to record the completion of these activities.

Copies of all

settings and/or calibrations of instruments and controls, pressure switches, trips and alarm settings confirmed and recorded in the commissioning schedules shall be forwarded to be included in the Operating Instructions. [15]sets of draft copies of the manuals shall be submitted to KNOC for review [6] months before commissioning commences. texts.

They shall be submitted as complete

In the event that amendments or alterations to the draft manuals are required,

the Bidder shall submit revisions for review without delay so that the final documents can be supplied within the date specified. [15]sets of the final documents shall be submitted within [4] months after the Taking Over Certificate. The whole of the operating and maintenance instructions shall be securely bound in approved covers and provided with an index for easy reference. The O&M manuals shall be provided in paper hard copy and in electronic copy on CD-ROM to a standard document reader format (ie Adobe Acrobat Reader). The instruction manuals shall conform to the following format: a.

Index The index system shall provide rapid and easy access to particular subjects, drawings and illustrations. It should include a master index and a sub-index to each main section of the manual.

b.

Description This section shall include basic data on the Plant.

4-22 KHABAT TPP UNITS 1&2 - VOLUME I

i.

Descriptions of the Plant both for individual items and for the systems into which items are assembled.

ii.

Drawings sufficient for the understanding of descriptions.

iii. Flow sheets or single line and block diagrams which explain the functioning and logic of the system.

Where related systems are shown on composite

diagrams, individual systems shall be identified by colour, or coding as agreed. iv. Schedules which assemble references to items of a like kind, eg valve schedules, piping schedule, operational limit schedule, switchboard outline schedule, etc. v.

Data sheets which assemble in a concise format relevant technical details of a plant item or system.

The purpose of a data sheet is to provide quick

reference to the essential facts omitting all reference to general descriptions, operating or maintaining principles and instructions. c.

Operation This section shall include basic step-by-step instructions on how to operate the Plant both with regard to individual items and to systems under all patterns of normal and abnormal conditions. The instructions shall include reference to the applicable operation limits. Precautions and warnings relative to the safety of life and equipment shall be included where relevant.

d.

Maintenance This section shall include the following: i.

Build-up and assembly of systems and description of plant items.

ii.

Schedule of equipment giving manufacturer’s name, the make/model No/catalogue No and parts list including any special spares ordering instructions. Spare parts catalogues shall be provided for the various items of equipment supplied.

iii. Routine maintenance schedule. iv. Preventative maintenance and schedule of inspections. v.

Details necessary to carry out overhauls.

vi. Details necessary to locate and rectify faults. 4-23 KHABAT TPP UNITS 1&2 - VOLUME I

vii. Details necessary to set up, test and adjust plant systems and plant items. To include as a minimum, fuel systems, cranage, ventilation, fire protection, water treatment plant and compressed air equipment. viii. Spares schedule. ix. Schedule of recommended lubricants. x.

Sectional drawings of major items of plant fired boiler, steam turbine, condensers, pumps, valves, electric generators, transformers etc with dismantling instructions.

xi. As built copies of all relevant drawings corrected as necessary to incorporate any late modifications. xii. Plant layout drawing. xiii. Schematic diagrams and general arrangement drawings of “as-built” control panels. xiv. Wiring and cable diagrams. xv. Plant equipment and performance curves. xvi. Lifting gear register. xvii. The final records shall include the construction and pre-commissioning data dossier with signed record sheets. e.

Spare parts This section shall comprise the definite and optional spares as required by the KNOC and the spares as recommended by the Bidder. Details and full ordering procedures for each item of main plant, auxiliary plant, electrical and C&I equipment and vendor equipment and shall include: i.

Spare part lists together with referenced sectional drawings from which the manufacturers descriptive name and part number can be clearly identified for ordering purposes.

ii.

Clear details of spare part suppliers address, spare part ordering procedure and including all appropriate plan item reference numbers including serial numbers, type reference numbers, original order numbers, etc as required for the immediate and correct supply of spare parts from various original plant suppliers.

4-24 KHABAT TPP UNITS 1&2 - VOLUME I

In this context the term “suppliers address” means the sub-vendor or original equipment manufacturer.

It will not be acceptable for the Bidder to

nominate himself as the supplier of a spare part unless he manufactures the particular equipment, or it is manufactured by a third party in accordance with the Bidder’s own manufacturing drawings. iii. A list of spares for each type of overhaul/inspection shall be provided. Note: where spare parts are not available and full item replacement is necessary this fact is to be advised and the appropriate ordering details provided as defined above. For spares that are available from a multitude of sources (eg seals, “O” rings, gaskets, nuts, bolts, etc the Bidder shall supply details of the sizes, standards and materials used. Details shall be provided of any special storage requirements or limitations on spare parts, lead time, shelf life, storage requirement, quantity etc. f.

Plant preservation schedule and methods This section shall cover the procedures for shutting down plant.

Preservation

during hibernation and re-starting of plant. g.

Manual production Accepted abbreviations of units of measurement are permitted in the text and illustrations. A list of the abbreviations the Bidder proposes to use in the text and schedules is to be approved before work begins on the manuals. As a guide it may be taken that abbreviations of terms will be permitted only where they are in common use and readily understood, eg ac, dc. Drawings and diagrams shall, wherever practicable, be reduced to a convenient size, eg A3, and bound into the manual.

The reduced size drawings and

diagrams shall be completely legible and suitable for reproduction.

Drawings

which are referred to several times in the text shall be either of the “fold out” type or visible when referring to other parts of a manual or be repeated as

4-25 KHABAT TPP UNITS 1&2 - VOLUME I

necessary.

Throw-clear drawings are to be included at the back of the relevant

subsections, and their locations noted in the Section drawing index. Detailed engineering drawings necessary for maintenance and mentioned in the text but not included in the manual because of size reduction difficulties, should nevertheless be listed in the drawing index. The words “NOT INCLUDED” must be entered against them. Drawings are to be identified at the bottom right corner by title and number. Black on white line drawings should be used wherever possible, using line shading, and cross hatching as necessary for clarity. Multi-colour and half-tone drawings using shading techniques, eg air brush, should only be used in preference to line drawings where the additional information conveyed justifies the effort and cost. Isometric and perspective illustrations are preferred to engineering (orthographic) drawings, although engineering drawings may be included if they are more suitable due to the size and complexity of a particular item of equipment.

Where engineering drawings are used, clarify of detail

necessary to support the text shall be retained and in addition all irrelevant information such as unnecessary dimensions, manufacturing information, borders, centre lines, etc should be removed.

All drawings shall be clearly

marked by legend. The manuals shall be produced as a book or books, with page size international A4, bound into strong durable covers inscribed upon the front generally in the form of the title page to the Specification, except that the references to the contents will be replaced by “Operation and Maintenance Instructions”. Bidders standard pattern covers may be used, subject to KNOC’s approval. The name of the main Bidder but not that of any subBidder may also be inscribed upon the cover after the description of the Plant. The name of the KNOC, the title of the project and Contract number followed by a brief description of the Plant (eg turbo-generator plant, etc) shall be inscribed upon the spine of the cover. If the text is bulky it shall be divided into conveniently sized volumes, and each shall be marked with the appropriate volume number. 4-26 KHABAT TPP UNITS 1&2 - VOLUME I

4.6

HAZOP Studies The design of the plant shall take into account good engineering practice with an emphasis on safe and efficient operation and maintenance practices.

The Bidder

shall perform hazard and operability (HAZOP) studies to demonstrate to KNOC that where possible all risks concerning safe and efficient construction, operation and maintenance have been identified and solutions implemented to eliminate such risks. In the event that the HAZOP studies identify residual risks which cannot be avoided, the Bidder shall incorporate measures in the design, implementation and project documentation (O&M Manuals) to ensure that the effects of the risk is mitigated and the likely effects on the operating personnel, the environment etc are minimized. KNOC shall be provided the opportunity to participate in the HAZOP reviews. 4.7

Places of Manufacture, Testing and Inspection The manufacturers and the places of manufacture, testing and inspection before shipment for the various portions of the Works shall be as stated in Schedule D. As soon as practicable after entering into the Contract, the Bidder shall, having obtained KNOC's consent in accordance with the Conditions of Contract, enter into the subcontracts he considers necessary for the satisfactory completion of the Works.

4.8

Packing and Marking on Packages All apparatus shall be carefully packed for export shipment and storage at site in such a manner that it is protected against all climatic conditions, which shall be as stated in Section 6.25. The packing cases and packing materials are included in the Contract and shall become the property of the KNOC. Key equipment shall be transported with monitoring dew meters within each transport case.

4.9

Training The Bidder shall provide training for the MOE/KNOC’s staff, and give the price in his Bidder, as required in the EPC Contract.

The price shall assume for [172] man-

weeks of offshore training and [198] man-weeks of onshore training.

4-27 KHABAT TPP UNITS 1&2 - VOLUME I

4.9.1

General The Works shall include for separate training sessions for operating and for maintenance staff. Such training shall be at the Bidder’s expense and to an agreed pre-scheduled programme.

The level of training shall be suitable for each member

of staff to ensure individual competence in the overall operation, troubleshooting, protection

schematic,

interlock

matrix,

maintenance,

administration

and

management of the Power Station. The Bidder will be responsible for the planning and co-ordination of the training in conjunction with KNOC.

A fully detailed training

programme with dates shall be submitted to KNOC for approval [4] months after award of the Contract. The training shall be ongoing during the testing and commissioning period so as to ensure that operating and maintenance instructions have been given on all commissioned plant items handed over to MOE/KNOC.

4.9.2

Contents of training The Bidder shall implement following training program for personnel from the MOE's Generation Department. Training will be in English language however a Kurdish translator will be required during Onshore training to assist with technical explanation.

4.9.2.1 Plant management training The Bidder shall conduct a minimum of 40 man weeks Offshore Plant Management Training(4 weeks × 10 MOE Personnel). This training program will cover the following topics: a. Power Plant Construction Management. b. Power Plant Operational Management; Concepts & items necessaries for successful management. c. Power Plant Management; Developing Procedures effectively. d. Performance Power Plant Management taken from existing overseas Power Plants. e. World Thermal Plant Residual Oil & HFO market overview and fuel consumption procurement strategy. f. Power Plant Quality. g. World Power Generation Business Status and Outlook. This training program will be conducted within execution of the Contract the first year.

4-28 KHABAT TPP UNITS 1&2 - VOLUME I

4.9.2.2 Plant operations training Offshore Training:The Bidder shall conduct a minimum of 60 man weeks of Offshore Plant Operations (4 weeks × 15 MOE Personnel). The training will be conducted at the manufacturing facility. At least 70 percent of the training program will be conducted in a classroom. The instruction will be evenly divided between the following: a. Electricity and Thermal Power Plant Generation and Transmission. b. Steam Turbine Generator and Excitation Equipment. c. Oil Fired Boiler Operation and Emissions (including Flue Gas treatment) d. Digital Control Systems e. All Balance of Plant Items. f. Fuel Treatment. g. Water Treatment. h. Occupational Health & Safety in a Thermal Power Plant. Items shown in Section 4.9.2.2. A ~ H, above will also include but not limited to the Start-up, Operation, Shutdown, Troubleshooting, LOTO (Lock Out Tag Out) Procedures, and Preservation of Plant during extended shutdowns. Onshore Training:The Bidder shall conduct a minimum of 90 man weeks at the jobsite providing Plant Operations on-the-job training (6 weeks × 15 MOE Personnel). Of these 90 man weeks, at least 20 percent and no more than 40 percent will be classroom training. The remaining 60 to 80 percent of the training will be conducted in the field. It is preferred that this training be coordinated with significant field activities such as unit oil flush, initial gas fill (if required), initial turbine roll, and initial synchronization. The instruction shall consist of at least the following phases: a. 40 percent of the time will be devoted to discussing the theory of items Section 4.9.2.2. A ~ H above. b. 60 percent of the time will be expended discussing operation of items Section 4.9.2.2. A ~ H above. This will be coordinated with the significant field activities previously identified above. 4.9.2.3 Plant maintenance training Offshore Training:4-29 KHABAT TPP UNITS 1&2 - VOLUME I

The Bidder shall conduct a minimum of 72 man weeks of Offshore Maintenance training for 18 individuals. (4 weeks × 18 MOE Personnel) The training will be conducted at the manufacturing facility during a time when the major components for the Contract are at a stage of construction that would prove beneficial to the trainees. At least 50 percent of the time will be spent with the equipment and at least 25 percent of the time will be expended addressing the theory of maintenance, including preventive maintenance activities. a. Electricity and Thermal Power Plant Generation and Transmission. b. Steam Turbine Generator and Excitation Equipment. c. Oil Fired Boiler Operation and Emissions (including Flue Gas treatment) d. Digital Control Systems e. Balance of Plant Items. f. Fuel Treatment. g. Water Treatment. h. Occupational Health & Safety in a Thermal Power Plant. Items shown in Section 4.9.2.3. A ~ H, above will also include but not limited to Maintaining and Repairing, Troubleshooting, LOTO (Lock Out Tag Out) Procedures, and Preservation of Plant during extended shutdowns. Specific training for each Engineering Discipline shall be included. Onshore Training:The Bidder shall conduct a minimum of 108 man weeks at the jobsite providing Plant Maintenance on-the-job training (6 weeks × 18 MOE Personnel). This training will be a continuation of the Section 4.9.2.3 Offshore Portion items A ~ H, and will consist primarily of field instruction. At least 20 percent but no more than 40 percent of the time will be classroom instruction. The program will be scheduled to take advantage of

significant

phases

of

construction

and/or

testing

activities

such

as

turbine/generator alignment, generator rotor insertion, unit oil flush, piping system hydro testing, steam blowing, main valves restoration, DCS commissioning, etc. Specific training for each Engineering Discipline will be included. Miscellaneous Training Requirements The MOE/KNOC can change the above percentages between classroom and hands-on training for either the sessions at the manufacturer's facility or the sessions at the job site, but not the overall time at each location. 4-30 KHABAT TPP UNITS 1&2 - VOLUME I

The field training overall duration will not be less than 90 days, the program can be integrated. The Offshore Operations Training and Maintenance Training will not be performed simultaneously. If portions of the on job training are to be accomplished entirely by the Bidder's personnel that are performing an activity to satisfy another section of the contract, the Bidder shall identify in detail how this will be accomplished, including how either activity will be performed as effectively. 4.9.3

Breakdown of training plan ITEM

Minimum Man-weeks Offshore Onshore

z Plant Management Training Offshore 4 weeks of plant management training for 10 people. 4 weeks

×

10 people

=

40 man weeks

40

z Plant Operations Training Offshore 4 weeks of Off-shore plant operation training for 15 people. (5 Shifts, 3 people from each shift) 4 weeks

×

15 people

=

60 man weeks

60

Onshore 6 weeks of plant operation on-the-job training for 15 people. 6 weeks

×

15 people

=

90 man weeks

90

z Maintenance Training Offshore 4 weeks of plant maintenance training for 18 people. 4 weeks

×

18 people

=

72 man weeks

72

Onshore 6 weeks of maintenance training for 18 people 6 weeks

×

18 people

=

108 man weeks

108

6 × I&C people 6 × Electrical people 6 × Mechanical people TOTALS:

172

198

4-31 KHABAT TPP UNITS 1&2 - VOLUME I

4.10

Spare Parts and Consumables The Bidder shall provide with its tender a Firm Fixed priced list of Spare Parts using two (2) years of operation after Operational Acceptance in Schedule H1. The list shall be developed on an estimated usage basis and supporting data from existing plants shall be provided to substantiate the spares holding and usage proposed. The priced list shall include a recommended stockholding to cover all initial inventory, planned maintenance and strategic reserves up to and including the first major overhaul. The list shall be developed on an estimated usage basis and supporting data from existing plants shall be provided to substantiate the spares holding and usage proposed. The Bidder shall fill up the form of the Commissioning Consumables in Schedule H2 within the Firm Fixed price form. The Bidder shall provide all the commissioning consumables for two (2) years of operation after Operational Acceptance. In general it shall be understood that all parts, materials, consumables etc, to be consumed or replaced during installation, commissioning, start-up or test run, that are prior to the plant take-over shall be considered as installation material, and shall be included in the price of equipment and Installation work.

4.11

Special Tools and Lifting devices The Bidder shall supply a complete set of any special tools and other equipment necessary for the dismantling, work storage, re-erection and adjustment of any part of the plant within the Fixed Firm price form in Schedule J. Tools shall be provided in new condition, adequately labeled to their use and contained in stout and suitable padlocked boxes. Any special lifting devices/slings required shall be provided and clearly marked by embossed labels which show safe working loads.

Test Certificates shall be

provided where applicable. Suitable lifting equipment shall be provided to facilitate removal and maintenance of plant and equipment.

Lifting devices shall be designed in accordance with the 4-32 KHABAT TPP UNITS 1&2 - VOLUME I

latest editions of the relevant ISO standard or equivalent.

All electrical and

mechanical functions shall be tested before despatch from the manufacturer’s works. Operational and overload tests shall be carried out on site. Suitable lay down areas and methods of retrieving the equipment should be included to support the integrated approach to the crane facilities.

4.12

Warranty Engineer A warranty engineer shall be located on site for [one] year following the date of Operational Acceptance.

The warranty engineer shall have not less than eight

years experience of power plants similar to the Facility and shall act proactively to ensure the best performance and availability of the plant is achieved.

A CV for the

proposed engineer shall be submitted for approval prior to him taking up the appointment. The approval shall not be unreasonably withheld. The Contract shall include for all travelling, accommodation and subsistence costs of the engineer and for his replacement by a similarly experienced engineer during periods of leave or long-term sickness.

The replacement engineer shall be to

approval. Such approval shall not be reasonably withheld. The warranty engineer shall be available on site between 0800 – 1700 hours Saturday to Thursday, and available for callout duty outside of these hours. The warranty engineering shall be responsible for the following throughout the warranty period: a.

Ensuring that the O&M operator is operating and maintaining the entire plant in accordance with the manufacturers’ instructions, and notifying the MOE and the O&M operator of any shortcomings.

b.

Providing technical advice and support to the O&M operator.

c.

Monitoring the performance and availability of the plant.

d.

Assisting with troubleshooting.

e.

Acting as liaison with the Bidder’s head office for the clearance of any defects existing on Takeover or occurring during the warranty period, to ensure that they are cleared promptly.

4-33 KHABAT TPP UNITS 1&2 - VOLUME I

MOE/KNOC will monitor the performance of the warranty engineer.

Should his

performance be unsatisfactory, the Bidder shall provide a replacement engineer to the satisfaction of MOE/KNOC.

4.13

Risk Management Guideline

4.13.1

Introduction Risk Management is a continuous process that identifies, analyzes, mitigates, reports, and tracks risk that have the potential to adversely affect the project. Risk, along with scope, schedule, and cost, is a fundamental element of the construction project that must be actively controlled and managed. Contractor shall use a formal, systematic process for the management of risk. The Risk Management Plan defines the scope and process for the identification, impact evaluation, and management of risks. It is integral part within the overall project management process to achieve scope, schedule and cost results and shall be factored into every project decision at all levels throughout the lifecycle of the project. Additionally, identifying, managing, and exploiting opportunities is equally important. To that end, the Project shall also employ a formal, systematic process for managing opportunities. The following shall be accomplished: a.

A risk management process is developed and implemented that includes: z

Risk

z

Risk Assessment

z

Risk handling strategies for each item including mitigation steps for

Identification

moderate or high risks. z

Analysis of the cost and schedule impacts to implement a mitigation plan versus realizing the risk, including the development of cost and schedule contingency estimates

b.

z

Tracking of risk and residual risk mitigation plan implementation

z

Reporting on risk status, ownership and ranking

Defines organizational responsibilities regarding the management of risk. z

Provides a summary discussion of the risk assessments of the key risks facing the project and the respective mitigation actions, and

z

Delineates the methodology to execute the risk management workflow process.

The Risk management plan facilitates the matching of the primary Work Breakdown 4-34 KHABAT TPP UNITS 1&2 - VOLUME I

Structure (WBS) elements with the established organizational breakdown structure for the purpose of assigning accountability within the risk management workflow process for subsequent risk handling actions. Contractor shall review risks on a monthly basis in responsible department and integrate them twice a year. 4.13.2

Risk Definitions and Concepts Uncertainty in a project is called risk. It is formally defined as an uncertain event or condition that, if it occurs, has a positive or negative effect on a project objective. Risk is an inherent part of all activities, whether the activity is simple and small, or large and complex. The relative size and/or complexity of an activity may or may not be an indicator of the potential degree of risk associated with that activity. There are two main sources of risks to the project.

4.13.2.1 Event Risks Event Risks are potential occurrences that can have an impact on project scope, increase project cost and/or schedule, reduce safety margins, or reduce the quality of the final product. Event Risks can be caused both internally and externally, and, in many cases can be foreseen by project management within some reasonable planning horizon. Examples of a foreseeable event include instabilities in qualified craft labor at a construction site, or the ability of component suppliers to meet their delivery schedules.

Event Risks include the following categories:

Event Risks a. Technical z

Design

z

Safety

z

Environment

z

Technology

z

Interfaces

b. Programmatic All projects are based on a set of assumptions that affect the scope, schedule, and cost of the project.

These assumptions establish the basis for determining the

estimated schedule duration and cost for each activity in the WBS. The expected completion date of the project and the estimated cost-at-completion are predicated on these assumptions holding true. Many of these assumptions address future conditions that shall not be known with certainty until later in the project. Therefore, there is a probability that something may happen to render an assumption false. 4-35 KHABAT TPP UNITS 1&2 - VOLUME I

These are referred to as “Events” Risk, whether having a positive or negative effect on a project, is the product of the probability of the Event occurring multiplied by its impact on the project. There are some Events that are either random or of such a nature that they cannot be influenced (such as natural disasters). Random events such as these usually cannot be effectively managed (i.e., because the probability of such events occurring can not be controlled and their impact usually can not be quantified until “after-thefact”). On the other hand, many Events can be managed (either in terms of proactively influencing their probability of occurrence or minimizing their impact). Since management resources are limited, it is the role of the Risk Management process to identify which of the hundreds of Events that could affect the Project should be proactively managed. 4.13.2.2 Uncertainty Risks Uncertainty Risks are the result of variability of the estimating data used to create the project baseline cost and schedule estimates. A baseline plan is a series of logically linked activities, with duration and cost established through a structured estimating process. All estimates contain uncertainty that can be bounded within predicable ranges based on information available to an estimator, including whether the proposed activity has been performed before. Importantly, through simulation, the effect of schedule and cost variation can be modeled and understood, and, with appropriate feedback, the causes of uncertainty can be managed during the project execution, thus lowering the potential risk impact. Historically, estimating uncertainties have been included in project cost estimates as “traditional contingency.” This primarily covers uncertainties in project cost and schedule estimates that result from: a. Errors and omissions, b. Inflation, c. Adverse weather, d. Pricing variances, e. Quantity variances, f. Complexity, and g. Facility access. 4.13.2.3 Key Definitions Risk and Opportunity Management embrace various concepts, terminology, and elements that are designed to enhance the overall Project Management and 4-36 KHABAT TPP UNITS 1&2 - VOLUME I

Integration process for the project. Some Key Definitions are provided below: a. Consequence of Occurrence A qualitative or quantitative representation of the potential impact of an identified risk materializing. b. Contingency Resources required to increase confidence for project success and effectively manage the risks that are normally considered within the project’s control (i.e., “known unknowns”) c. Event A discrete occurrence that may affect scope, schedule, and/or cost of a project for better or worse.

Internal events are those within the control of the project.

External events are outside the control of the project. d. Event Risk Broad-based issues that can have an impact on project scope, increase project cost and/or schedule, reduce safety margins, or reduce the quality of the final product (examples: labor, contract issues, inability of suppliers to meet delivery schedules, regulation changes, etc.) e. Monte Carlo Analysis An automated probabilistic risk assessment technique used to measure the effects of uncertainty within defined probability distributions. f. Probability of Occurrence A qualitative or quantitative representation of the relative probability of realizing an identified risk. g. Programmatic Risk The impact associated with disruptions created by decisions, events, or actions that have the potential to affect a project’s outcome. h. Qualitative Analysis A subjective assessment of the level of confidence within the defined scope of work. i. Quantitative Analysis An objective assessment of the level of confidence within the defined scope of work. j. Residual Risk Risk elements remaining after the implementation of selected risk handling strategies. k. Risk 4-37 KHABAT TPP UNITS 1&2 - VOLUME I

An uncertain event or condition that, if it occurs, has a negative effect on a project objective or goal.

Risk is always derived quantitatively by obtaining the product

of probability of occurrence and consequence of occurrence. l. Risk Management The act or practice of dealing with risk.

It includes planning for risk, assessing

(identifying and analyzing) risk areas, developing risk handling options, monitoring risks to determine how risks have changed over the course of a project, and documenting the overall risk management program. m. Technical Risk The impact associated with uncertainties regarding the development of a new design, or the use of existing technologies within different applications, either to provide a greater level of performance or to accommodate imposed requirements or constraints. n. Uncertainty Risk Issues directly tied to the project scope, cost, and schedule, and which are the result of the natural variation in events and processes within the project. o. Worse-Case Schedule Impact (Risk Assessment Form) This is defined as the total delay in months associated with the occurrence of a risk event without the benefit of mitigation strategies. p. Worse-Case Cost Impact (Risk Assessment Form) This is defined as the total cost in € associated with the occurrence of a risk event without the benefit of mitigation strategies.

4-38 KHABAT TPP UNITS 1&2 - VOLUME I

4.13.3

Risk Management Process Baseline: (Scope, Schedule & Cost) Assumption Plans

Integration Cost & Schedule Baseline

Action Item List

Planning Identification By WBS Risk Management Plan

Mitigation Strategies Implementation Cost & Schedule Impacts

Risk /O p Ass portun es s m ity ent

Residual Risk Cost & Schedule Impacts (Risk-based Contingency)

Quantification

Handling Event Screening Checklist

Impact Determination

Potential New Risks/Opportunities

Risk/Opportunity Assessment Report

Inputs Outputs Process Function

Risk and Opportunity Management Process Each block represents a step in the functional performance of risk management. All encompassing in this plan is the qualification of risks from on-going identification to final close-out of the risk.

Risk Management is essentially an ongoing and iterative

process, which applies the best efforts of a knowledgeable project staff to a suite of focused and prioritized issues. At the center of the risk management process are the four fundamental steps for risk quantification/assessment needed for effective risk management: a. Risk Identification b. Risk Quantification c. Risk Handling/Mitigation Planning d. Risk Impact Determination 4.13.3.1 Risk Identification Risks may be “project-wide” or be isolated to one or more areas of the project WBS. The development of the preliminary baseline shall identify risks at the total project, subsystem/procurement package and activity levels. Risks may be of many types, including but not limited to: technical (physics, 4-39 KHABAT TPP UNITS 1&2 - VOLUME I

research, or engineering), schedule/time, budget/cost, funding, resource availability, procurement, integration, performance variances, proposed changes, and many other types (e.g., political, economic, etc.), and may be of a source internal or external to the project.

Risks may be at the “project-level” (generally affecting the

entire project) or at any sub-level of the project, which may also be at different project levels. Key sources of input to risk identification are: a. Task descriptions (Scope statements, etc) The nature of the activity shall have a major effect, for example, an activity involving proven technology may have significantly less risk when compared to an activity involving new technology, or highly complicated manufacturing processes, which may require extensive development and thus have a higher risk. b. Other Planning Documents Cost and/or schedule estimates may provide greater risks when developed from early or incomplete information. Procurement arrangements may identify unusual market conditions such as regional sluggishness or lack of multiple suppliers. Finally, the DA may develop hazard lists that identify additional sources of risks. c. Historical information This information can be extracted from previous activity files, other Tokamak projects, and commercial databases.

Lessons learned can also provide input.

d. Assumptions Assumptions identified during the functional and operational requirement development phase of the system engineering process are often good sources for potential risk and should be considered risks until the uncertainties can be resolved. Risk identification shall be initiated by using risk source checklist, process flow charts, interviews with subject matter experts and team brainstorming. In using checklists, the process of identifying different types of risks shall be started. The results of the risk identification phase are clear statements of risk with corresponding bases. The event that creates the risk shall be identified, as well as the effect could have on the project or activity.

This information shall be

documented in a Risk Assessment Form. Meetings shall serve as standing mechanisms for identifying new project risks. Technical and Programmatic – The following occurrences may prompt re-evaluation of project risks, if appropriate: a. Upon significant changes to project scope, including the addition of major scope, 4-40 KHABAT TPP UNITS 1&2 - VOLUME I

b. Upon the reduction or addition of available resources or changes to the funding profile, c. Upon a delay or acceleration of the project schedule, d. Upon significant changes to field conditions, e. Upon the realization that project baseline changes are imminent, f. Upon changes to major procurement cycles, or g. As directed by project senior management. Cost and Schedule – A qualitative analysis shall be performed at the following milestones to assess the level of management confidence with project scope, cost, and schedule: a. Upon completion of Conceptual Design, b. Upon completion of Preliminary Design, and c. Upon completion of Final Design 4.13.3.2 Risk Quantification Risk quantification or assessment involves assessing risks to determine potential project consequences.

This consists of determining the likelihood of the identified

risk actually occurring, assessing the impact if it does occur, and then assigning an overall rating to the risk. The contractor shall collect this information and communicate it with all involved members of the project team. The guidelines for use of the project risk assessment matrix are given below. a. Determining Likelihood Risks shall be categorized by likelihood or probability of occurrence. Generally, a risk that is determined to be in the “Very Likely” to occur category is one that has a probability of 80% or greater of occurrence.

A risk that is “Likely” to occur is

one that has a probability between 40%–80%.

A risk that has less than a 40%

chance of occurring is categorized as “Unlikely”. It should be noted that even risks categorized as “Very Unlikely” or “Not Credible” to occur may still happen. b. Determining Impact Risks can also have varying impacts/consequences on a project. If a risk occurs, a negative consequence usually results. The consequence shall typically adversely affect the technical accomplishment, result in a schedule or milestone slip, and/or cause a cost impact. The degree of the consequence is what is measured in this step. Each risk shall be categorized as follows z

Negligible

z

Marginal

z

Significant 4-41 KHABAT TPP UNITS 1&2 - VOLUME I

z

Critical

z

Crisis

c. Overall Risk Rating A risk’s probability shall be weighed against its potential impact in order to effectively gauge the measure necessary for dealing with that risk. Each risk shall be assigned an overall risk rating as high, moderate or low based on the X and Y axis intersection point of the risk assessment matrix. The management actions to be taken correspond to the overall risk rating. High Risks. Require close monitoring and active on-going involvement of the contractor. These risks also require the identification of a mitigation strategy (recorded on the risk register), and regular review at project management meetings. Frequent high-level visibility of these risks is required. Elimination and/or mitigation of risks rated as “High” overall is a priority. Moderate Risks. Require regular periodic assessment and action by the Contractor., as appropriate to reduce the chance of these risks occurring or escalating. Although not usually of the severity of “High” risks, the risks with an overall categorization of “Medium” can still have, in some cases, a high impact to the project if they occur. “Medium” risks shall also be reviewed at the project status meetings. Low Risks. Risks with an overall categorization of “Low” shall be monitored by the Contractor.  d. Risk Assessment Matrix The project employs an established risk methodology for consistency and quality in the risk management process, as represented by the risk assessment matrix shown below. The y-axis determination (Likelihood of occurrence) is first made for an identified risk, followed by the x-Axis (Impact/Consequence). The table then yields an “overall risk rating”. This overall rating is initially reviewed and validated as the “best fit” by the person identifying the risk, and then presented to their Management for their review.

Adjustments may be made based on an initial

“fact finding” period. The risk is then expeditiously entered into the Project Risk Register. Later adjustments in the overall risk rating may be made, up or down, depending on governing events and/or the relative success of applied mitigation strategies. Risk assessment matrix is shown below.

4-42 KHABAT TPP UNITS 1&2 - VOLUME I

Probability of Risk

Very Likely

Moderate

Moderate

High

High

High

Likely

Low

Moderate

High

High

High

Unlikely

Low

Moderate

Moderate

High

High

Very Unlikely

Low

Low

Moderate

Moderate

High

Not Credible

Low

Low

Low

Low

High

Critical

Crisis

Negligible

Marginal

Significant

Consequence 4.13.3.3 Risk Handling and Mitigation Risk handling and/or mitigation is the identification of the course of action or acceptance selected for the purpose of effectively responding to a given risk. There is generally four risk handling strategies for responding to risks: 1.) Avoid, 2.) Transfer, 3.) Mitigate, or 4.) Accept. a. Avoid This strategy focuses on totally eliminating the specific threat or risk-driving event usually by eliminating the potential that the risk event can occur (i.e. – take action to drive the likelihood of occurrence to zero). This can be accomplished through total structure, system, or component redesign, or by selecting an alternate design approach, which does not include the particular risk event, etc. Generally it is not possible to eliminate all risks, but specific risk events can often be eliminated with this strategy. If the strategy is to avoid the risk, the cost and duration to implement this strategy is determined and documented on the Project Risk Register. Once the strategy is implemented, the risk level for the specific element shall be reduced to zero. No residual risk remains with this strategy.

In some cases, substitute activities or

processes may introduce new risk. b. Transfer This strategy is used when an activity scope with identified risks can be transferred to another activity or entity, especially when this risk can be more easily handled within the receiving activity or entity. A risk can be transferred to an outside. This in itself is a risky strategy in that the organization may fail to meet the agreed requirements, or introduce news risks into the organization. In any case, the individual or organization receiving the risk must accept the risk transfer.

4-43 KHABAT TPP UNITS 1&2 - VOLUME I

If the strategy is to Transfer the risk, the cost and duration to implement this strategy is determined and documented. Once the strategy is implemented, the risk level for the specific site shall be reduced to zero. No residual risk remains with this strategy. c. Mitigate This strategy identifies specific steps or actions that shall improve the chances that an activity shall succeed by: z

Reducing the likelihood of the occurrence of the risk event, or

z

Mitigating the consequence of a risk event, or

z

A combination of the two.

The expected outcome of a risk event can be reduced by using proven technology to lower the likelihood that the activity shall be impacted, or by adding specific mitigation actions to the activity scope. Any corresponding cost and schedule implementation impacts due to the mitigating actions must be addressed during impact determination. at a reduced level.

Using this strategy, a risk remains, but

The remaining diminished risk is called residual risk.

The

impacts of these residual risks shall be identified during impact determination. If the strategy is to Mitigate the risk, then the cost and duration to implement this strategy is determined and documented.

Included in the analysis is a

determination of whether to initiate a mitigation plan – depending on the plan cost and schedule opposed to the cost and schedule impact if the risk is realized. In addition, the likelihood, the consequence, and the risk level of the residual risk (i.e. risk after mitigation action) are then determined. The potential cost and schedule impacts of the residual risk are identified using three data points, namely the best case (or most optimistic), the most likely, and the worst case (or most pessimistic). These are used in a triangular distribution to assess the cost and/or schedule uncertainty brought on by the risk element. d. Accept Accepting a risk is essentially a “no action” strategy. Selection of this strategy is based upon the decision that it is more cost or schedule effective to continue the activity as planned with no resources specifically dedicated to addressing this risk. However, the “no action” strategy may be hedged by developing a contingency plan in case the risk event occurs and then tracking the risk to assure that it does not increase during contingency execution. In this case, the contingency plan does not mitigate the consequence, but seeks to control the impacts that typically result from the event consequence. Low risks are typically accepted. However, 4-44 KHABAT TPP UNITS 1&2 - VOLUME I

even though Low risks may be accepted, one must not overlook the cumulative impact to an activity resulting from a multitude of Low risks, especially if those risks are concentrated in one specific activity area. For a handling strategy of Accept, the residual risk equals the initial risk because this strategy does not change the risk level.

If the risk is accepted, without

additional actions, then the cost and duration of this handling strategy implementation is zero, which is documented on the Project Risk Register. 4.13.4

Integration with Project Management Once the risk handling strategy has been selected, it shall be reviewed by the responsible management and approved and integrated into the project planning. The Contractor shall collect and communicate the risks to all involved members of the project team. For risks that are designated as intra-site risks, the risk handling strategy must be integrated in the specific procurement arrangement. For risks that are inter-site or project-level, the risk handling strategies shall be revied and approved by project manager. Once approved, the risk handling strategy activities, cost, and schedule impacts must be integrated into the baseline plan.

4.13.4.1 Risk and Baseline Change Control Relationship Changes to the Project scope, schedule and cost shall be managed through a formal change management process. All proposed internal and external changes shall be formally evaluated for their impact and risk to the project, as part of the approval process. Proposed baseline changes may be merited to mitigate risk(s). Correspondingly, The Contractor shall evaluate proposed changes to fully understand the potential risk consequence, either positive or negative. Externally directed changes shall also be evaluated for risk consequence. Any risk emanating from proposed or authorized project baseline changes shall be managed through the Project risk management process. 4.13.5

Risk Closure Closure of a risk is dependent on closure of the actions necessary to implement the chosen strategy.

It begins by closing out the action item(s) and accompanying

schedule item(s). Once all the actions posted against the risk mitigation strategy(s) are completed, the risk can be closed.

Once closed the Project Risk Register

should be updated, sent to related parties and then archived. 4.13.6

Opportunity Management Process 4-45 KHABAT TPP UNITS 1&2 - VOLUME I

The Contractor shall establish an opportunity management process similar to the risk management process.

Opportunity management is to identify elements that

may enhance or provide benefit to the project cost, schedule and/or technical performance. The opportunity element identification process shall be assessed simultaneously with the risk element identification. 4.13.6.1 Opportunity Handling Strategies Opportunity handling is the identification of the course of action or acceptance selected for the purpose of effectively responding to a given element.

There are

generally four opportunity handling strategies for responding to opportunities: 1.) Exploit, 2.) Share, 3.) Enhance, or 4.) Ignore. a. Exploit This strategy may be selected for Events with positive impacts where the organization wishes to ensure that the opportunity is realized. This strategy seeks to eliminate the uncertainty associated with a particular upside Event by making the opportunity definitely happen.

Directly exploiting responses includes

assigning more talented resources to the project to reduce the time to completion or to provide better quality than originally planned. b. Share Sharing a positive Event involves allocating ownership to a third party who is best able to capture the opportunity for the benefit of the project.

Examples of

sharing actions include forming risk-sharing partnerships, teams, special-purpose companies, or joint ventures, which can be established with the express purpose of managing opportunities. c. Enhance This strategy modifies the “size” of an opportunity by increasing probability and/or positive impact Events.

Seeking to facilitate or strengthen the cause of the

opportunity, and proactively targeting and reinforcing its trigger conditions, might increase probability.

Impact drivers can also be targeted, seeking to increase

the project’s susceptibility to the opportunity. d. Ignore This is to document that the opportunity was considered, but not implemented. Reasons for not implementing an opportunity may be due excessive implementation cost and/or schedule increase, compared to the return from this element.

4-46 KHABAT TPP UNITS 1&2 - VOLUME I

5

SITE DETAILS AND SAFETY REQUIREMENTS

5.1

Location of Site, Access and Use of Site The site conditions are given in Volume 2, Schedule A and drawings showing the location of the site are included in Volume 3. The Bidder shall inform himself fully as to all transport facilities, requirements and loading gauges to ensure that all equipment as packed for transport shall conform to these limitations, and shall be responsible for all damage to roads, bridges, etc., during transportation. The location of the laydown parking and construction areas will be the responsibility of the Bidder. The Bidder shall provide his own hardstanding storage, working areas, access ways, any roofed accommodation and security arrangements where necessary. Such facilities shall be removed from site on completion of the Contract after the agreement of the KNOC. The Bidder shall, and at his expense, take precautions to keep all existing and new temporary and permanent roadways clear of any spillage from his traffic. All such spillage, which occurs, shall be cleared immediately, including excessive earth or other materials brought in on wheels or tracks of the traffic. The Bidder shall confine his labor, material, plant and equipment to within the designated areas of which he has been given possession. No lands or other places which are the property of the MOE shall be used except in accordance with the instructions of the MOE. The Bidder shall at any time move any vehicle, temporary work, plant or other obstruction within his control that may be required to be moved by the KNOC and the Bidder shall move any such vehicle, temporary work, plant or obstruction promptly on the instruction given by the KNOC, all at the Bidder’s own cost. The Bidder shall maintain access for the inspection, operation and maintenance of any of the KNOC’s premises, plant or works which are within the contract site boundaries. 5-1 KHABAT TPP UNITS 1&2 - VOLUME I

The Bidder shall maintain the whole of his operations in a clean, tidy and safe condition and shall arrange his materials in an orderly manner. All rubbish, waste materials, debris and the like shall be regularly and systematically cleaned off the working areas as it accumulates and deposited in collecting points from which the Bidder shall regularly dispose of waste materials. The Bidder shall ensure that the site and adjoining lands belonging to third parties are kept free from construction materials of any kind arising from the works and that no damage occurs to third party property. On sites which are in use, or have been in use, or sites in which services may cross, the position of any existing services in or near the proposed work area shall be pinpointed as accurately as possible by means of site plans. The Bidder shall use locating devices to confirm the position of the services. Any pipe or cable which is uncovered shall be treated as live unless proven otherwise. Upon completion of the work in a particular area, any warning tiles or tapes shall be replaced.

5.2

Site Facilities The Bidder shall provide portable office site accommodation for his own and sub Bidders staff, which shall conform to the requirements of any local and statutory authorities, for the area in which the work is situated. Site accommodation and arrangements shall be subject to the approval of the KNOC in all respects. The Bidder shall establish and operate a site security system, all staff employed at site will be issued with security passes by the Bidder to permit access to and from the site. It shall be the Bidder's senior representative’s responsibility to ensure that security rules are complied with. No vehicles will be allowed on site except those carrying materials, or necessary for construction. 5-2 KHABAT TPP UNITS 1&2 - VOLUME I

The Bidder shall ensure that at least one person amongst the site staff during site working hours is trained in first aid and a first aid facility shall be maintained with basic needs. Medical centre shall be provided with all accessories included. The Bidder shall supply, maintain and service for the duration of the contract, site office accommodation for the KNOC/MOE’s construction management personnel. This accommodation shall be separate from but adjacent to the Bidder’s own offices and other facilities. It shall comprise of a number of offices and include toilet and kitchen facilities. The offices shall be suitably furnished with desks, chairs, benches and lockable filing cabinets. The offices shall be installed with full office facilities, such as lighting and small power, telephone lines, water supply and drainage. The Bidder shall supply graded parking areas for KNOC’s vehicles. Canteen facilities shall be provided by the Bidder during the construction phase. On commencement on site the Bidder shall insure the KNOC/MOE’s offices and contents against fire, and other risks ordinarily insured against. Before the erection of any temporary huts, sheds or other buildings which the Bidder may require for his own purposes, the Bidder shall obtain approval from the KNOC for the size, type, location and drainage arrangements. Notice shall also be given to the KNOC of any intention to dismantle any hut or remove the same from site. After completion of erection of the office(s) and other temporary accommodation, the Bidder shall arrange an inspection, to be attended by the KNOC and the local fire authority. The Bidder shall comply with all recommendations made by local fire authority. Any costs involved in making the buildings comply with the fire officer’s requirements shall be deemed to be included in the contract price.

5-3 KHABAT TPP UNITS 1&2 - VOLUME I

The Bidder shall provide sanitary conveniences for the use of workmen employed on the works and in such a manner and number as shall conform to the statutory or other appropriate regulations and the whole shall be installed to the satisfaction of the KNOC. The conveniences shall be located centrally to the works and shall be to a high industrial standard, heated/ventilated (as necessary) and maintained in clean, hygienic and in good working order at all times. The Bidder shall include for removal of all temporary offices, welfare facilities, sheds and other temporary buildings at the completion of the works and restore the site to a state, to the satisfaction of the KNOC.

5.3

Site Services During Construction Period The Bidder shall be responsible for the provision of all site temporary or construction services. Refer also to the Civil Works section.

5.3.1

Site construction electricity supplies The KNOC shall make arrangements for the site construction electricity required for the construction of the works. The cost of infrastructure necessary to provide necessary connections shall be the responsibility of the Bidder. The Bidder shall provide suitable generation as a backup to KNOC supplies. KNOC accepts no responsibility for loss of supply to the site during the construction and commissioning periods. The KNOC cannot guarantee the availability and/or reliability of any supply identified as existing at the site. All cables installed for temporary electrical supplies shall be routed so that they are clear of building operations or constructional work, shall not impede access and egress, and shall be at least 150mm clear of steam, gas and water pipelines. Lampholders and other accessories shall not be suspended from electric cables. Cables passing under roadways and access ways for transport and mobile plant shall be laid in ducts at a depth of 600 mm. A cable marker shall be 5-4 KHABAT TPP UNITS 1&2 - VOLUME I

installed at each end of the road crossing. Records and drawings of the temporary distribution system and cable routes shall be kept up to date. As soon as any parts or whole of the Bidders installation is no longer required for carrying out the Contract Works, the Bidder shall disconnect and remove the same to the satisfaction of the KNOC.

5.3.2

Water supplies The Bidder shall be responsible for making his own arrangements for any water supplies required during the construction of the plant, including any metering apparatus and the payment of any charges.

5.3.3

Other services The Bidder shall also provide at least the following and others if required: a.

at laydown areas and at work faces temporary fencing, lighting and guarding and all other materials and services necessary for the safety and security of persons and property;

b.

temporary roads, parking areas etc;

c.

telephones

d.

fire-fighting equipment;

e.

waste disposal facilities;

f.

sanitary facilities;

g.

all necessary temporary equipment for construction, commissioning and testing; until project completion has occurred.

The Bidder shall include for the removal and disposal off-site of all ground works associated with the temporary services, including the removal of temporary sewage works, the safe demolition and infill of manholes, chambers etc, and the safe termination and/or blanking off from permanent services under the control of the KNOC and/or other public or private bodies, to the satisfaction of the KNOC.

5-5 KHABAT TPP UNITS 1&2 - VOLUME I

5.4

Health and safety at work The KNOC will monitor the Health and Safety practices of the Bidder against the agreed H&S Plan which shall be prepared and developed by the Bidder and be subsequently approved by the KNOC. Within 30days of contract award, but before construction work begins, the plan shall be prepared and passed to the KNOC for comment/approval and the Bidder shall ensure that it is regularly and properly adjusted to accord with the Bidders involved and to site activities. The Bidder must incorporate into this plan comprehensive method statements for all major construction activities and provide copies of these to the KNOC. The method statements will include, but not be limited to, working methods, plant utilization, construction sequence and safety arrangements. The KNOC will authorize construction activities to start only when advised by the Bidder that there is a sufficiently detailed execution stage of the Health and Safety Plan in place. The Bidder shall provide a full time safety officer at site all times-the incumbent should be appropriately qualified for this role. The Bidder is fully responsible for site safety. The Bidder shall make allowance within his program for carrying out his duties in the above respects. The Bidder shall prepare comprehensive method statements for all interface construction activities and submit these to the KNOC for review at least thirty (30) days prior to the commencement of the relevant activity. The method statements will include, but not be limited to, working methods, plant utilization,

construction

sequence

and

safety

arrangements,

permit

requirements etc.

5.4.1

Risk assessment It will be the responsibility of the Bidder to provide both their generic and site 5-6 KHABAT TPP UNITS 1&2 - VOLUME I

specific risk assessments related to undertaking any hazardous work and/or use of any hazardous materials, and major HAZID and HAZOP studies as required to demonstrate the safety of the proposed design and operation of the plant, or as required under statutory legislation. The Bidder shall ensure that risk assessments on the design elements of the plant are carried out, and the relevant information is included in the construction phase Health and Safety Plan.

5.4.2

Specific risks produced by Bidder activities The detailed Health and Safety Plan to be developed by the Bidder shall include method statements for all high-risk activities to be engaged upon by the Bidder and Sub-Bidders. Work will not be allowed to start on site until method statements have been submitted and accepted by the KNOC. High risk activities that have been identified for the construction works include, but are not limited to:a.

Work on fuel gas and gas oil systems

b.

Chemical handling

c.

Working on and adjacent to water

d.

Diving operations/working under water

e.

Steel fabrication and erection

f.

Scaffolding

g.

Heavy crane lifts

h.

Working at height

i.

Hot work

j.

Large plant handling and installation

k.

Noise

l.

Working with HV, MV and LV systems

m. Excavations n.

Construction of foundations

o.

Contamination

p.

Working in confined spaces

q.

Working adjacent to highways

r.

Tunnelling operations

s.

Tie-ins to existing systems 5-7 KHABAT TPP UNITS 1&2 - VOLUME I

t.

Working adjacent to overhead cables/power lines

u.

Radiographic testing of welds

v.

Operation of plant.

On-site works must be fully co-ordinated by the Bidder. The Bidder should make due allowance for regular co-ordination meetings between all subBidders actively working or about to start working on the site. The Bidder, KNOC and representatives of the KNOC will attend the meetings.

5.4.3

Documents The Bidder shall provide the following documents: a.

The Statement of Safety Policy and Organization with Charts and Appendices.

b.

The Health and Safety at Work Manual.

c.

The Statement of Local Arrangements for Health and Safety, including:i.

any Safe System of Working,

ii.

any Permit to Enter system, and

iii. any Permit to Work System. iv. 5.4.4

Bidder's safe systems of working Prior to commissioning on Site, the Bidder shall establish a Safety and Permit-to-Work system for the Site to ensure that plant is put into and taken out of service in a safe and controlled manner, that the integrity of any adjacent operational plant is maintained and any adjacent construction work can be undertaken in a safe manner. The system shall incorporate where applicable any Permit-to-Work system employed by the KNOC. Where any part of the Works is not covered by the Bidder's Safety Policy or is a High Risk activity (as described below) the Bidder shall submit to the KNOC a method statement covering such part of the Works. He shall immediately submit to the KNOC any subsequent additions to or amendments of his method statement. No work covered by any method statement shall be commenced unless the KNOC has approved the method 5-8 KHABAT TPP UNITS 1&2 - VOLUME I

statement. High risk activities include the following: a.

Steel erection/heavy crane lifts

b.

Hot work

c.

Entry into confined spaces

d.

Use of explosives

e.

Roof work

f.

Excavation work

g.

Degassing vessels/systems

h.

Working at height

The Bidder's Safe Systems of Working as described in his method statements shall: a.

be not inferior to the KNOC's Safe Systems of Working for any part of the Site where both will apply;

b.

incorporate where applicable any Permit to Enter or Permit to Work system employed by the KNOC;

c.

incorporate where applicable any of the documents listed above or any leaflet or card associated with them;

For the purposes of this Clause, references to the KNOC or his employees shall be deemed to be references to any other party present or likely to be present on the Site at the same time as the Bidder.

5.4.5

Training The Bidder shall provide or arrange appropriate training for his employees or any other persons carrying out, or put at risk by, his operations. Such training shall include written instructions incorporating the relevant portions of the Bidder's Safe Systems of Working. Where training is required relating to the KNOC's operations, the KNOC will if so requested provide such training. In this event, the KNOC shall have the right to be paid by the Bidder or the party given training the reasonable cost 5-9 KHABAT TPP UNITS 1&2 - VOLUME I

thereof.

5.4.6

Safety equipment The Bidder shall provide all safety equipment for use on the Works; particularly for above ground and confined space working.

Where such

equipment is subject to statutory inspections, the KNOC shall be provided with copies of the inspection reports. When there is a risk of drowning the Bidder shall provide lifebelts and ensure that personnel wear adequate buoyancy equipment or harness and safety lines, especially full body harness when working above 2m, and ensure that rescue personnel are present when work is proceeding.

5.4.7

Assistance to KNOC When the Bidder is required under the Contract to provide manual assistance to the KNOC or his staff, the Bidder shall ensure that the person or persons so provided are aware of the dangers or hazards which may be encountered on the Site.

5.4.8

Confined spaces Where any part of the Works is to be carried out in a confined space the Bidder shall:a.

Display at the entrance to each confined space a sign warning of the need for oxygen and gas levels to be monitored before access and while work is proceeding.

b.

Provide every person entering the confined space with appropriate training in the use of atmosphere testing equipment, the use of respiratory protective equipment, elementary first-aid and rescue techniques.

c.

Provide fully equipped standy personnel for rescue purposes while persons are working in the confined space.

d.

Monitor the atmosphere in the confined space for oxygen depletion and dangerous gases before any person enters it.

5-10 KHABAT TPP UNITS 1&2 - VOLUME I

e.

Provide every person entering the confined space with breathing apparatus, which shall be suitable for use while working or for emergency use only, depending on the degree of ventilation.

f.

If sufficient means of natural ventilation cannot be guaranteed to provide at all times an adequate circulation of uncontaminated air, provide forced air ventilation even if regular/routine oxygen or other gas levels are shown to be safe.

g.

Ensure that all persons within the confined space vacate it as soon as any alarm sounds, without waiting to record the gas level.

h.

Provide appropriate harness, safety ropes and rescue facilities and if practicable two means of access top to bottom.

i.

Provide when work is in progress radio or telephone communication, or safe visual and oral communication where this is appropriate and background noise levels permit.

j.

Ensure that all electrical tools and equipment are of the appropriate types.

When access to a confined space is expected to be prolonged, for example during the construction of a tunnel, the Bidder shall augment the above procedures by installing continuously reading and recording oxygen and gas monitors within the entrance to the confined space and at the place of working. Such monitors shall operate for 24 hours per day, seven days per week, for the whole period of access to the confined space. The Bidder shall provide copies of the recordings to the KNOC at weekly intervals. The Bidder shall include for training of the KNOC’s resident staff in confined space techniques.

5.4.9

Land owned by third parties The Bidder shall take care when working on land owned by third parties to safeguard the KNOCs or occupiers of such land.

5.4.10

Temporary electricity supply Where the Bidder obtains any temporary electricity supply from a switchboard or other source in the MOE's control, he shall submit to the KNOC and MOE a copy of a certificate of testing and compliance with IEC 60364 before connection to the MOE's source is made, and again at the 5-11 KHABAT TPP UNITS 1&2 - VOLUME I

intervals for re-testing required by the Standard. If at any time the KNOC and MOE does not hold a current certificate, the MOE will disconnect the Bidder's supply.

5.4.11

Fire precautions The Bidder shall take all necessary precaution to prevent fire. Where new risks are introduced in the Works during the construction period, the Bidder shall provide appliances suitable for such risks. When working in potentially explosive atmospheres the Bidder shall employ approved non-electric tools and apparatus suitable for use in such areas.

5.4.12

Compressed gases The Bidder shall make adequate arrangements for the safe storage (including appropriate warning notices) and handling of all compressed industrial gases.

5.4.13

Access, fencing and safety barriers The Bidder shall give notice to the KNOC's operating staff whenever he proposes to start any work which may impede the safe passage of persons and vehicles in an emergency. The Bidder shall provide appropriate safety barriers with hazard warning signs attached around all exposed openings and excavations when the work is in progress. Permanent or approved temporary covers to openings shall be replaced at all other times.

5-12 KHABAT TPP UNITS 1&2 - VOLUME I

5.4.14

Site rules

5.4.14.1 Statutory and other regulations The Bidder shall comply with all Iraq National Acts and Statutory or other regulations. If the law is broken or regulations disregarded, the KNOC may exercise his right to refuse to allow the offenders to remain on Site and will not be responsible for any cost penalty arising therefrom. In the event of the Bidder employing subBidders, it must be clearly understood that it is the responsibility of the Bidder to ensure that the subBidders understand and comply with all regulations in every respect. 5.4.14.2 Safety helmets and safety footwear The Bidder shall provide all safety equipment for use on the Project and ensure adequate training in the use thereof. The safety equipment provided shall be in accordance with internationally recognized standards for this location and weather conditions. Where such equipment is subject to Statutory Inspections, the KNOC shall be provided with copies of the inspection reports. Personal protective clothing which will provide adequate protection for workers such as high visibility jackets, safety helmets, safety footwear shall be worn at all times and shall be provided by the Bidder. Adequate arrangements shall be made for regular cleaning of the protective clothing. Non-slip or studded boots should always be worn because of the risk of slipping on greasy surfaces. All studs should be non-sparking. 5.4.14.3 Protection of hearing Where sound levels cannot be reduced at source, the provision of suitable hearing protection is required when noise levels indicate an equivalent level (Leq) of more than 85 dB(A). When hearing protection is used arrangements should be made to ensure the wearers can be warned of other hazards. 5.4.14.4 Eye protection

5-13 KHABAT TPP UNITS 1&2 - VOLUME I

The following are engineering jobs which always require eye protection by persons doing or closely observing the work: a.

The grinding of metal, stone, concrete or similar materials by a mechanically powered wheel or disc.

b.

Breaking, cutting, dressing or carving of stone, concrete, slag or similar materials by a powered or non-powered tool.

c.

Chipping or scaling of painted or corroded metal surfaces or wire brushing of such surfaces by mechanical power.

d.

Cutting out or cutting off of cold rivets or bolts.

e.

Welding

5.4.14.5 Respiratory protective equipment Where there is a risk to persons at work from a dangerous atmosphere, appropriate breathing apparatus must always be readily available for use and all persons concerned must have received adequate training in the working principles and use of this equipment. Breathing apparatus may need to be used in both routine operations and emergency situations. It is important that the correct equipment is selected for the particular environment for which the user requires protection and that approved procedures are followed in the general care, use and maintenance of such equipment. 5.4.15

First aid and medical facilities The Bidder shall be responsible for the provision of first aid facilities at Site, for the use of his own workforce and that of his subBidders. The Bidder shall also be responsible for the contingency planning for emergency services in the event of incidents, accidents or other emergencies at Site. Medical facilities will not be provided by the KNOC and the Bidder shall be required to make his own arrangements for these services as may be required for his expatriate or locally engaged staff.

5.4.16

Emergency evacuation of the site The Bidder will establish a Procedure for the evacuation of the Site in the event of fire, bomb warning or other emergencies. The Bidder shall provide any adequate checking system to ensure that all his employees and site 5-14 KHABAT TPP UNITS 1&2 - VOLUME I

visitors are removed from the Site in the event of such emergencies. The Procedure will include arrangements for practice evacuation as necessary and twice a year evacuation drills and shall be agreed with KNOC. 5.4.17

Safety management The Bidder shall formally appoint a suitably qualified member of his staff to be responsible for safety aspects of the work on Site and shall ensure compliance with all safety matters of the appropriate local legislation.

5.4.18

Cranes, hoists, lifting equipment and scaffolds, etc All lifting appliances (cranes, pulley blocks, gin wheels, etc) hoists and lifting gear (chain slings, rope slings, etc) must be tested and inspected in strict conformity with the requirements of Schedule G. Records and certificates must be available for inspection at any time. The Bidder is responsible to see that hired cranes comply with the regulations and current certificates are available for inspection. All overhead scaffolds and suspended loads must be properly secured. Approach ladders must be removed or made unscalable whenever the Site is left unattended. Scaffold boards and/or cat ladders must be used when working on roofs. Aluminium alloy scaffolding may not be used. Kick plates shall be provided on all scaffold boards

5.4.19

Electrical safety conditions All work on the site shall be carried out in compliance with the relevant Iraq National and local Construction Regulations.

5.4.19.1 Portable and transportable equipment All portable hand-tools and equipment should operate on 50 volt ac supply unless specified otherwise. Under certain circumstances, tools and equipment for use on 110 volt ac supply may be used, but only if written permission is given by the KNOC, who will first ensure that the earthing arrangements are satisfactory. If only 240 volt ac or 400 volt ac equipment is available special dispensation must be obtained, in writing, from the KNOC. Dispensation will only be given 5-15 KHABAT TPP UNITS 1&2 - VOLUME I

if a monitored earth leakage unit is fitted. Portable lighting shall operate at not more than 110 volt ac single-phase. All electrical equipment must be in safe working condition to the satisfaction of the KNOC. Should equipment be found to be faulty it must be made good by the Bidder at his own expense or otherwise replaced. 5.4.19.2 Supplies The Bidder shall be responsible for obtaining any electrical supplies required to carry out his contract works including all that is necessary to provide a safe and satisfactory supply and distribution system. 5.4.19.3 Bidder's wiring The Bidder's distribution, lighting systems and hut wiring shall be in accordance with Internationally acceptable standards for the distribution of electricity on construction and building sites. 5.4.19.4 Lighting It is the responsibility of Bidder to provide adequate lighting in every work place. The lighting system shall be such that nuisance to local residents shall not be caused.

5-16 KHABAT TPP UNITS 1&2 - VOLUME I

6.1

Steam Generators and Auxiliaries

6.1.1

Boiler proper and accessories

6.1.1.1 Design and construction A. General The boilers shall be designed throughout so as to insure continuous, safe and economical operation providing the maximum of reliability and without undue heating, vibration or noise. The boilers and its auxiliaries shall be in slide along arrangement. A proven furnace design shall be chosen such that flow stability is assured during startup and under constant pressure operation as specified. Complete Boiler, pressure vessel, and piping shall be designed and installed in accordance with ASME Boiler, Vessel, and Piping Codes. B. Heat Transfer Surface 1) The furnace shall be structurally designed with no permanent deformation to the furnace enclosure for transient draft pressure conditions of at least ±900 mmH20. The draft-side design pressure shall be of sufficient magnitude to accommodate this transient condition. In addition to design the unit for the above transient pressure conditions, the Bidder shall describe what additional provisions, if any, will be incorporated to accommodate or prevent boiler explosions/implosions. If additional controls are required, these shall be furnished as a part of the boiler control system and burner fuel control systems. 2) The Bidder shall show that furnace, drum, superheater, reheater, economizer as well as the other sections or components of the steam generator are designed with liberal margin in regard to water-cooled or water and steam cooled heat absorbing area, tube sizing and spacing, 6.1-1 KHABAT TPP UNITS 1&2 - VOLUME I

combustion gas velocities entering and through the superheater and reheater sections, and any other factors which affect such design in order that tube corrosion and erosion are minimized and unit availability will be as high as possible. 3) The flue gas temperature at entry to the first convection section shall not effect on tube materials at any load. 4) The Bidder shall show that the average and peak heat absorption or volume heat release rates in the furnace, particularly at or near the burner zone are minimized with resulting minimum waterwall tube metal temperatures. 5) Projected area heat release rate(EPRS heat release rate) shall not exceed 420,000 kcal per square meter per hour. Volume heat release rate shall not exceed 240,000 kcal/m3.h for two(2) pass type and one(1) pass or box type boiler. The Bidder shall specify maximum burner input for oil in his proposal data sheets. 6) The following definition shall be used to calculate the heat release rates. a) The first convection section means the first superheater or reheater section having a clear transverse spacing less than 380 mm. b) Effective Projected Radiant Surface (EPRS) of one pass or box type boiler shall be taken as the total projected area of the planes which pass through the centers of all furnace wall tubes, plus the area of the plane perpendicular to the gas flow at the location where the furnace gases reach the first convection section. EPRS of two pass type boiler shall be taken as the total projected area of the planes defined by furnace volume. In calculating the EPRS, the surfaces of both sides of the superheater and reheater platens extending into the furnace, 6.1-2 KHABAT TPP UNITS 1&2 - VOLUME I

provided that a clear transverse spacing is great than 380 mm for two pass boiler and to first convection section for one pass or box type boiler shall be included. c) Furnace volume of two pass boiler shall be that of the furnace space enclosed by the planes which pass through the centers of all furnace wall tubes and the imaginary vertical plane perpendicular to flue gas stream just above furnace nose apex or straight along with the rear wall tube center lines at lateral pass inlet in case of no furnace nose apex. Furnace volume of one pass or box type boiler shall be that of the furnace space enclosed by planes which pass through the centers of all furnace wall tubes and the first row of the heating surface just above the furnace. d) Projected area heat release rate is equal to the total heat in the fuel actually burned, plus the heat in the preheated air above 30 degree C, minus the sum of radiation losses, heat in unburned combustibles, latent heat of the moisture in the fuel and from the oxidation of hydrogen in the fuel, divided by the EPRS and expressed in kilocalorie per square meter per hour. e) Volume heat release rate is equal to heat input based on higher heating value from fuel only divided by the furnace volume and expressed in kilocalorie per cubic meter per hour. f)

Furnace plan heat release rate is based on heat input based on higher heating value from fuel only at horizontal cross section plane of the furnace through the burner zone and expressed in kilocalorie per square meter per hour. The area of the plane shall be calculated from the horizontal depth and width of the furnace taken from the center line of the tubes. Burner zone surface is calculated as the circumference of the combustion chamber at the level of the upper burner row times height of burner belt, i.e. center line of lowest burner up to center line

6.1-3 KHABAT TPP UNITS 1&2 - VOLUME I

of upper burner plus half of the distance of the two(2) lowest as well as the two(2) highest burner rows. 7) The Bidder shall provide steam generator heat balance diagrams at BMCR, indicating the following data for furnace, each tube bank and air preheater; a) Furnace heat input by fuel (Qf), kcal/h b) Furnace heat input by air (Qa), kcal/h c) Furnace heat input by gas recirculation (Qg), kcal/h d) Gas temperature at first convection section (Tg),

degree C.

e) Heat absorption (Qb), kcal/h f) Heat of furnace radiation (Qr), kcal/h g) Heat of convection, (Qc), kcal/h h) Heat transfer coefficient (K), kcal/m2.h.K i) Steam or water flow (W), kg/h j) Gas flow (Wg), kg/h k) Air flow (Wa), kg/h l) Heating surface (HS),m2 m) Steam or water inlet temperature (T1), degree C. n) Steam or water outlet temperature (T0), degree C. o) Gas temperature (Tg), degree C. p) Air temperature (Ta), degree C. q) Boiler heat losses by gas (Qg), kcal/h 8) The Bidder shall provide steam generator material diagrams with his proposal, indicating the following data for each tube row of superheater, reheater and economizer, and each tube section of furnace; a) Material

6.1-4 KHABAT TPP UNITS 1&2 - VOLUME I

b) Tube outside diameter (Do), mm c) Tube thickness (Ts), mm d) Design pressure (P), kg/cm2 g e) Calculated maximum gas temperature (Tg), degree C. f) Fluid temperature from entering to leaving each tube row or section (T), degree C. g) Calculated mean metal temperature (Tm), degree C. h) Calculated maximum metal temperature (To), degree C. i) Allowable metal temperature (Tx), degree C. j) Tube length (L), mm k) Welding location, due to material thickness change or material change. l) Tube side spacing and back spacing (L∥, L⊥), mm m) Header design temperatures, design pressure, material, and inside diameter and thickness dimensions. C. Shop Fabrication 1) All stubs which are furnished on headers for tube connections or tubes which are joined directly to the headers shall be strength welded to the headers in the shop, and the headers shall be stress relieved after the stubs or tubes have been welded on. The stubs on the headers shall have end preparation for welding to the tubes in accordance with ASME Section I or equivalent codes. 2) Tube ends that are not shop attached to headers shall be prepared ready for welding in the field. 3) Steam generator shall be designed to avoid tube damage by soot blowing. 4) Shop fabrication of tube and header assemblies shall be made to the maximum degree practicable. Superheater tubes, reheater tubes and 6.1-5 KHABAT TPP UNITS 1&2 - VOLUME I

economizer tubes should be shop assembled into modules of two or more elements along with stringer tube supports and element spacers. The Bidder shall state dimensions and weight of largest and/or heaviest assembly to be shipped. 5) Steam generator tubes and headers will be acid cleaned by KNOC after the erection of each steam generator.

Before shipment, these

tubes shall be cleaned by the Bidder of all foreign material, including loose dirt, mill scale, oil, etc. by blowing with compressed air, sponging or mechanical means as required and sealed with securely attached caps. The Bidder shall furnish an adequate number of connections at suitable locations for acid cleaning and a detailed procedure for acid cleaning shall be approved by KNOC. 6) Minus tolerance shall not be allowed for the thickness of tubes, header stubs and headers of furnace water wall, superheater, reheater and economizer. E. Boiler Vibrations The steam generator shall operate free of objectionable vibration under all conditions of operation associated with service in a central power generating station.

If the steam generator shows, in the opinion of KNOC ,

evidence of excessive or objectionable vibration, the Bidder, at his own expense, shall promptly eliminate such vibration to the satisfaction of KNOC . The Bidder shall submit calculations and other data to show that his design prevents vibrations. 6.1.1.2 Furnace A. Furnace walls shall be suitably arranged for the type of steam generator. B. Tubes shall be seamless and all connections shall be welded. Backing rings shall not be permitted in all tube weld joints of the water-cooled furnace. 6.1-6 KHABAT TPP UNITS 1&2 - VOLUME I

The water wall tube of the lower furnace (chamber) shall be considered to prevent departure nucleate boiling. Tube spacing and arrangement shall permit the removal and replacement of any tube without removing others. C. Headers shall be provided with necessary inspection holes with seal welded cover plates. D. The Bidder shall state method of obtaining balanced water flow through the boiler water wall panels, and means of protecting such circuits from blockage by scale or foreign matter in the water. E. The Bidder shall provide water wall tube temperatures measurements for control and monitoring. The Bidder shall indicate the maximum allowable difference of wall temperature between two adjacent furnace wall tubes. F. The forged or welded ‘Y' pattern pieces such as bifurcate tube, trifurcate tube, etc.

are not acceptable, except the use of inverted ‘Y’ pattern piece.

G. The number and location of access doors in the upper furnace shall be submitted for KNOC approval. H. A gas tight welded fin-tube-fin furnace wall construction shall be supplied. The construction can be with either extruded finned tubing with bars welded between plain tubes, or with fusion welded fins. The fin end shape between tube and tube shall be round trimmed for thermal stress reduction. Maximum furnace wall tube thickness in high flux (lower furnace) zones shall be less than 7 mm including corrosion allowance of not less than 1.0 mm. The Bidder shall specifically describe any areas where welded fin-tube-fin wall construction will not be used.

6.1-7 KHABAT TPP UNITS 1&2 - VOLUME I

I. Rear wall shall be accessible from the bottom elevation of furnace to an elevation above the nose cone for installation, operation, and maintenance of sootblowers, instrumentation, and other accessories. J. Hopper bottom shall be entirely water cooled with two sides inclined at least 30 degree C from the horizontal. K. Furnace tube arrangement shall be described in detail giving full constructional details, including tube attachments and the methods of support of the furnace walls. L. The Bidder shall state the structural fatigue limits of the furnace walls. M. There shall be sufficient measuring taps for the furnace pressure measurement and protection. N. The Bidder shall provide the boiler tube leak detection system of a wall welded contact type. Complete system including twenty(20) sensors, electronic cubicle, workstation, monitor(min. 21 inch) and printer shall be provided. Boiler tube leak detection system shall be interfaced with PCS for the monitoring and alarm in CCR. O. The Bidder shall provide the furnace temperature monitoring system with laser type. Complete system including fifteen(15) pairs of laser sensors, electronic cubicle, workstation, monitor(min. 21 inch) and printer shall be provided. Furnace temperature monitoring system shall have capability of making thermography for thermal distribution of combustion zone and be interfaced with PCS for the temperature monitoring in CCR. P. Division water wall in the furnace shall not be allowed. 6.1.1.3 Steam drum A. The steam drum shall be of fusion welded construction fabricated from steel plate, and equipped with two(2) 450mm diameter manholes. The inside surfaces of the drum shall be shop shot-blasted leaving smooth, clean surfaces. The steam drum shall have a min. 3.2mm corrosion allowance above ASME min. wall thickness.

6.1-8 KHABAT TPP UNITS 1&2 - VOLUME I

B. The steam drum shall be equipped with the following internals. 1) Internal feed distribution piping and supports. 2) Continuous blowdown collection piping and supports. 3) Chemical feed distribution piping and supports. 4) Steam deflecting baffles 5) Steam/water separating devices designed to ensure a minimum steam pressure drop and to provide a maximum free space in drum and a minimum carryover of impurities into the superheater. C. All drum internals shall be fabricated in sizes to permit removal from the drum through manholes. D. Necessary welding end inlet and outlet connections and nozzles shall be provided by the Bidder to accommodate the required valves and accessories. E. The following drum accessories shall be provided ; 1) Level transmitters, level gauges and isolation valves(Left, right, center) 2) Safety valves with piping including common silencer. 3) Double blow-off valves including motor operated valve. 4) Vent valves including motor operated valve. 5) Remote control metering valve including inching motor operation for continuous blowdown 6) Thermocouples 7) Connections for instruments 8) Local pressure gauge with valves

6.1-9 KHABAT TPP UNITS 1&2 - VOLUME I

F. The necessary drum supports shall be furnished. G. Twelve(12)

ports

electrode

type,

bi-color guage systems shall be

provided at each side of the drum. H. The bi-color gauge glass of the each side of the drum shall be furnished. I. Electronic level indicators for monitoring drum level locally and in central control room, possible to distinguish between water and steam shall be supplied. Three(3) drum level transmitters and three(3) drum pressure transmitters for pressure compensation shall be supplied for drum. The drum level signal used for control purposes shall be the median of the three and outputs shall be provided for hardwired recording of the median and indication of the two levels. Drum level high and low trip contacts shall be provided for the boiler control system. 6.1.1.4 Superheater and reheater A. The superheater and reheater shall provide uniform distribution of steam and temperature at all loads, and provide thermal expansion of headers, tubes, spacers and supports, and shall be accessible for cleaning and removal of elements. B. The superheater and reheate tube material of high temperature zone shall be selected material to resist vanadium attack. C. The Bidder shall arrange the superheater and reheater tube banks as conveniently as possible to perform maintenance and periodic inspection. The Bidder shall describe what programs are being undertaken, if any, to resolve problems of gas side corrosion and erosion of superheater and reheater tube materials at elevated temperatures.

Tube sections of

superheater and reheater shall be arranged with clear spacing between tubes in the gas flow at least equal to tube diameter. Tubes shall be arranged in parallel rows.

6.1-10 KHABAT TPP UNITS 1&2 - VOLUME I

Tube banks in the convective pass may have minimum baffling installed for the prevention of acoustical standing wave formation. Staggered spacing and extended fins and studs will not be accepted. Maximum depth of bank of tubes shall not exceed twice the rated throw of soot blowers or 2.0 meter, whichever is less. Space shall be allowed between banks for retractable soot blowers. D. The minimum wall thickness of superheater and reheater tubes for corrosion allowance shall not be less than 1.5 mm for high temperature zone and 1.0 mm for low temperature zone. E. All superheater and reheater tube joints including connection to headers shall be of welded construction in accordance with ASME Section I. F. Superheater and reheater tubes shall be arranged and terminated in outlet headers in a manner which will yield through mixing of the steam, thereby resulting in equal temperature at each of the main steam and reheat steam outlets. G. Tube connections shall be shop-welded stub ends on headers. Stub ends shall be prepared for field welding of superheater and reheater tubes. Any welding of ferritic to austenitic stainless metals shall be done in the Bidder's shop. H. For the pendant type superheater and reheater, the Bidder verify that special consideration was given to his design to minimize temperature difference of each tube due to drain plugging during start-up and that his experience of such design has not shown any adverse effect to the steam generator operation capability. I. The minimum temperature control range of superheater and reheater shall be, as a minimum, 55 % of MGR to BMCR and 50 % of MGR to BMCR respectively when firing the design fuel oil. J. Provisions shall be included to prevent a temperature unbalance between superheater sections and between reheater sections. 6.1-11 KHABAT TPP UNITS 1&2 - VOLUME I

K. Peaking maximum gas velocity through tube banks shall not exceed 21 m/sec at any location at all ratings. Space shall be provided in convection pass for addition of a minimum of 10 % more superheater and reheater surface, if required. L. Spacers and hangers for superheater and reheater tubes shall be designed to provide for appropriate sliding expansion, and shall be of material suitable for temperature encountered, and shall be steam or water cooled where necessary. M. All headers shall be external to the gas stream, unless otherwise approved by KNOC , and shall be provided with welded inspection hole covers as required for inspection. Inlet and outlet headers and/or lead pipes shall be provided thermowells with thermocouples and test connections for pressure gauge and/or transmitter. The metal and pad thermocouples shall be provided with enough length wires to local temperature transmitter boxes. The length will be fixed at the detail design. 6.1.1.5 Attemperators A. Superheater steam attemperator shall be provided with two(2) stages. B. Reheater steam attemperators for emergency use and back-up control of reheat steam temperature shall be provided. C. The number of stages of the attemperators will be left for the Bidder. D. Maximum spray flow rate of superheater and reheater shall not exceed 7% and 1.5% respectively at any load when firing oil. E. The Bidder shall be provided with attemperator control valve, nonreturn valve, flow nozzle and bypass system. 6.1.1.6 Economizer

6.1-12 KHABAT TPP UNITS 1&2 - VOLUME I

A. The economizer shall be of a continuous loop drainable type and arranged for the upward flow of water and downward flow of flue gas. Staggered spacing and extended fins or studs will not be accepted. The horizontal banking tubes which are located above economizer shall be ensured an enough clear space for automatic tube welding. B. Economizer shall be arranged in banks of not more than 2.0 meters depth with mass soot blowers between banks. C. The minimum wall thickness of economizer tube for corrosion allowance shall not be less than 1.0 mm. D. Thermocouples with protection wells shall be provided by the Bidder. Where required for access and inspection, doors shall be provided with tight gasketed joints. E. All headers shall be external to the gas stream unless otherwise approved by KNOC and shall be provided with welded inspection hole covers as required for inspection. Inlet and outlet headers and/or lead pipe shall be provided thermowells with thermocouples and test connections for pressure gauge and/or transmitters. The inlet feed water line of economizer shall be provided with motor operated shut off valve and non-return valve. 6.1.1.7 Structural steel A. As used in this specification, the term “structural steel"

includes all

building and support structural steels, duct and pipe supports, all miscellaneous platforms, handrails, girts, purlins, girders, trusses, floor plates, metal roof decking and other steel designed to support superimposed loads and platework. B. Structural steel design engineering and erection shall be in accordance with UBC and AISC as amended to date of contract award and/or applicable local building codes.

6.1-13 KHABAT TPP UNITS 1&2 - VOLUME I

C. Structural steel framing and erection shall be in accordance with AISC Code of Standard Practice for Steel Buildings and specification for Bridges and AISC Structural Steel for Buildings as amended to date of contract award. D. Structural steel and plates shall conform to the ASTM designation A 36 and A 572 as amended to date of contract award. The Bidder shall furnish KNOC five (5) copies of the material test reports with Bidder's certificate on chemical composition and physical properties as described in the above ASTM standard specifications. E. All steel connections may be structurally welded and seal welded, or bolted with high strength structural bolts conforming to ASTM A 325 or A 490. F. The complete unit together with the steelwork shall be designed for a seismic force. G. The complete unit together with the steelwork shall be capable of withstanding wind loading. H. The structural steel design by the Bidder shall make his equipment selfsupporting. The structural steel shall also support loads imposed by the required walkways, platforms, stairways and ladders, elevator access platforms, and in addition, such loads as may be imposed by the KNOC 's piping, elevator access platforms, electrical cable tray (with cable) and conduit and miscellaneous equipment.

Some of these additional loads

may be partially or totally supported by the structural steel. I. Structural steel shall be fabricated and shop assembled to the greatest extent possible and delivered to the jobsite ready for installation unless otherwise required by design and installation conditions or shipping limitations. J. The Bidder shall, in accordance with KNOC's time schedule, provide all information required for the design of adjacent or connecting steelwork furnished by KNOC.

6.1-14 KHABAT TPP UNITS 1&2 - VOLUME I

K. The Bidder shall furnish the complete structural buckstay and hanger system. L. All welding shall be in accordance with the Structural Welding Code AWS D 1.1 as amended to date of contract award. M. Base plates shall be furnished by the Bidder. The top bearing surfaces of the base plates shall be true plain surface after cutting, either by re-rolling, pressing, planing, or milling with all beads, burrs and deformations along the edges and holes removed.

Base plates shall be center punched and

scribed. They shall be provided with levelling nuts and grout holes. Bottoms of base plates will be established approximately one(1) meter below finished floor elevation. All horizontal column base shear shall be transferred through bearing of the base plates and shear key on the foundation concrete in accordance with ACI 318 as amended to date. N. Columns shall be milled at the bottom and at splices for a full bearing surface perpendicular to the longitudinal axis and to exact lengths required. Where welding is required, edges shall be properly prepared and free of any harmful foreign material. O. Filler and splice plates shall have full surface contact, with all beads, burrs and other deformations removed from along the edges and around the holes. P. Anchor bolts and nuts shall be furnished by the Bidder. The Bidder shall specify the anchor bolt sizes and furnish an anchor bolt setting drawing. Q. Two (2) sets of stairs shall be provided by the Bidder, one(1) on each side of the steam generator. All stair treads shall have checkered nosings and be similar to grating. Slip ladders will not be permitted.

6.1-15 KHABAT TPP UNITS 1&2 - VOLUME I

R. The top of each boiler shall be provided with a suitable sun and weather protection canopy which extends downward so as to give protection to all access and operating platforms down to cover the bottom burner level. The canopy shall be provided with suitable ventilation louvers and shall slope towards gutters for collecting rainwater that shall run to the site drains. Operating platforms and instrument and electrical panels shall also be provided with suitable sun and weather protection canopies. S. The last elevator stop and one of the stairway landings shall terminate on the roof. Termination of the stairway shall be an enclosed and waterproof structure located on the roof. T. The Bidder shall submit engineering drawings, and fabrication and erection drawings in which the marking of the structural steel number for erection can be easily recognized and distinguished. U.

Material improperly detailed or wrongly fabricated which necessitates extra field work shall be the responsibility of the Bidder who shall bear the entire cost of the correction or shop errors and the replacement of material.

V.

Checkered plates at the burner location shall be used for platforms, and the remaining platform shall be grating for easy operation and maintenance of boiler.

W. The surface area calculation of the structural steel shall be submitted with the bill of material list of the structural steel. 6.1.1.8 Soot blowing system A. Adeq uat e soot blower ar r ang em ent sho wing num ber , t ype and location shall be provided to ensure that the heating surface of the boiler and air preheaters can be kept free of fouling, and the conditions of operation and the guaranteed gas outlet temperature can be maintained continuously. B. The sootblowers shall be automatically operated by time interval and boiler conditions. 6.1-16 KHABAT TPP UNITS 1&2 - VOLUME I

C. The sootblowers shall be capable of maintaining the boiler in a clean condition when operating at any loads with the fuel oil. The Bidder shall advise the minimum pressure and corresponding load at which satisfactory operation of the blowers can be maintained. D. Provision shall be made for installation of any additional sootblowers in the superheater, reheater, economizer and air preheaters which may be found necessary to enable the plant to satisfy the requirements of the specification. E. If,

anytime within

the guarantee period of the Bidder, it is found that

additional sootblowers are required, the Bidder shall provide all materials and labor to furnish and install the additional units including all piping, wiring, controls, and platforms with structural steel, at his own expense, and to integrate the additional blowers into the system. F. The sootblowing system shall include all necessary blowers, electric driver motors, all piping including automatic drain system, piping, control valve, motorized valves, safety valves, switches, hoses, electrical accessories, relays, support frames, hangers and supports. The pressure control valve for sootblowing steam shall be more than two (2) stage controlled. The Bidder shall provide complete instrumentation and controls. Sootblower piping drains shall be routed to the drain tank or suitable location selected by KNOC . G. Sootblowing medium shall be the steam suitably extracted from between primary superheater and final superheater. The automatic drain shall be possible according to steam quality. H. The soot blowers for the air preheaters shall have a second source of supply from the auxiliary steam system as specified.

6.1-17 KHABAT TPP UNITS 1&2 - VOLUME I

I. The Bidder shall state maximum quantity of steam required for blowing for each blower offered, and maximum quantity of steam required for each 24 hours to keep unit in clean condition. J. Provisions with handcrank shall be included to manually retract equipment in case of power loss. K. Sootblower control system shall be furnished with programmable logic controller(PLC), interface devices with PCS, programmable loader, motor starters and accessories and provisions for control of additional sootblower. Bidder can incorporate sootblower controls into PCS. L. The following safeguard and interlocks shall be furnished. 1) Loss of steam for blowing 2) Failure to complete time cycle for blowing 3) Drop in steam pressure 4) Reset device 5) Time delay M. Operator workstation shall be provided for the control and monitoring of the sootblowing system. The process graphic diagrams shall show the following monitoring measurements and which blower or group of blowers are operating and physical location in reference to the steam generator. 1) Steam flow 2) Steam pressure/temperature 3) Drain pressure/temperature 4) Other operating graphics

6.1-18 KHABAT TPP UNITS 1&2 - VOLUME I

N. All retractable blowers will immediately retract automatically on motor overload or reduction of blowing pressure. The following interlocks shall be included ; 1) No blowing medium 2) Low header pressure 3) Elapsed time interlock 4) Loss of voltage interlock 5) Magnetic overload interlock 6.1.1.9 High pressure bypass system A.

A complete high pressure(HP) bypass system shall be provided by the Bidder. The equipment furnished by the Bidder shall include, but not necessarily be limited to the following ; 1) High pressure bypass control valves. 2) Attemperating spray water control valves and isolation valves. 3) Necessary piping. 4) Pressure and temperature control system to operate the bypass control valves and the spray water control valves. 5) Hydraulic power units and control fluid piping to the actuators

B.

One(1) high pressure bypass control valves shall be of 40% capacity and high pressure bypass control valves shall be installed in main steam connecting pipes, respectively.

C.

The bypass control valves shall be provided with low velocity trim. This bypass system will dump steam from the main steam lines into the cold reheat system and be controlled by the pressure in the main steam system. Spray water for de-superheating will be supplied from the boiler feed pump discharge to the spray water control valve.

D.

The

Bidder

shall

pressure/temperature

provide

all

transmitters,

necessary smart

pressure

positioner

with

switches, position

transmitters and installation materials, etc.

6.1-19 KHABAT TPP UNITS 1&2 - VOLUME I

E.

High pressure bypass system shall be controlled and monitored in the PCS.

6.1.1.10 Piping and valves A.

Piping 1) All

required

acid or chemical cleaning connections shall be

provided for KNOC's chemical cleaning. Miscellaneous piping, including igniter fuel, air and service water piping shall be provided as specified herein. 2) The Bidder shall provide limit stops for lines

where there are

reactions from the Bidder furnished safety valves and power relief valves. B.

Valves 1) The

quantity, size and pressure rating of valves shall be in

accordance with the requirements of the ASME Boiler and Pressure Vessel Code.

The steam generators shall be equipped with the

necessary nozzles to accommodate all of the required valves and accessories. All boiler pressure connections must have double valves with weld end construction.

Drain valves shall be suitable for acid cleaning.

2) All hydraulic power system for hydraulic actuated valve shall have two(2) 100% capacity hydraulic pumps. 3) Safety Valves and Power Relief Valves. a) Safety

valves

including

one(1) set

hydraulic jack

shall be

provided on drum, superheater and reheater. Number and type of valves shall be in accordance with ASME Boiler and Pressure Vessel Code. Safety valves shall be of a type which will reseat at a pressure above the 96% of set pressure after operation. Each safety valve shall be supplied with a suitable gag. b) Power

relief

valves

with a full size shutoff gate valve shall

be provided on the superheater outlet header. The power relief valve shall be an addition to the number of valves required on the superheater by the boiler code, and shall be actuated by superheater pressure. The power relief valves shall have a capacity not less than 5 percent of maximum superheater outlet flow. 6.1-20 KHABAT TPP UNITS 1&2 - VOLUME I

c) The Bidder shall furnish silencers for safety valves and power relief valves.

The silencers are preferred to be arranged for a

combined and reverse flow type. d) The

Bidder

shall

supply

walkways

and

stairs

to allow

access to superheater power relief valves and silencers up to roof. Slip ladders will not be permitted. e) The complete controls

for

safety

valves

shall

be provided

including control logic hardware(system), all instruments, field housings, installation materials, etc. 4) Drain and Vent Valves All drain and vent valves for steam and water headers for start-up and shutdown systems shall be motorized type suitable for remote and automatic operation. All drain and vent valves shall be installed as close as possible to the source, accessible from the boiler platforms. The downstream of drain and vent valves shall be grouped to common lines considering the function of boiler design. 5) Sample Valves Sample valves for sample nozzles shall be stainless steel and socket weld construction. 6) Control

valves,

solenoid

valves,

valve motor operators and

electrical valve actuators and accessories shall be supplied according to this specification.. 7) Root Valves. All root valves for instruments shall have DN25 outlet tap connection and shall be designed in accordance with related codes and standards. 6.1.1.11 Steam generator setting A.

All

refractories,

brick,

tile, fittings, bonding, seals, clays, cements,

packings, insulation and other materials required to make complete setting for steam generator and furnace shall be provided. B.

Enclosure shall

include

a

membrane wall or a welded steel plate

casing fastened directly to furnace tubes, necessary insulation and an outer lagging or ribbed type aluminum alloy 3004 with pebbled finish, not less than 1.0mm thick.

6.1-21 KHABAT TPP UNITS 1&2 - VOLUME I

Furnace and rear pass enclosure walls shall be suitable for water washing. Sealing boxes shall be arranged where the superheater and the reheater bundles penetrate the furnace vertical waterwalls and the furnace roof. Special care shall be required to the seal design of boiler opening. The rounded configuration of sealing box corner and sleeves at penetration part shall be applied for thermal stress reduction. C.

Hinged access doors, arranged to permit convenient and safe access for maintenance, shall be provided at floor and platform levels. Access and observation doors shall be also provided to permit access to all compartments. diameter.

6.1.2

Access doors shall be not less than 500 mm in

All doors shall be provided with seals.

Draft system

6.1.2.1 Air preheaters A.

Two(2) 50% regenerative vertical type air preheaters per unit shall be provided to heat the combustion air.

B.

The regenerative air preheater shall be sized at BMCR condition.

C.

Air preheater rotor shall be driven by an electric motor through a totally enclosed speed reduction drive unit and a back-up auxiliary air motor driver complete with solenoid valve, strainer, piping, air set etc., that will start automatically upon failure of the electric motor, or remote manually or locally.

D.

The maximum air preheater leakage shall be less than nine(9) % of the gas flow entering the heater at BMCR load.

E.

Rotor shell shall be constructed of steel plates, not less than 12 mm thick, and shall be amply braced to prevent deformation.

Shaft shall be of

corrosion resistant material where exposed to flue gases. Heating elements shall be basket type and shall be readily removable. Platforms at the air preheater level shall be provided for basket laydown. Material for hot end heating elements shall be carbon steel plate of thickness not less than 0.6 mm. Material for intermediate section heating element shall be corrosion resistant low alloy steel(CRLS) plate of thickness not less than 0.8 mm. Material for cold end heating elements shall be enamel coated steel plates of thickness not less than 1.2 mm. 6.1-22 KHABAT TPP UNITS 1&2 - VOLUME I

Material of the heating element baskets shall be corrosion resistant low alloy steel (CRLS). F.

Radial bearings shall be self-aligning, antifriction type. Thrust bearings shall be pivotal segmental construction of antifriction type, employing the flat cylindrical principle or antifriction type of taper roller thrust bearing. Bearing housings shall be oil-tight and readily accessible. A complete shop-assembled oil lubrication system shall be provided including oil reservoir, pump with motor, oil coolers, piping with hangers and supports, temperature switches, instrument, and alarm contact.

G. Housing shall be fabricated of welded steel plate not less than 6 mm thick, and shall be rigidly braced against deformation and stiffened, especially where used as a bearing support. Connection shall include angle flanges for attachment to air and gas ducts.

Access doors

shall

be air and gas tight when closed and shall be adequate size for inspection, cleaning, and replacement of parts. Provisions shall be made for expansion and contraction so that no undue strain is placed on component parts, with due regard to differential expansion of the heater elements and differences in the pressure of the media. Provisions shall be made to minimize temperature stratification in the gas outlet duct from air preheater. H.

Access

for

replacement

purposes shall be provided for all air

preheater baskets. Suitable beams, lifting hoist and monorail which shall be permanently installed, shall be provided for cold end and intermediate basket removal.

These baskets shall have attachments to facilitate

handling without the use of welding equipment. I.

The Bidder shall show diagrammatically, in his proposal, how his air preheater system for combustion air is arranged.

J.

“Stop Rotation" alarm device shall be provided for each rotating element of the air preheater. Output signals from the device shall be provided for use in Bidder's control and monitoring system and in PCS.

K.

Steam cleaning shall be provided as needed with water-wash feature incorporated in the hot end cleaning device. The cleaning devices controls shall be incorporated into the sootblower control panel. The water washing device and wash water heating system with chemical injection device shall be provided. 6.1-23 KHABAT TPP UNITS 1&2 - VOLUME I

L.

Fire protection system for air preheater shall be provided.

M. Isolation dampers shall be provided on the gas inlet and air outlet side of the air preheaters.

Provision shall be made to install blanking plates

which shall provide tight shut off to allow maintenance and repair work to one air preheater while the unit is in service. Each isolation damper shall be assembled in its own separate frame and shall be designed to minimize binding from dirt and combustion products. Actuators shall be either electric or pneumatic. N.

The layout of gas ducts upstream of the air preheater as well as the air preheater arrangement shall be selected so as to minimize ash pluggage of the air preheater elements.

O. The Bidder shall provide the complete control system including local control panels, instruments with installation materials. etc. 6.1.2.2 Steam coil air heater A.

Two (2) 50% steam coil air heaters per unit shall be provided between forced draft fan and air preheater to maintain minimum average cold end metal temperature as required by effective cold end corrosion protection with minimum temperature specified in job site condition when burning specified fuel oil.

B.

Coil sections shall be of heavy duty type design to provide positive drainage to prevent freezing. Tubes shall be steel and be a minimum of 25 mm OD provided with fins. Fins shall of the mechanically bonded to the tube, or of the integral type with fins extruded directly from the walls. Fin material shall be copper and thickness of fin shall not be less than average 0.4 mm. The fin shall not move relative to the tube as a result of expansion and contraction.

C.

Minus tolerance shall not be allowed for the thickness of heater tubes and fins.

D.

A draw type duct casing shall be provided and shall consist of a rigid frame constructed of 6 mm formed plates or equivalent structural channels with suitable braces.

The arrangement shall be such as to

assure self draining of the tubes, headers and pipe to prevent water hammering at any load. Adequate space shall be provided for coil removal. E.

The stubs on the headers shall have end preparation for welding to the tubes in accordance with ASME section Ⅰor equivalent codes. 6.1-24 KHABAT TPP UNITS 1&2 - VOLUME I

6.1.2.3 Fans A.

General Number of fans and drivers, and types provided for each steam generator shall be as follows ; 1) Two(2) 50% centrifugal type Forced Draft Fans (FDF) with backward inclined airfoil blade and constant speed drivers. 2) Two(2) 50% centrifugal type Combined Induced Draft Fans(CIDF) with backward inclined airfoil blade and constant speed drivers. 3) One(1) 100% centrifugal type Gas Recirculation Fans(GRF) with constant speed drivers and automatic clutched turning device, if required. 4) Two(2) 100% (one stand-by) centrifugal type Scanner Cooling Air Fans (SCAF) with constant speed drivers. 5) Two(2) 100% (one stand-by) centrifugal type sealing air fans(SAF) with constant speed drivers, if required. 6) The Bidder shall provide electric motor driver for each fan. The Bidder shall be responsible for the selection of the motor characteristics, the motor mounting, all accessories necessary to satisfy the requirements of the fan motor driver unit in all operating mode. 7) In those instances where a variance from these instructions can be shown not to detrimentally affect the performance or serviceability of the fans, the Bidder may include appropriate exceptions in his proposal.

The Bidder shall also enumerate his reasons for these

variances in his proposal. B.

Design Requirements 1) Fan design speed shall not exceed 1,000 rpm for forced draft fans, 600 rpm for gas recirculation fans, 750 rpm for induced draft fans, 1,500 rpm for scanner cooling air fans. 2) Fans shall be designed for continuous operation either singly or in parallel over their full operating range without excessive vibration, surging, or other undesirable character- istics. 3) Fan design efficiency shall have the maximum value at BMCR and high efficiency shall be maintained over a wide range of fan output. 4) Test block conditions of fan size and performance shall have adequate margin as follows ; 6.1-25 KHABAT TPP UNITS 1&2 - VOLUME I

a) Forced draft fans shall have 20 % margin for volume and 25 % margin for static pressure at the ambient temperature of 30 degree C. b) Induced draft fans shall have 20 % margin for volume and 25 % margin for static pressure and 15 degree C margin for gas temperature. c) Gas recirculation fan shall have 25 % margin for volume and 30 % margin for static pressure and 28 degree C margin for gas temperature, if required. 5) The Bidder shall consider the draft losses of across the electrostatic precipitator through the stack in selecting the combined induced draft fan. 6) The Bidder shall provide the following characteristic curves and performance curves for each fan. a) Static pressure versus capacity over entire range. b) Fan brake horsepower with inlet vane control over entire range of capacity. c) Efficiency. d) System

resistance

curve

including

30%MGR,

50%MGR,

75%MGR, 100% MGR, BMCR and test block points. e) Surging curves Performance data to be supplied by the fan manufacturer shall include performance with and without evase. 7) The sound levels generated by furnished draft equipment during normal operation shall not exceed 85 dBA weighted, slow response, at a horizontal distance of one(1) meter from all surfaces of the equipment and at a height of 1.5 meter above or below the platform or floor on which the equipment is mounted. The Bidder shall complete the data in the bid form for sound levels from basic draft equipment, together with his recommendations for sound reduction modifications. 8) Maximum acceptable vibration at any load and speed up to 110 % of design speed shall not exceed 2 mils double amplitude for up to 750 rpm fans, 1.5 mils double amplitude for 1000 rpm fans, and 1.0 mils

6.1-26 KHABAT TPP UNITS 1&2 - VOLUME I

double amplitude for 1500 rpm fans in operation when mounted on foundation. Vibration shall be measured at the bearing housing. 9) Where auxiliary

equipment

such

as

dampers,

inlet

vanes,

silencers or inlet boxes are to be provided with the fans, draft losses will be added to the system requirements and the fan shall be selected for the sum of the pressure losses. 10) Shaft grounding devices

shall

be

provided by the Bidder to

prevent the bearing failures of fans due to electrostatic voltage. 11) Automatically engaged and disengaged turning device for gas recirculation fan shall be provided. 12) The fan rotor and impeller constructed to be readily removed. 13) The band brake unit shall be fitted to prevent the stack draught prolonging the run down rate of the induced draft fans or rotating it while out of service. This brake shall be arranged to operate automatically at rundown of the fan and automatically released as part of the fan starting sequence. 14) The Bidder shall provide the seaing air fans (if required) for preventing the shaft from corrosion. C.

Construction Features 1) Housing and inlet boxes a) Fan scrolls and inlet boxes shall be of welded steel plate construction. b) For fan service

where

operating

temperatures

are

in

excess of 80 degree C, fan housing and inlet boxes shall be of not less than 13 mm in thickness. c) Where C,

operating

temperatures

are

less

than

80

degree

a minimum thickness of 10 mm shall be furnished.

d) Sufficient bracing

and

reinforcements shall be employed to

withstand imposed pressures without vibration or distortion during operation for the life of the fan. e) Scrolls and boxes shall be fitted with drains of at least 100 mm diameter pipes and positioned in the bottom of the housings and inlet boxes.

Each drain shall be provided with an isolation valve.

f) The housing and inlet boxes shall be provided with suitable removable sections or split for access and removal of the rotor.

6.1-27 KHABAT TPP UNITS 1&2 - VOLUME I

g) Access doors shall be provided for entry into the fan housing and inlet boxes. 2) Rotor a) The rotor shall be of the all welded construction utilizing the ASTM specification materials or approved equivalents. Where a high strength alloy steel is to be employed, the Bidder shall notify KNOC to this effect including what components and alloys are to be furnished. b) Af t er t he f inal m achining t he r ot or shall be posit ioned permanently on its shaft and dynamically balanced in the manufacturer's plant. c) The rotor assembly shall be designed so that its installed resonant speed is not less than 1.30 times the full operating speed of the rotor for all clean air or gas applications. d) During rotation, the run out of similar points on the rotor structure shall not exceed a deviation from the median path of 3/8 of one(1) % of the wheel diameter axially and 3/16 of one(1) % of the wheel diameter radially. 3) Bearings a) Each fan shall have two bearings with rotor suspended between bearings. b) Radial bearings for all fans shall be of the self-aligning sleeve type with horizontally split housing and adequate seals to prevent entrance of dust. c) Main Shaft bearings shall be located out of gas stream. d) Thrust bearing shall be manufacturer's standard. e) Bearing housing shall be arranged for complete draining of the cooling medium. f) The double inlet fans shall be designed to withstand the thrust unbalance resulting from the shut-off of one inlet of the double inlet fan while the other inlet is open. g) The construction of bearing pedestals shall be such as to permit shimming and shall also allow disassembling the bearing without having to remove the rotor. Soleplates, anchor bolts and fittings shall be included.

6.1-28 KHABAT TPP UNITS 1&2 - VOLUME I

h) Each fan shall be fitted with a fixed bearing at the motor side sufficient to locate the fan rotor in its proper running position. Overhung wheels are not acceptable. i) Each bearing housing shall have surfaces tapped to permit the installation of vibration monitors mounted 90°apart. 4) Shaft couplings a) The coupling shall be of the limited end float type. The coupling of fan and motor shall be mounted in the manufacturer's shop. A suitably designed coupling guard shall be furnished by the fan Bidder. This guard shall comply with OSHA requirements. b) The coupling shall be attached to the shaft by either keying or by having a shrinking fit. c) The flexible couplings shall be non-lubricated type. d) All coup ling s shall be bot h st at icall y and dynam ica ll y balanced to minimize vibration of the couplings. 5) Inlet vanes a) I n l e t v a n e s a r e o n e o f t h e p r e s s u r e a n d v o l u m e c o n t r o l devices for controlling the operation of the fans. b) The vanes shall be equipped with the necessary linkage arm for attachment of a control drive furnished by the Bidder. Particular attention shall be given to the design of the cross connection of the inlet vanes on a double inlet fan to minimize the possibility of one vane assembly suddenly closing while the fan is in operation. The Bidder shall provide a design of vane control where moving parts, bearing, etc., are out of the gas stream entering the fan. Access to these devices shall be provided for normal maintenance and inspection while the fan is stopped. c) The vane control blades

shall

be

supported

in bearings at

each end of the blade spindle. Bearings shall be provided with the permanently lubricated selfaligning type. d) The entire vane control assembly shall be of a design so that it can be split horizontally for ease of access to and removal of the fan rotor. 6.1-29 KHABAT TPP UNITS 1&2 - VOLUME I

e) All fans equipped with variable inlet vanes shall be provided with a spoiler device or dorsal fin to assist in minimizing ductwork and fan casing pulsations when the inlet vanes are in the partially closed position. D.

Lubricating Oil System 1) Lubrication system for bearings for FDF, CIDF, GRF and their drivers shall be by water cooled circulating lube oil system. 2) Lubricating oil system for FDF, CIDF, GRF, and their drivers shall consist of one(1) oil reservoir, indirect type electric heaters, filters, two(2) 100 % capacity oil pumps with motors, two(2) 100 % capacity oil coolers, piping, valves, flexible connections, and instruments and controls necessary for operation. 3) Joints in lube oil piping shall be welded where practicable. Flanged joints shall be used only where necessary for assembly and dismantling of oil piping. Connections and provisions shall be made for field flushing of the system.

E.

Dampers 1) Each fan shall be provided with a discharge damper and inlet damper(s)/vane(s) to permit isolation of an idle fan while the unit is in service. 2) The dampers shall be housed in heavy channel frames. Each damper leaf shall be supported by and welded to a shaft spindle and supported in bearings at each end. 3) T hese bear ing s shall be per m anent l y lu b r icat ed and self aligning. In no case shall grease be utilized. 4) The dampers shall be provided with the necessary linkage arm for attachment of a control drive furnished by the Bidder. 5) Particular attention shall be given to the design of the cross connection of the inlet dampers on a double inlet fan to minimize the possibility of one damper assembly suddenly closing while the fan is in operation. 6) The damper tightness will be

such

that

leakage across the

damper shall not exceed two(2) percent of the specified maximum design flow. F.

Instrumentation and Control

6.1-30 KHABAT TPP UNITS 1&2 - VOLUME I

1) Instrumentation shall include all pressure, temperature, flow, and level switches required for interlocks and alarms, all pressure gauges, thermometers, and other devices required for operation. 2) Two(2) thermocouples shall be furnished on thrust bearing ; one for the thrust face and the other for radial journal. 3) Each radial bearing shall be furnished with a vibration pickup, a vibration transducer and special cable for installation between the pickup unit and the monitor in accordance with the section 8 of this specification. 6.1.2.4 Flues, ducts, dampers, and windbox A.

The Bidder shall furnish air ducts

and

gas flues connecting fans,

economizer, air preheater, electrostatic precipitator, stack and windbox including complete air ducts to FD fans, dampers, seal air ducts, expansion joints, supports, deflecting vanes, stiffener angles, insulating clips, windboxes, etc. The air intake location of forced draft fans shall be arranged penthouse levels of the boiler building to utilize the radiation heat rejected from the boiler, and shall be provided with the silencers. The gas recirculation system, if required, shall be designed and the design scope of this system is all recirculation fan and duct with necessary appurtenance. B.

The velocity of

air or gas in the ductwork shall not exceed 20 m/sec

at any point, at the maximum continuous rating of the steam generator. The measurement of total air flow of combustion control shall be taken from the inlet of FD fans supplying combustion air to the steam generator. The required length of straight duct shall be provided including suitable air flow measuring devices. Gas ducts shall be provided with suitable sampling connections. The suitable test and sample connection shall be located easily accessible, and shall be provided with suitable caps to seal them when not in use. In designing the flue gas system, the Bidder shall consider, in addition to the requirements of the proper gas velocity, gas distribution in the duct work, minimizing draft loss, and minimizing dust deposition on the floors of the breeching and on the surfaces of corrective devices, such as turning vanes, distribution plates, expansion joints, etc.

6.1-31 KHABAT TPP UNITS 1&2 - VOLUME I

The Bidder shall design and arrange the duct to distribute flue gas flow equally into the two electrostatic precipitator

streams.

Moreover, the Bidder shall incorporate the result of gas flow model studies in connection with electrostatic precipitator for the flue gas system between the downstream of the air preheater and the upstream of the induced draft fan. C.

Air ducts shall be fabricated of steel not less than 4.5mm thick. Gas ducts shall be fabricated of steel not less than 6.0 mm thick, shall be of corrosion resistant low alloy steel(CRLS). Air ducts and windbox shall be reinforced with steel angles and straps having a minimum thickness of 6.0 mm. Gas duct shall be furnished with supports to carry weight of duct, insulation, dust on the bottom, and vertical live load on horizontal projection of roof surface of 250 kg/m2. Air and gas ducts with internal flow area in excess of 10 m2 can be reinforced with internal bracing having a minimum thickness of 6.0 mm. Access doors shall be fabricated steel plate with positive closing mechanism, gas and air tight. Minimum size opening shall not be less than 400 mm on vertical and 500 mm on the horizontal axis. Steel plates bolted over access openings are not acceptable. The location and number of access doors will be reviewed by KNOC .

D.

Duct

and windbox shall be welded wherever practicable. Where not

welded, ducts and windbox shall have bolts not less than 8 mm in diameter spaced not more than 76 mm apart, and joints shall be sealwelded in the field. The windbox connected to the furnace wall tube shall be designed and arranged not to damage by mal-distributed air flow. E.

Expansion joints in the ducts shall be provided as required by the design to permit the free movement of the ducts without distortion and without inducing stresses at the air preheater and fans. The flexible elements for gas duct expansion joints shall be stainless steel for high temperatures zone, corten(or equal) for 1ow temperature zone . The flexible elements for air duct expansion joints shall be corrosion resistant low alloy steel or KNOC approved equal.

6.1-32 KHABAT TPP UNITS 1&2 - VOLUME I

F.

All plates

to be field welded shall be shop beveled or otherwise

prepared so that the field welding may be done without additional field preparation. Clips shall be shop welded to each section to facilitate alignment of the plates during field welding. G. Abrupt

turns

of

radius

of

less than five (5) diameters shall be

avoided, but if such turns are required, guide vanes shall be provided. Guide vanes shall be not thinner than 3 mm spaced to minimize draft loss, suitably welded, supported, and reinforced. Distribution plates and other corrective devices, such as teardrop vanes, shall be incorporated as required on duct transition pieces. H.

Permanent scaffold brackets shall

be

provided where required for

maintenance. I.

Spring

hanger

assemblies,

where required, shall be pre -engineered

and preset for movement and loading. All hanger and tie rod assemblies shall be adjustable. J.

Balanced

multiple

leaf

type

dampers

shall

be

provided in

separate, flanged duct sections with rigid shaft mounted on ball, roller or sleeve bearings arranged so as to be protected from excessive temperatures.

Bearing

lubrication

shall

be

capable

of

being

accomplished from permanent access platforms which shall be provided. Dampers shall operate freely in all positions and shall make tight seals when closed. each damper shall have an external position indicator. Automatic controlled dampers shall have a lever with clamping device for manual operation. Dampers shall be suitable for throttling to 10 % of maximum rating. Dampers for air ducts shall be louver type and shall employ a strip of spring steel at the blade edge which closes against a knife edge stop. Dampers for air ducts shall be louver type and shall employ a strip of spring steel at the blade edge which closes against a knife dege stop. Dampers for gas flues shall employ an angle strip edge for high temperature service. K.

Power operators shall be provided for dampers requiring automatic control and non-modulating remote manual or automatic actuation. These shall include dampers in the burner and igniter control system which require remote operation or setting during normal startup, shutdown, or 6.1-33 KHABAT TPP UNITS 1&2 - VOLUME I

postemergency trip operation for the purpose of preventing fires or explosions due to retained fuel in the ducts, fuel pipes, furnace or steam generator passes. When air cylinders are furnished, they shall be equipped with integrally mounted pipes, solenoid valve actuator, air filter and regulator, with indicating gauge assembly suitable for the services. Two(2) adjustable limit switches of the double-pole-double-throw (DPDT) type shall be included for all power operated dampers for interlocking and monitoring in PCS. Modulating power operator shall have a position transmitter for feed back control. L.

The Bidder shall give a special consideration to the design of duct layout to accommodate the future installation of De-SOx facilities and shall furnish all of connecting flanges, dummy ducts and blind plates required for easy installation.

M. The Bidder shall provide duct design sheet, with his proposal, indicating the following data for each duct and windbox. 1) Mass flow, kg/h 2) Design temperature, degree C 3) Volume flow, m3/min 4) Specific volume, m3/kg 5) Maximum velocity, m/s 6) Maximum pressure (operating/transient), mm H2O gage 7) Design pressure (positive/negative), mm H2O gage 8) Duct area, m2 6.1.3

Fuel burning system

6.1.3.1 General A.

The steam generator shall be equipped with fuel oil and light oil burner systems which comply with NFPA standard.

B.

All

burners

shall

be

capable

of

maintaining stable operation

over the complete burner load range and a steam generator firing rate range equivalent to minimum/maximum steam generator capacity. C.

The fuel oil burning system shall be complete with fuel oil burners with steam atomizing type, supply and return flow control for all burners, associated piping and valves, windbox with dampers, instruments and 6.1-34 KHABAT TPP UNITS 1&2 - VOLUME I

controls, and other accessories required for integration with the system. The flow element type for flow control shall be the ultrasonic liquid flowmeter. D.

The light oil burning system shall be complete with automatic electric igniter assemblies, light oil burners with mechanical and/or air atomizing type, supply and/or return flow control for all burners, associated piping and valves, windbox with dampers, instruments and controls, and other accessories required for integration with the system.

E.

The light oil burning system shall be suitable for lighting the fuel oil burner and establishing stable flame conditions under all normal and abnormal operating conditions including off- stoichiometric combustion.

F.

The fuel oil burners shall be designed to burn fuel oil, complete with retractable oil guns, pneumatic retractors, air registers and vanes.

G. Light oil burners shall be designed to burn light oil complete with retractable oil guns, and shall be capable of carrying the steam generator load not less than 30 % of BMCR and during steam blowing out operating. H.

The ignition

system

shall

be

suitable

for

continuous or

intermittent operation. I.

The Bidder shall state in his proposal what provision is considered to improve the reliability of the ignition system.

J.

All parts of oil burners and associated equipment shall be suitable for continuous service with preheated air leaving the air preheaters.

K.

Each burner shall have a peep door with tinted glass to permit observation of flame, and a tight closing, hinged or swing door, if necessary.

L.

The fuel burning

equipment

shall be designed to be operable with

full automatic control during startup, normal operation and planned or emergency shutdown. 6.1.3.2 Fuel oil burner A.

Burners shall be capable of sustaining BMCR load with one gun out of service when burning fuel oil.

B.

Each burner shall have proper turndown range based on BMCR load without requiring change of any burner parts and without evidence of flame instability or other combustion difficulties in this range.

6.1-35 KHABAT TPP UNITS 1&2 - VOLUME I

C.

The Bidder shall be supplied low NOx type burners for NOx emission control.

D.

Burner shall be capable of withstanding the furnace heat with air leakage while not in service.

E.

Piping shall

include

the fuel

oil

piping,

and steam atomizing

piping. This shall include fuel oil burning pumps, in-line service tank suction heaters, fuel oil heaters and drain cooler, supply and return flow meter(indicating integrator type), all valves, fine duplex type strainers, regulators, accumulators, and automatic shut-off valves, leak check valves and flexible piping required for safe operation of the burners. Oil valves shall be designed so that the open or closed position is easily determined. Each connection to the burner shall have a manual shut-off valve. F.

A scavenging system for each oil atomizer shall be provided and shall be interlocked with the light oil system.

G. Openings and tubes for optical flame scanners shall be provided. H.

Provision shall be included for thermal expansions of pipe and equipment.

I.

The design of the oil piping and location of the shutoff valves shall prevent any oil from leaking into the windbox.

J.

Oil trip valve and burner control cabinets shall be furnished. Oil trip valve shall be solenoid or power cylinder operated.

K.

A single gun cleaning facility shall be provided (for each unit) at each side for each burner level.

6.1.3.3 Light oil burner A.

Piping shall include light oil supply and return piping, and air atomizing piping. This shall include supply oil line flowmeter(indicating integrator type), all valves, fine duplex type strainers, regulators, accumulators, and automatic shut-off valves, leak check valves and flexible piping required for safe operation of the burners and igniters. Oil valves shall be designed so that the open or closed position is easily determined. Each connection to the burner shall have a manual shut-off valve.

B.

A scavenging system for each oil atomizer shall be provided and shall be interlocked with the igniter control system.

C.

Light oil consumption rate during start-up operation shall be submitted data in his proposal. 6.1-36 KHABAT TPP UNITS 1&2 - VOLUME I

D.

Openings and tubes for optical flame scanners shall be provided.

E.

Provision

shall

be

included

for thermal expansions of pipe and

equipment. Flexible stainless steel hose shall be provided with the burners for connecting the burner piping to the light oil header. F.

The design of the oil piping and location of the shutoff valves shall prevent any oil from leaking into the windbox.

G. Oil trip valve and igniter control cabinets shall be furnished. There shall be one trip valve for the light oil system. Oil trip valve shall be solenoid or power cylinder operated. H.

A single gun cleaning facility shall be provided (for each unit) at each side for each burner level.

6.1.3.4 Igniter A.

The igniter shall be provided each oil burner for lighting.

B.

An automatic electric ignition system with electrodes, high voltage cables, transformers, relays, controls, mounting brackets, and all required accessories shall be provided. The control shall be automatic by limit switches on the igniter.

C.

The electric portions shall be designed for satisfactory operation in high temperature service.

D.

Interlock with the light oil shut-off valve that prevent opening of the oil valve without the igniter being energized shall be provided.

6.1.3.5 Emission control A.

The Bidder shall submit the expected NOx emission rate such as NO2 based on 3% O2 dry flue gas basis leaving air preheater at any load when burning the fuel oil. The Bidder also shall submit a report which takes into account all necessary design parameters that will allow compliance with the emission limitations specified above.

The means by which compliance is

accomplished is left entirely to the Bidder. The techniques by which compliance is achieved and the contribution by each technique shall be specified by the Bidder. B.

The following items used for the control of NOx emissions shall be incorporated into the original design. The expected reduction in boiler efficiency resulting from each technique shall be stated by the Bidder. 1) Off-Stoichiometric Combustion(OSC) 6.1-37 KHABAT TPP UNITS 1&2 - VOLUME I

2) Overfire Air Ports(OAP) The steam generator shall be equipped with overfire air ports (or DeNOx ports) capable of supplying the required percent of the total air flow for combustion. 3) Gas recirculation(GR) 4) Burner Control System and Boiler Control System. The automatic burner logic system shall have sufficient operating flexibility to permit satisfactory burner operation under all emission reduction techniques. 5) Any emission reduction technique considered by the Bidder to be technically feasible other than those specified above may be bid. If the above techniques can not meet the emission limit of NOx, the Bidder shall provid the SCR system. To enable KNOC to make a satisfactory evaluation, it is necessary for each Bidder to submit the steam generator efficiency changes associated with each technique. C.

The Bidder shall provide the ash burden and particle size in flue gas leaving the air preheater when firing the fuel oil.

6.1.4

Blow down system Blow down system is combined by blow down tank and flash tank, the flash tank supply re-flashed steam from blow down water to deaerator, intermittent blow down or drain flow in blow down tank, the water drains to drain pit thru over flower pipe. This blow down system is not operated continuously, the conductivity of boiler water in steam drum is checked in sampling cooler system automatically. When the conductivity value is higher than limit set point value, alarm is rung, operator open drain valve properly by remote device. Blow down system including drain tank and vent stack is insulated.

6.1.5

Instrumentation and controls A.

The Bidder shall furnish a complete instrumentation and controls necessary to meet the requirements of this specification, and that shall

6.1-38 KHABAT TPP UNITS 1&2 - VOLUME I

offer a high degree of reliability and safety to both personnel and apparatus. B.

Instrumentation and controls shall be designed in accordance with the section 8 of this technical specification unless otherwise specified in this section.

C.

All field instruments shall be weather-proof and dust-tight suitable for use under ambient conditions prevalent in a specific plant. Field instruments shall be installed in a vibration free location.

6.1-39 KHABAT TPP UNITS 1&2 - VOLUME I

6.2

Fuel Supply and Storage System

6.2.1

Plant fuels The Plant is to fire fuel oil under normal operating. During normal operation conditions the plant shall be operated with fuel oil. The light fuel oil system shall only operate during start-up when firing fuel oil. Typical fuel analyses are provided in Schedule A.

6.2.2

Oil filtering systems The fuel oil filtering system is for removing of impurity over the range of the fuel oil for suitable firing of the boiler. The fuel oil filtering system shall be generously sized to cope with a wide range of fuel qualities delivered to the site without the need of frequent cleaning. They shall be easily cleaned without the need to provide sealing material. The filter will be used in a power plant facility to fulfill the conditions of service.

6.2.2.1 Design and construction The filter furnished under this specification shall be designed to the requirements of the code/standard and this specification. Information on the material of the internal parts shall be given and submitted to the KNOC. The filter shall be designed to function in ASME B31.1 piping systems with the service conditions. Filter basket shall be removable for cleaning without removing the strainer from the pipeline. Cap threads, if used shall be straight, not tapered. Filter basket shall be designed capable of taking the full line operating pressure across a fully blocked filter without any deterioration, and shall be suitably reinforced as required to accommodate this feature. All filters shall undergo tests at the manufacturer's works in accordance with the specific requirements of the approved Code of Practice. The Bidder shall design to consider provisions against leakage, damage and failure of strainer major parts.

6.2-1 KHABAT TPP UNITS 1&2 - VOLUME I

The Bidder shall be responsible for selecting the pressure seal materials to be zero leakage. The Bidder shall describe the information which you need to let the Purchaser know in constructing. 6.2.3

Fuel oil supply and transfer systems

6.2.3.1

General The function of the fuel supply and transfer systems is to supply the fuel oils from the fuel storage tanks and, from there, to transfer oil to the inlets of the burners located in the respective boiler units under all ambient conditions. The fuel oil supply and transfer system shall also provide light fuel oil for the ignition of the burners and to the storage tanks of the emergency diesel generators and the fire fighting pumps. The design of the fuel supply and transfer system shall be such that the Plant is able to meet all of its operational requirements. Moreover, the system design shall achieve the minimum pressure, temperature and other conditions at the inlets to the burners in each Plant boiler unit.

6.2.3.2 Fuel oil An effective communications system shall be provided between the fuel interface points and the plant to ensure the routing of fuel oils to the appropriate fuel oil storage facilities and to avoid tank overfilling. The oil supply pressure to the storage facilities shall be observed at local and PCS by a pressure measurement system. Fuel oil service pump shall be installed in a fuel oil pump house which shall be a common pump house for all fuel oils. The fuel oil service pump capacity and system parameters shall be based on all power units operating at their maximum capacity taking account of the operational requirements of Section II, unit start ups and intermediate conditions when some units are not operating. The pump configuration shall include appropriate levels of redundancy including at least one pump set and its auxiliary equipment. All of the fuel oil fuel oil service pump skids shall discharge into a common 6.2-2 KHABAT TPP UNITS 1&2 - VOLUME I

header that shall then transfer fuel oil to the fuel oil heaters and then to each boiler unit. The fuel oil heaters shall be designed to heat the fuel to an appropriate temperature for atomization in the boiler burners and shall also incorporate a minimum redundancy represented by one spare heater unit. Appropriate oil recirculation facilities shall be provided to accommodate load fluctuations such that the Plant is able to meet all of its operational requirements. Duplex filtering and associated differential pressure switching/alarm and valve/drain facilities shall be provided on the inlet side of each fuel oil service pump skid. Each fuel oil service pump skid shall be complete with a differential pressure gauge and appropriate valves shall allow the isolation of each fuel oil service pump. Flow detectors and non-return valves shall provide pump protection, and pressure switches shall be used to sense the pressure at the pump suction and provide a trip/permissive signal for start-up. The fuel oil service pump discharge pressure shall be indicated on a local pressure gauge. Appropriate vents, drains and valves shall be provided. The flow element type for flow control shall be the ultrasonic liquid flow-meter. All of the fuel oil service pumps and heating facilities shall be located indoors in a purpose designed building. Tariff quality flow metering shall be provided as part of the fuel supply and transfer system. Each boiler unit shall have its own metering system for measuring the flow of oil to the respective boiler. Such metering shall maintain its accuracy over the full range of incoming flow rates during tank filling. Metering signals indicating the instantaneous and cumulative flow rates shall be provided to the central control room. Such metering shall be capable of being isolated for maintenance, and duplex filtration (with steam cleaning) and pressure differential measurement facilities shall be provided upstream of the metering for meter protection purposes. Facilities shall be provided to allow the drainage of the metering systems to a local drain pit. Fuel oil heaters shall be of the horizontal shell and U-tube type with removal 6.2-3 KHABAT TPP UNITS 1&2 - VOLUME I

tube bundle. The fuel oil heaters shall be TEMA type AEU. Fuel oil heaters shall be controlled with control valves located on the condensate discharge and will operate partially flooded with condensate. Heaters shall be designed for this operation and shall withstand any thermal stresses. 6.2.3.3

Light oil Light oil shall be delivered to the Plant by road tankers for storage on site. During normal operation the Plant shall be operated with fuel oil ; the light fuel oil system shall only operate during start-up on fuel oil. A tanker unloading station shall be provided and one(1) unloading pump skid lines of identical design shall enable one(1) road tankers to simultaneously supply light oil to the storage facilities. Each unloading pump skid shall be complete with a suction filter and differential pressure gauge located on the suction side of the unloading pump and appropriate vents and drains. Flow detectors shall also be provided on the suction side of each unloading pump. The discharge side of each unloading pump shall be provided with a nonreturn valve and a local pressure gauge to indicate the pump discharge pressure. Appropriate valves shall allow the isolation of each pump line. The tanker unloading shall be controlled at a local level once the tank to be filled is released by the central control room i.e the tank inlet valve is opened and all other routes are isolated. Tariff quality flow metering shall be provided to measure all road tanker unloading. Such metering shall be capable of being isolated for maintenance, and duplex filtration (with steam cleaning) and pressure differential measurement facilities shall be provided upstream of the metering for meter protection purposes. Such metering shall maintain its accuracy over the full range of incoming flow rates during tank filling. A metering signal indicating the instantaneous and cumulative flow rate shall be provided to the central control room. Facilities shall be provided to allow the drainage of the metering system to a local drain pit. Light oil service pumps shall be installed in the fuel oil pump house. The capacity and system parameters shall be based on starting all power units 6.2-4 KHABAT TPP UNITS 1&2 - VOLUME I

simultaneously. All of the light oil service pump skids shall discharge into a common header that shall then transfer light oil to each boiler unit. Light oil recirculation facilities shall be provided as appropriate. Duplex filtering and associated differential pressure transmitter and valve/drain facilities shall be provided on the inlet side of each fuel oil service pump skid. Each light oil service pump skid shall be complete with a differential pressure gauge and appropriate valves shall allow the isolation of each fuel oil service pump. Flow detectors and non-return valves shall provide pump protection, and pressure switches shall be used to sense the pressure at the pump suction and provide the signal for start-up. The light oil service pump discharge pressure shall be indicated on a local pressure gauge. Appropriate vents, drains and valves shall be provided. All of the light oil service pumps shall be located indoors in a purpose designed building together with the fuel oil forwarding facilities. Two (2) additional 100% capacity light oil service pump skid and its associated filtering, venting, pressure monitoring, draining, pump protection and valves etc. facilities shall also be provided in the common fuel pumping station to transfer light oil to the emergency generator storage facilities and fire fighting pumps, as appropriate.

6.2.4

Oil tanks

6.2.4.1

Fuel oil and light oil tanks The light and fuel oil tanks shall be of the self supporting fixed roof type, designed, constructed, tested and painted in accordance with API standard 650 and the supplemental requirements of this Specification. The storage tanks shall each be enclosed in a concrete wall type bund with a containment volume, which complies with the requirements of the NFPA relating to oil storage. The tanks shall be complete with stairs, handrails (to stairs and roof), internal and external coatings, instruments (level indication and high level alarm, 6.2-5 KHABAT TPP UNITS 1&2 - VOLUME I

displayed locally and on the PCS), vents, manholes, drains, filling and extraction pipework, and any other equipment necessary for the safe operation of the distillate and heavy fuel oil systems. Design of the tanks shall take into account the loadings from various equipment, platforms, fire protection piping and equipment, ladders and stairways, personnel, interior coatings, wind, and earthquake as specified herein. All walking and working surfaces shall comply with applicable standards. Tanks shall be vented during filling, and any excess oil from any venting operations shall be collected and suitably disposed of. All safety interlocks to prevent overfilling of the fuel oil tanks shall be provided including High and High High alarms of the tanks to automatically stop the tanker unloading pumps to prevent tank overfilling. A float level indicator (contents gauge) suitable for observation from ground level, calibrated in liters, complete with remote level indicator, high and low level alarm switches, is required for providing an indication of the quantity of fuel in each oil storage tank. Floats, guide wires, tensioning eyes and bolts for fitting inside the tanks together with outside level indicator, counterweight, counterweight guides, connecting wires, pulleys, brackets and seals where wires pass through the tank roof shall be supplied. The remote tank level indicator shall be arranged to provide a readout of tank contents in the control room. Corrosion allowance for the tank roof, shell and bottom plates shall be a minimum of 1.5 mm. A minimum of [one(1)] light oil storage tank, [two (2)] fuel oil storage tanks and [one(1)] fuel oil emergency storage tank shall be provided.

Emissions of volatile organic compounds from the fuel oil tanks shall be limited by installation of appropriate VOC removal plant, such as active carbon filters. 6.2.4.2 Pressure accumulators Pressure accumulators shall be provided by the Bidder, if considered 6.2-6 KHABAT TPP UNITS 1&2 - VOLUME I

necessary to maintain fuel oil supply pressure during a switch from a duty to standby pump. The pressure accumulators shall be located in the pump discharge header, and shall be designed for operation under all possible operating combinations of pumps. 6.2.4.3 Fuel storage capacity The required storage tank capacity of all fuels shall be as following. - Fuel oil storage tank A and B : 7,000m3 - Residue oil emergency storage tank : 4,000m3 - Light oil storage tank : 500m3 6.2.4.4 Fuel oil pipework, valves and fittings All fuel oil pipework shall be designed, constructed, installed and tested in accordance with ANSI B31.3 or equivalent internationally recognized standards. All buried fuel oil pipework shall be accommodated in trenches which are excavated, prepared and backfilled in accordance with internationally recognized codes and standards ; the depth of cover over the crown of the pipe shall be not less than 900 mm. All isolating valves in the fuel oil systems shall be of the non-lubricated ball type with Teflon seals and resilient faces, where applicable. The valves shall be of the fire-safe design. Threaded valves shall only be used where required for equipment compatibility. Cast iron valves shall not be used for oil service. All piping and equipment shall be protected against excess pressure utilizing pressure relief valves. Over pressurization of blocked or isolated pipelines and equipment by solar heating and ambient temperature changes shall be considered in the design. Relief valve discharge shall be piped to the return header or pump suction, as required. Vents and drains equipped with a ball valve shall be provided at strainers and all high points and low points respectively. In addition, connections required for periodic tests shall be equipped with valves and threaded nipples which shall be protected by threaded caps.

6.2-7 KHABAT TPP UNITS 1&2 - VOLUME I

6.2.4.5 Pressure accumulators Pressure accumulators shall be provided by the Bidder, if considered necessary to maintain fuel oil supply pressure during a switch from a duty to standby pump. The pressure accumulators shall be located in the pump discharge header, and shall be designed for operation under all possible operating combinations of pumps. 6.2.4.6 Thermal insulation The piping and equipment of fuel oil shall be insulated and traced heat and the insulation shall be lagged. Insulation shall be asbestos free and shall be suitable for the service in each location of the installation. The outside surface temperature of the lagged insulation shall not exceed the ambient air temperature by more than 30℃ ambient air velocity of 15 m/min for indoor equipment and 1 m/s for outdoor equipment. Ambient air temperature for the design of thermal insulation shall be 30℃. Lagging for piping and equipment insulation shall be of aluminum alloy 3003 or 3005, minimum thickness of 0.5 ㎜ and fastened with stainless steel bands. Thermal insulation on pipe and equipment shall be calcium silicate or mineral fiber block type insulation complete with aluminum outer lagging. Heat tracing for the piping and equipment of fuel oil shall be furnished by the Bidder. All insulation which is normally removed during routine inspection shall be of the reusable type. The Bidder shall describe the method of preventing detachment of lagging plate in stormy weather.

6.2.5

Steam cconverter system

6.2.5.1 General Steam converter system shall be designed to supply sufficient heating steam for two(2) fuel oil storage tanks suction and bottom heaters, one(1) fuel oil emergency storage tank bottom heater and suction heater, fuel oil heaters. 6.2.5.2 Steam converter

6.2-8 KHABAT TPP UNITS 1&2 - VOLUME I

A.

The steam converter and appurtenances shall be designed in accordance with the requirements of the HEI(Heat Exchange Institute) code and this specification including ASME Section Ⅷ. The steam converter shall be stamped, certified, and documented in accordance with the code. The steam converter assembly shall be designed to withstand loads imposed by fluid pressure, thermal expansion, and piping reaction. Stress resulting from static and dynamic loads, individually and together, shall be within code-specified allowable limits.

B.

The steam converter shall be designed for full shell side design pressure and temperature with atmospheric pressure on the tube side, and for full tube side design pressure and temperature with atmospheric pressure on the shell side.

C.

Reliability in service and accessibility of all parts (where practicable or specified) for inspection, maintenance, and repair shall be a design objective.

D.

The steam converter shall be of the horizontal shell and U-tube type with removable tube bundle. The steam converter shall be TEMA type AKU. Support saddles and lifting lugs designed in accordance with the requirements of the code shall be provided for the steam converter. Attached piping loads shall be considered in designing shells and support saddles.

E.

Tubes for the steam converter shall be steel A-556. The tubes shall be rolled full depth to the tube sheets. Minimum allowable tube size shall be 15.88mm(5/8") OD, and average wall thickness 20 BWG for U-tube type.

F.

The tubesheets shall be welded to the shell and channels.

G. The channels shall have full size flanged and min. 457mm(18"). I.D circular manways providing complete accessibility to the tube-totubesheet joints. H.

Baffles, tube support plates, and tierods shall be provided in sufficient number and adequately spaced to prevent tube vibration. Impingement plates shall be provided under the shell inlet nozzle to protect the tubes against erosion and to prevent vibration. Bundle entrance and exit areas shall be in accordance with TEMA Class R requirements. The natural frequencies of all unsupported tube spans shall be sufficiently removed from hydrodynamically and system generated fluid pulsations to avoid damaging tube vibrations. 6.2-9 KHABAT TPP UNITS 1&2 - VOLUME I

I.

Shell material shall be steel A-286 and tube sheet shall be steel A-226. A shell corrosion allowance shall be minimum 3.2mm. Other materiel not specified in this specification shall conform to HEI requirements.

J.

Adequately sized venting orifices for removal of noncondensable gases shall be provided. Air vent limiting orifices for heat shall be installed in the external piping.

K.

Vent, drain, and pressure and temperature instrument connections shall be provided as required by TEMA requirements.

L.

All connection nozzles and heat exchanger supports shall be designed to withstand safely, forces and moments imposed by connecting piping in addition to the operation weight of the heat exchangers including insulation.

M. The steam converter shall have an electrical grounding connection. N.

The Bidder shall size a connection and provide a heavy duty thermal relief valve to protect the tube side of the heat exchanger. Valve size, type, and material shall comply with ASME and HEI code requirements.

O. The Bidder shall size connections and provide safety relief valves to protect the shell against tube breakage in accordance with the HEI code. P.

The heat exchanger shall be insulated by the Bidder. Thermal insulation shall be provided.

Q. Integral drain cooling zones shall be designed to allow satisfactory operation with a minimum level variation of condensate in the heater shell for both normal and abnormal conditions. On the heater with integral drain cooler, a separate high level drain outlet bypassing the drain cooler section located in the condensing section of the heater shell and having at least the same capacity as the normal drain, shall be provided. Separate and independent level-sensing instrumentation connections shall be provided for normal level, high level and emergency high level. The normal heater drain outlet from the drain cooling section shall be sized for the drain flow that occurs with maximum tube side flow. R.

The maximum water velocity through the tube shall be in accordance with the Heat Exchange Institute Standard at the normal full load operating conditions and shall not exceed 3 m/sec(10 ft/sec).

6.2-10 KHABAT TPP UNITS 1&2 - VOLUME I

S.

The steam converter shall be designed to ensure continuous, safe and economical operation providing the maximum reliability at any operating conditions of temperature changes.

T.

Supports for the steam converter shall be capable of with standing the loads and moments calculated by the Bidder in addition to normal loads and moments, and shall provide for transfer of loads to building structure by positive means.

6.2.5.3

Steam converter feed pumps A.

The pumps shall be inherently stable when running together in parallel at all loads. The feed pumps shall be motor driven with coupling and the water flow to the steam converter shall be controlled by the control valves and the constant speed of the pumps.

B.

The pumps shall be horizontal, centrifugal, diffuser or volute type, with impellers arranged in series specially designed for feedwater pumping service.

C.

Pumps shall be of a design and construction that has been proved reliable

and

satisfactory

for

continuous

operation.

Design

and

workmanslip shall be such that the pumps are readily assembled or dismantled, and they will operate satisfactorily under all operating conditions without undue wear, vibration, cavitation or overheating. D.

Each pump shall be provided with isolating valves on the suction and discharge sides, and also a non-return valve on the pump discharge. Each pump suction shall be provided with a strainer and differential switch. The pumps shall also be provided with separated arrangements to automatically recirculate water back to the steam converter condensate return tank for protection of pumps at low and no load conditions.

E.

The characteristics of the pumps must be such that the shut off head is not greater than 120% of the duty point head.

F.

The flow from each pump is monitored, and a minimum flow recirculation valve is opened to maintain flow above that pumps minimum flow requirements. During normal flow conditions the recirculation valve is closed.

6.2.5.4

Steam converter feed tank, drain receiver tank and blowdown tank

6.2-11 KHABAT TPP UNITS 1&2 - VOLUME I

A.

Steam converter feed tank, drain receiver tank and blowdown tank shall be designed, fabricated, examined, inspected, and constructed in accordance with the ASME Code Sec. VIII.

B.

All the inlet impingement baffles and their supports shall be designed to withstand all forces resulting fron an occasional water slug.

C.

All necessary manholes and access doors for the tanks shall be provided.

D.

The tank drains shall be located to flush with the bottom of tank so that complete drainage can be assured.

6.2-12 KHABAT TPP UNITS 1&2 - VOLUME I

6.3

Electrostatic Precipitator

6.3.1

System description The electrostatic precipitator shall be a cold side flue gas electrostatic precipitator, capable of removing the particulate matter from the flue gas discharge of steam generator. The cold side electrostatic precipitator will be located between the airpreheater outlet and the combined induced draft fan(CIDF) inlet. After passing through the precipitator the gas will be induced to the combined induced draft fan.

6.3.2

System design criteria

6.3.2.1

The electrostatic precipitator shall be designed based on the fuel oil an specified Vol. 3 Schedule A and guaranteed to operate at the flue gas flow rate, flue gas temperature, particulate inlet loading and outlet load ing.

6.3.2.2 Precipitator of each steam generator shall consist of two(2) 50 % precipitators. Each precipitator shall be divided into equally sized chambers. 6.3.2.3 The precipitator shall be sectionalized into fields for ease and flexibility of operation. Each section shall be provided with its own power supply. 6.3.2.4 The precipitator aspect ratio shall be at least 1.0 and maximum gas velocity between collecting electrodes to be limited to 1.2 meter per second. The flue gas conditioning system, if required, shall be a complete and operable system. 6.3.2.5 The precipitator shall be so designed that the guaranteed performance can be continuously sustained on a year-round basis without undue maintenance under any condition of normal operation of steam generator. 6.3.2.6 Design shall apply lubrite or teflon plates or approved equal at those supports where movement due to thermal expansion occurs. The precipitator shall be capable of start-up form a clod condition simultaneously with start-up of the steam generator. The Bidder shall arrange the electrical equipment and control accessories of the precipitator for each unit, in two(2) 50 percent independent interleaved groups.

6.3-1 KHABAT TPP UNITS 1&2 - VOLUME I

6.3.2.7 The precipitator shall be sized and designed so that under any operating condition the outlet particulate loading will not exceed the specified guaranteed limits. Compliance with this guarantee shall be demonstrated through actual field testing. 6.3.2.8 Design flue gas temperature shall apply actual flue gas temperature plus 22 degree C. 6.3.3

Design and construction features The electrostatic precipitator shall be of rigid frame type. All flanges, bolt size, holes, studs, threads, connectors, electric lugs and cable connectors shall be in conformance with ANSI standards. Design temperature for structural design shall be 260 degree C for continuous operation and 400 degree C for thirty (30) minutes for transient condition.

6.3.3.1 Casing A. The precipitator shall be self-supporting above the supporting steel and shall withstand all forces caused by wind, snow or earthquake loads with the internal forces due to pressure, dust load, operating temperature and the dynamic loading imposed by vibrators and rappers. B. The roof of the precipitator shall be designed to support maintenance personnel and tools as well as the loads.

A 1,100 mm high continuous

handrail shall be provided around entire roof. The roof shall be sloped for drainage and protected from accumulation of rainfall. The roof of the precipitator shall be provided with insulation. The finished surface shall also be pitched for drainage. The Bidder shall provide suitable gutter and drain piping terminating 30cm from grade in accordance with the standard plumbing code. Piping shall be fabricated from Schedule 40 carbon steel pipe conforming to ASTM A120 Grade A or B. The insulation shall be covered with 4.5 mm thick seal welded, hot dipped galvanized platform grating for walk-on access to roof mounted equipment. Insulation will be field cut. Cover plates shall be shop cut. The roof cover shall be designed to allow for differential thermal expansion between the cover and the precipitator. Suitable flashing shall be provided at all

6.3-2 KHABAT TPP UNITS 1&2 - VOLUME I

penetrations through the cover. The high voltage insulators shall have heated enclosures. C. Flue gas flow distribution devices shall be designed at the upstream gas duct of EP inlet nozzle by the Bidder. These distribution on devices shall be provided by Bidder, if required. D. The precipitator casing shall be fabricated from low carbon steel plate to ASTM A 36 or equivalent and the wall of the casing shall have a minimum thickness of 6.0 mm. E. The casing shall be of welded construction, except where impractical for access or maintenance. Component sections shall be designed to keep the amount of field welding to a minimum. F. The precipitator shall be designed to withstand the maximum internal transient draft pressure and negative pressure of ± 900 mm H2O at design gas temperature, and adequate provision shall be made for expansion and differential expansion. G. The casing shall be designed to minimize the inward leakage of air or the escape of gas. 6.3.3.2 Ash hoppers A. Hoppers shall be of the inverted pyramidal shape, with a valley angle not less than 55 degrees to horizontal. They shall be fitted with round flanged outlets. The bottom third of each hopper shall have a curved radius transition to facilitate ash flow. B. Hoppers shall have a minimum thickness of 6.0 mm and fabricated ASTM A588 steel plates. The following fly ash densities shall be used in the hopper design : - For volumetric calculation, no settlement

:

150 kg/cu.m

- For structural design and related calculation

: 1000 kg/cu.m

- All hoppers shall be structurally designed for the loads imposed when the hopper is completely filled with fly ash. 6.3-3 KHABAT TPP UNITS 1&2 - VOLUME I

C. Exterior and interior siding for hopper area shall be of minimum 0.55 mm steel sheets, hot dipped galvanized, ASTM A 525, G 90 coating weight or equivalent and with shop coated polyvinylidene fluoride on outside, epoxy primer on inside for insulated metal siding, minimum thickness 25 micron for preventing oxidation and wearing-out and pigment for sun-proof or equal. D. The fly ash hoppers shall be sized so that each hopper shall store all the ash collected in its corresponding part of the precipitator during at least 24 hours of operation at maximum fly ash load using lowest fuel oil without decrease in collection efficiency or increase in draft loss through the unit. Sufficient allowance in capacity shall be made for unequal distribution of ash between front and rear hopper sections. Hopers shall generally not span two(2) electrical fields, but may span two complete electrical fields if adequately baffled to prevent gas flow through the hoppers. E. Each hopper or baffled hopper section shall be equipped with one hopper ash level switch. The level switches shall be operated by fly ash level and be equipped with two(2) DPDT switches for high level. All level switches shall be wired to a subpanel. All level switches shall be designed for high temperature operation. F. The subpanel shall be provided by the Bidder. The subpanel shall have numbered indicating lights for the precipitator hoppers and shall be wired to activate a common alarm. The arrangement of lights shall mimic the precipitator hopper arrangement. G. All hoppers shall be equipped with unbalanced weight type or electromagnetic vibrators and baffle plates, as required, with two(2) 50 mm flanged poke holes located 90 degree C apart with bolt on caps. The electromagnetic vibrators shall be externally mounted on each hopper. Interlocking equipment shall prevent the vibrators from being operated before the fly ash removal system comes into operation. Hopper baffles shall be structurally designed to support a full dust load on one side with the other side completely empty.

6.3-4 KHABAT TPP UNITS 1&2 - VOLUME I

H. All hoppers shall be furnished with steam heating system. The heaters shall be automatically controlled. The heaters shall be sized and located to maintain the temperature of the entire inside face of the hopper plates above 120 degree C under all operating conditions. In addition the heaters shall be capable of heating the entire inside face of the hopper plates to a temperature of 70 degree C above ambient from a cold start in four(4) hours. I. The hopper insulation shall be applied in panels designed for quick removal and replacement. 6.3.3.3 Penthouse Penthouse shall be provided to protect equipment from inclement weather. The heated purge air shall be supplied. Stand-by heated purge air blower per E.P shall be provided. 6.3.3.4 Distribution devices There shall be one or two gas distribution plates or equivalent gas distribution devices at the inlet and outlet of each chamber. The type of plated or device shall completely cover the entire width or each chamber. The design and positioning of the gas flow distribution device shall be in accordance with the results of the gas flow model study. Plates shall be equipped with rappers as necessary to keep them clean. 6.3.3.5 Collecting and discharge electrodes A. Collecting plates shall be of at least 1.2 mm thickness and fabricated ASTM A 366 or equivalent steel plate, The collecting surface shall be free of kinks or excessive “oil canning". B. Plate to electrode alignment shall be per the following table ; - 250 mm(10 in)

± 4.0 mm(± 3/16 in.)

- 275 mm(11 in)

± 8.0 mm(± 5/16 in.)

- 300 mm(12 in)

± 9.6 mm(± 3/8 in.)

- 400 mm(16 in)

±15.9 mm(± 5/8 in.)

6.3-5 KHABAT TPP UNITS 1&2 - VOLUME I

C. Plate spacing shall be between 250 mm(10″) and 400 mm(12″). Electrode design shall prevent oscillation due to electromotive forces, flue gas velocity and rapping accelerations. D. Discharge electrodes shall be of at least 1.6 mm thickness and fabricated corrosion resistance low alloy steel(CRLS) rigid frame type. 6.3.3.6 Rapping system A rapping system shall be provided for cleaning electrodes and collecting plates. As a minimum, system shall be capable of a 100g acceleration normal to the remotest section of the plates. Rapper controls shall be readily adjustable for frequency, and shall be independently adjustable for each electrical field.

All electrical parts of the

rapping system shall be out of the gas stream or protected therefrom. 6.3.3.7 Water washing facilities The Bidder shall furnish a complete automatic water washing system, NaOH mixing tank and injection facilities which will be used to wash the dust and ash from the electrodes when the unit is shutdown. 6.3.3.8

Discharge electrode supporting insulator The insulator shall have sufficient electrical and mechanical strength, and shall be suitable for the high temperature and humidity conditions. Particular attention shall be paid to the method of supporting the electrode with reference to strength, maintenance and performance stability.

6.3.3.9

Insulator chamber Insulator chamber shall be provided with a hot air ventilation system to prevent insulator breakdown. This system shall be complete with electric air heater, purge air fan with motor, inlet filter and distribution pipes. A thermometer with adjustable contacts shall be installed in the ductwork for high and low temperature alarms due to fan failure or heater failure. Each insulator shall be equipped with electric heating to ensure that the temperature at the insulator will not be below the dew point when the plant is started up from a cold state.

6.3-6 KHABAT TPP UNITS 1&2 - VOLUME I

6.3.3.10 Provisions for access and maintenance A. Adequate access for all necessary maintenance activities, inspection, repair and testing shall be provided from the ground level to the roof stairs, ladders and handrails. B. This shall include access platforms to all equipment, ducting, access doors, inspection doors, instrument connections and test connections in accordance with ASME PTC-38 test requirements. C. Access doors shall be provided in the roof of the precipitator and each precipitator hopper or casing. D. A hoisting facility to be supported from the roof of the precipitator, capable of removing each transformer-rectifier unit to grade, shall be provided. 6.3.3.11 Steel structures, stairs and walkway A. The Bidder shall design all structural and miscellaneous steel in accordance with the AISC steel specification or equivalent applicable local building codes. B. Structural steel and appurtenant materials shall conform to ASTM A36 or other higher strength steels. C. The supporting structure shall be of sufficient rigidity and strength so as to avoid undue vibration or undue deflection due to wind or operation of the equipment. The top bearing surfaces of base plates shall be true plane surfaces with all burrs or beads removed. They shall be scribed and centerpunched and provided with leveling nuts and grout holes. Curb plates and angles shall be shop attached to supporting steel whenever practicable. Filler and spice plates shall have full surface contact, with all beads and burrs removed. Walkways and stairs shall be installed on the left and right sides of the EP each stairs shall be complete from ground floor to the top of precipitator. Walkways and stairs shall be provided for all access doors. 6.3.3.12 Thermal insulation The entire precipitator unit shall be insulated and the insulation shall be lagged. Roof insulation covering shall be waterproof and self-draining without

6.3-7 KHABAT TPP UNITS 1&2 - VOLUME I

moisture pockets. Insulation shall be asbestos free and shall be suitable for the service in each location of the installation. All material shall be suitable for the highest temperature and the most severe service to which they shall be subjected, including the effects of vibration. All insulation materials and all associated binders, sealers, barrier sheets, finishes and attachments shall be noncombustible. All insulation which is normally removed during routine inspection shall be of the reusable type. The Bidder shall describe the method of preventing detachment of lagging plate in stormy weather. The insulation shall be designed and installed to minimize the convection current in the space between the hot metal surface and the inner layer of the insulation. 6.3.3.13 Electrical requirements The Bidder shall engineer, design and furnish completely all electrical equipment and accessories required for the operation of the electrostatic precipitator system and the Bidder shall design electrostatic precipitator(EP) equipment with minimum power consumption. A. Transformer-Rectifier Transformer-rectifier sets shall be of silicon type. The transformer- rectifier shall be adequately surge-protected and be of the oil immersed self-cooled type. B. High Voltage Ties The Bidder shall furnish the high voltage water tight metal clad bus connections between the rectifiers and the precipitator electrodes shall be grounded. C. The Bidder shall provide the all motors, heaters and accessories. 6.3.3.14 Instrumentation and control A. General a) The Bidder shall furnish a complete package of instrumentation and controls necessary to meet the requirements of this specification, and that shall offer a high degree of reliability and safety to both personnel and apparatus. 6.3-8 KHABAT TPP UNITS 1&2 - VOLUME I

b) PLC based control cubicles and complete field instrumentation for the automatically precipitator controls and monitoring shall be provided. c) Minimum one(1) operator interface station with dual LCD monitors(min. 21 inch) and printer per one(1) generating unit shall be provided. d) The EP control system shall be designed to enable the operator to supervise and operate the electrostatic precipitator system by using LCD/keyboard in local control room. e) EP control system shall be provided with the data communication interface devices with PCS for the supervisory control and monitoring in the central control room. g) The PLC shall be provided with redundant (hot back-up) CPUs, power supplies and data communication networks. f) Instrumentation and controls shall be designed in accordance with the section 8 of this technical specification unless otherwise specified in this section. g) The dust concentration monitoring system including dust analyzers shall be provided for the efficiency calculation and energy management of EP. Dust analyzers shall be installed each EP inlet duct and outlet duct and shall be used for precipitator control.

6.3-9 KHABAT TPP UNITS 1&2 - VOLUME I

6.4

Ash Handling System

6.4.1

General A.

The Bidder shall supply all equipment and piping, Ash storage silo support steel, pipes and equipment shall be shop assembled, match marked to facilitate field erection and slipped knocked down in the largest possible sections.

B.

The fly ash is collected at the EP hopper and transported to ash storage silo by vacuum system.

C.

The stored ash is dehumidified through the discharge gate damper rotary feeder, dustless unloader and unloaded into bag.

D.

The ash handling rate is designed to evacuate the ash within the two(2) hour that produced in an eight(8) hour shift at EP design condition of the BMCR. and ash is un loaded into container by using the rotary feeder/dustless unloader for truck trans port.

6.4.2

Design and construction features

6.4.2.1 Ash transfer system A.

The steam air heater shall be supplied to obtain the adequate hot air for preventing from ash plugging and corrosion problems in the ash piping.

B.

Seal air blower shall be supplied to prevent dust and corrosive gas from coming down into transport pipe, when dust transportation is rest and boiler shutdown.

C.

Angle type

plate shut-off valve is pneumatically operated to obtain

adequate vacuum, pre-warming and after cleaning of ash piping. D.

The flap type non-return valve shall be installed to prevent damage caused by reversal gas flow leakage from the interior of the EP at shutdown of the equipment.

E.

The Bidder shall be supplied following discharge devices. 1) Ball flap valve Nonsliding ball flap valve shall be provided and pneumatically operated. 2) Dust Hopper Dust hoper is provided for temporarily storing the ash collected by the cyclone and/or bag filter. Hot air aeration system is provided for the smooth discharge function of the ash in storage silo. 6.4-1 KHABAT TPP UNITS 1&2 - VOLUME I

3) Equalizer Valve Pneumatically operated ball valve shall be provided for equalizing the pressure between the transport pipe side and ash storage side. 6.4.2.2 Vacuum pump A.

The Bidder shall furnish two(2) 100 % Water Ring type vacuum pumps including the drivers.

B.

Each

pump

consists

of

water

sealing system and air-water

separator which have the function of silencer and gas cleaner. C.

Vacuum breaker shall be provided to prevent excessive torque at the time the vacuum pump is started and prevent plugging.

6.4.2.3 Bag filter A.

A bag filter shall be provided to separate ash from conveying stream into silo. Air to cloth ratio of bag filter shall be 0.67:1 Acu.m/min./sq.m (2.2:1 Acfm/sq.ft) if filters shall be compartmentalized so that

half of the filter is

taken out of service for maintenance, and acceptable air to cloth ratio of 1.34:1 (4.4:1) is still maintained without interrupting operation. B.

The bag filter shall have a collection efficiency of at least 99.5 % of all in fluent dust and shall be supplied with all complete accessories required for filter operation.

C.

The bag filter shall be provided with a complete system for overtemperature protection, including temperature probe and ambient air pulse valve.

D.

Automatic regeneration provision in bag filter shall be provided. Pulse air is used as the regeneration medium.

6.4.2.4 Ash storage silo A.

The ash storage silo shall be cylindrical, bottom supported, and fabricated structural grade carbon steel plate, of welded water and gas tight construction throughout. The silo shall be shop-assembled, match marked to facilitate field erection, and slipped knocked-down in the largest possible sections consistent with correct shipping practice.

B.

The net volume of the silo shall be based on storing material for a minimum of 72 hours.

6.4-2 KHABAT TPP UNITS 1&2 - VOLUME I

C.

The cylinder shall be fabricated from ASTM A 36 or equivalent steel plate, 6 mm thick minimum.

D.

The ash storage silo and support structures shall be complete with all auxiliary equipment including level indicators, vacuum relief valves, access door, electric vibrator and all necessary valves and controls.

E.

All structural steel for the support of the ash storage silo shall be provided along with all stairways, ladders, platforms, handrails and other equipment required for access. In areas were designated access for trucks and maintenance equipment, the minimum elevation shall be 3.5 m from ground to bottom of ash storage silo.

F.

The ash storage silo shall be furnished with steam heating system. The heaters shall be automatically controlled. The heaters shall be sized and located to maintain the temperature of the entire inside face of the hopper plates above 120 degree C under all operating conditions. In addition the heaters shall be capable of heating the entire inside face of the hopper plates to a temperature of 70 degree C above ambient from a cold start in four(4) hours.

G. The

ash

storage silo

unloading area shall be totally enclosed with

ventilating units to prevent dust emission. 6.4.2.5 Rotary feeder The Bidder shall be furnished Rotary Feeder to supply a constant volume of dust from ash storage silo to the dustless unloader by causing the action of a loader with vanes that rotate within the casing. The heaters shall be fabricated corrosion resistant low alloy steel. Sealing air is injected to prevent intrusion of the dust into the bearings. 6.4.2.6 Dustless unloader The dust transported by the rotary feeder moves towards the outlet while being water-sprayed and kneaded through vanes attached to the shaft. Dual shaft type unloader shall be provided with a gland seal and sealing air to prevent the dust form intruding into the bearings. 6.4.2.7 Ash transport pipe A.

Ash transport pipe shall be coated with special aluminium to prevent corrosion. 6.4-3 KHABAT TPP UNITS 1&2 - VOLUME I

B.

The expansion and contraction of the ash transport pipe at the lower part of the electrostatic precipitator hopper are absorbed through coupling or expansion joint.

C.

The piping from the outlet of steam air heater to the inlet of bag filter is steam traced

6.4.2.8 Instrumentation and controls A.

The Bidder shall furnish a complete package of instrumentation and controls necessary to meet the requirements of this specification, and that shall offer a high degree of reliability and safety to both personnel and apparatus.

B.

PLC based control system and complete field instrumentation for the automatically ash handling system controls and monitoring shall be provided.

C.

Minimum one(1) operator interface station with dual LCD monitors(min. 21 inch) and printer per one(1) generating unit shall be provided.

D.

The ash handling control system shall be designed to enable the operator to supervise and operate this system by using LCD/keyboard in local control room.

E.

The ash handling control system shall be provided with the data communication interface devices with PCS for the supervisory control and monitoring in the central control room.

F.

The PLC shall be provided with redundant (hot back-up) CPUs, power supplies and data communication networks.

G. Instrumentation and controls shall be designed in accordance with the section 8 of this technical specification unless otherwise specified in this section.

6.4-4 KHABAT TPP UNITS 1&2 - VOLUME I

6.5

Steam Turbines and Auxiliaries

6.5.1

Conditions of service

6.5.1.1 Description of service The steam turbine-generator will receive steam from oil fired, drum type steam generator for the generation of electric power. Each unit will operate in parallel with other station generating units within the MOE power system. The turbinegenerator unit may be subjected to sudden load rejection or rapid load pickup, and to adverse conditions due to maladjusted unit controls. The steam turbine-generator shall conform to the design and arrangement indicated on the drawings and requirements specified in the specification. 6.5.2

Design conditions

6.5.2.1 Type of steam turbine-generator A. The steam turbine-generator shall be of standard design condensing, tandem compound, single reheat steam turbine with 3000 rpm synchronous generator. B. The turbine shall be capable of operation both partial arc admission and on full arc admission. The turbine and control valves shall be capable of operation on constant pressure with the control valves operating sequentially.

In addition, the control valves should be capable of being

held at a position which offers the most desirable heat rate or advantageous operating condition. C. The turbine low pressure ends shall be arranged for bottom or axial exhaust and provided with an outlet for a bolted flange or welded connection to a condenser expansion joint. 6.5.2.2 Steam extractions and feedwater heating cycle The turbine-generator nominal rating and valve wide open rating shall be based upon a regenerative feedwater heating cycle with all heaters in service. Any extractions for operating auxiliaries and air heating purposes to be returned to the cycle will be returned to the main condenser. 6.5.2.3 Operating speed and allowable vibration

6.5-1 KHABAT TPP UNITS 1&2 - VOLUME I

A.

The turbine-generator unit at the rated speed of 3000 rpm shall not exceed the vibration and shaft movements specified hereinafter. The maximum vibration as measured on the turbine and generator shafts adjacent to all bearings shall not exceed 80 microns double amplitude throughout the load range. The maximum vibration as measured on the turbine and generator bearing pedestals will not exceed 4.5 mm/sec throughout the load range. Shaft movement in either axial direction shall not exceed 0.9 mm when measured from the center of the thrust cage clearance.

B.

The turbine-generator shall also be capable of operation at any speed above the rated speed up to 110 percent of the rated speed without exceeding the above specified maximum vibration and without showing any sign of stress or instability.

The unit shall be sufficiently strong to

withstand, without damage, any stresses or deflections that might result from transient speed up to 120 percent of the rated speed. 6.5.2.4 LP Bypass system capacity The turbine LP bypass system capacity shall be based on the following requirements ; A.

The times required for startup, loading and unloading shall be at the minimum values attainable.

B.

The bypass system capacity shall not increase the size of main condenser more than that required by a normal design without considering bypass system.

C.

The steam turbine shall be capable of withstanding 100% load rejection without an overspeed trip.

6.5.2.5 Allowable metal temperatures The Bidder shall describe in the proposal the maximum rate of change in allowable metal temperatures of HP turbine first stage and IP turbine bowl for the various load changing mode of cold start, warm start, hot start and restart 6.5.2.6

Performance condition and heat balances The Bidder shall state and satisfy for the steam cycle considered, the following performance of the steam turbine-generator according to design conditions All of the performance values shall be achieved without any measuring

6.5-2 KHABAT TPP UNITS 1&2 - VOLUME I

tolerance, i.e. uncertainty. The KNOC will not accept any deviations and exceptions for the entire paragraph A.

Performance Conditions 1) Performamce output at MGR 2) Turbine heat rate at MGR 3) Time required in minutes from steam to turbine to MGR for warm start 4) Rated generator capacity at 0.85 power factor. 5) Minimum stable load under full automatic control 6) Auxiliary Power at MGR

B.

Heat Balances The Bidder shall furnish the following ; 1) A heat rate curve over the full operating range which will show the effect of throttling. 2) Performamce heat balances at MGR 3) Calculated heat balances for the cases as follows ; a) VWO b) CR c) MGR with High Back Pressure d) MGR with Low Back Pressure c) 75% load of MGR d) 50% load of MGR e) 30% load of MGR f) MCR & THO rating g) House load 4) A thermal kit corresponding to the heat balances including the curves and data described in "Schedule C2." The correction equations and the application criteria shall be included in all correction curve drawings.

C.

Heat Balance Basis Heat balances shall be based on the following requirements ; 1) Final feedwater temperature shall be optimized at MGR condition.

6.5-3 KHABAT TPP UNITS 1&2 - VOLUME I

2) In

the

heat

balance

diagrams,

no

less

than

two

thermal

properties(pressure & temperature or pressure & enthalpy) shall be shown at any point where flow functions are described. 3) Condensate leaving the condenser hotwell shall be at the saturation temperature corresponding to the turbine exhaust pressure. 4) Properties of steam shall be in accordance with IF97 SI Steam Tables. 5) The main feed pump discharge pressure shall no less than 1.25 times the throttle steam pressure. 6) In all heat balances, the boiler feed pump shall be modeled to be driven by motor. 7) Compressed liquid values shall be used in determining the enthalpy of feedwater at any point after it leaves the main feed pump discharge. 8) All heat balances up to 30% MGR shall be predicated on No. 5 HP heater drain to deaerator. 9) Heat balances shall show turbine stage pressures and enthalpies at bleed steam extractions and first stage shell. The pressures at the extraction nozzles shall be shown where internal pressure drop occurs between turbine stage and extraction nozzle outlet. 10) Heat balances shall show the pressures and enthalpies at the downstream of bleed steam extractions such as heater inlet. 11) Heat balances shall show the ELEP, UEEP and vacuum at the condenser and the enthalpy and vacuum at feed pump turbine exhaust. 12) The throttle losses of main steam and control valve, reheat steam stop and control valve shall be shown. 13) Heat balances shall show turbine wheel power, fixed mechanical loss, generator loss, gear box loss (if installed) and generator terminal output. 14) The losses of generator and the power consumption of excitation shall be respectively shown on heat balance diagram. The heat balance shall be calculated and prepared on the basis of the generator output including the excitation power consumption. The following two heat rate shall be calculated and shown on heat balance diagram. 6.5-4 KHABAT TPP UNITS 1&2 - VOLUME I

15) Gross heat rate based on the generator output including the excitation power consumption. 16) Gross heat rate based on the generator output except for the excitation power consumption. 17) Mechanical vacuum pumps will be used to evacuate air and noncondensable gases from the main condenser. 18) Turbine-generator heat rate shall be calculated as follows ; GHR = [M1xH1 - M2xH2 + M3xH3 - M4xH4 - MixHi + MjxHj - MsxHs - MrxHr]/ [KWG] Where ; GHR : turbine-generator gross heat rate, kcal/kWh KWG : generator terminal net electrical output, kW M H

: flow of steam, feedwater, or drain, kg/h : enthalpy of steam, feedwater, or drain, kcal/kg

Affix to M and H ; 1

: throttle steam at stop valve inlet

2

: feedwater at boiler inlet

3

: steam leaving reheater

4

: steam entering reheater

i

: bleed auxiliary steam, and leakage

j

: drain of auxiliary steam returning to cycle, and makeup

s

: superheater spray water

r

: reheater spray water

※ It is needed to achieve steady state conditions during the test. 19) The values of the following steam properties shall be ;

6.5-5 KHABAT TPP UNITS 1&2 - VOLUME I

- pressure : rounded off to two decimal places, but LP Turbine, LP Heater and its piping pressure shall be rounded off to three decimal places - temperature, enthalpy and heat rate : rounded off to two decimal places 20) The Bidder shall provide the heat balance diagrams prepared in MKS and SI unit system. The major units or these system are as follows ;

6.5.3

MKS unit system

: kg/h, kg/cm2, kcal/kg, ˚C, kcal/kWh

SI unit system

: kg/h, bar, kJ/kg, ˚C, kJ/kWh

Design features for turbine

6.5.3.1 General The turbines shall be designed throughout so as to insure continuous, safe and economical operation providing the maximum of reliability and without undue heating, vibration or noise. The turbines shall be located indoor in slide along arrangement.

The turbine rotors shall be designed to prevent axial

movement during abnormal operating conditions. 6.5.3.2 Blading All blading shall be of proven design and shall be free of harmful resonant behaviour in the normal operating speed range of synchronous speed +/- 10%. The design of blade and its root fixing as well as the material of construction shall have been used in similar applications and at similar operating conditions for a period of not less than 3 years commercial operation without serious incident. Integral shrouding is preferred. Blading material and design shall be selected with regard to the operating conditions during all normal operation at full load and part load. 6.5.3.3 Casing The casing shall be drilled for temperature elements to indicate first stage shell temperatures, valve chest metal temperatures, etc. The main horizontal and vertical joints in the turbine shell shall be metal-to-metal.

Provisions

6.5-6 KHABAT TPP UNITS 1&2 - VOLUME I

such as manhole shall be provided on each IP/LP casing for inspection of IP/LP buckets without opening of the turbine casings. 6.5.3.4 Bearings and seals A.

All turbine-generator main shaft bearings shall be provided with seals to control oil and vapor leakage along the shaft. Bearings shall be of the self-aligning type and split to permit removal of the upper half for inspection.

Bearings shall be accessible for inspection without removal

of the turbine shells.

Each main shaft bearing shall be equipped with a

temperature element imbedded in each main bearing. In addition, temperature detecting sensors shall be located in all main bearing drains. B.

Each thrust bearing shall be equipped with temperature elements located in each front and back thrust bearing plate or shoe to provide for indication of excessive thrust bearing temperature. Electronic thrust bearing wear detectors for sensing thrust bearing position shall be provided and shall activate automatic tripping of the turbine in case of excessive thrust bearing wear.

6.5.3.5 Couplings The couplings connecting the turbine and generator and the various turbine shafts shall be of a type that can be readily disconnected for purposes of inspection and repair. 6.5.3.6 Serviceability of parts All parts of the turbine shall be accessible and capable of ready removal, assembly or replacement. Upper casing and main bearing caps shall be provided with lifting lugs or eyes. 6.5.3.7 Drainage All interior recesses in the turbine in which condensate may be pocketed shall be designed for adequate drainage. 6.5.3.8 Sound enclosures The Sound Enclosures over the turbine-generator shall be suitable for indoor operation. It shall cover all major turbine-generator part with complete auxiliary equipment such as ventilation and lighting system, etc. It shall be easy to disassemble and assemble during routine overhaul activities.

6.5-7 KHABAT TPP UNITS 1&2 - VOLUME I

6.5.3.9 Leakage When the steam generators are in the hydrostatic test condition, it will be necessary to load the main steam leads with water in excess of normal operating pressure. Leakage through stop valves shall be zero during these conditions. Construction of steam passages shall be such that small quantities of water which may leak through stop valves incidental to starting the unit will be diverted to drains. The combination of stop valves and draining shall preclude the possibility of water getting into the turbine. The Bidder shall provide all special devices and equipment to assure protection of the turbine generator set during hydrostatic test. 6.5.3.10 Pressure connections No pressure connections, valves, or cylinders containing flammable oil or fluid shall be used on turbine valves above steam pipes or hot surfaces. 6.5.3.11 Packings The packings shall be steam throttling device consisting of stationary and rotating teeth arranged concentrically with small radial clearances. The effectiveness of the packing to minimize leakage shall be dependent upon the sustained radial clearance between the packing teeth and the rotor. 6.5.4

Steam contamination

6.5.4.1 Contamination The steam for the operation of the turbine may contain small quantities of volatile, alkaline materials originating from ammonia or volatile amines and hydrazine introduced to the feedwater system for corrosion control. Steam contamination may occur as an end result of condenser circulating water inleakage and as a result of corrosion products from the feedwater system and boiler. 6.5.4.2 Materials The Bidder shall provide turbine materials which are most suitable for the service and which shall be resistant to corrosive attack from steam contaminants originating from the above sources, and shall be based on a plant operating life. 6.5.5

Erosion prevention 6.5-8 KHABAT TPP UNITS 1&2 - VOLUME I

The turbine shall be designed to minimize as far as possible the erosive effect of moisture in the steam and of water upon those parts of the turbine subject to their action. The material as well as configuration of stationary and moving blades selection shall be such as to minimize erosion from steam generator tube scaling. The Bidder shall describe his technique for moisture removal and erosion controls. 6.5.6

Turbine stop and control valve systems The turbine inlet valves shall be fast-closing hydraulically actuated type of established design. The inlet stop valves shall be designed for tight shut off. All main inlet and control valves shall be provided with facilities for on-load testing. The stop valves shall be fitted with permanent steam strainers designed as an integral part of the turbine stop valves. The strainers shall prevent the passage of foreign objects larger than [3] mm.

6.5.6.1 Main stop valve A.

Hydraulically operated stop valve shall be provided in the main steam lead and shall be capable of being tripped automatically during overspeed or at other predetermined limit points.

B.

The stop valves shall be equipped with an internal bypass valves, if required by design, for chest warming required prior to rolling the turbine. Internal bypass valve controls shall be provided from the Bidder control system via Bidder operator interface in the control room. Stop valve shall be suitable for hydrostatic testing of the steam generator, without requiring stop valve at the steam generator.

6.5.6.2 Reheat stop valves Reheat stop valves shall be designed with provisions for sequential remote testing while the unit is in operation. These valves shall be furnished with valve-travel limit switches (one normally open and one normally closed pairs of contacts at each end of each valve mechanism) per valve for indication of valve position. 6.5.6.3 Steam blowdown cover plates

6.5-9 KHABAT TPP UNITS 1&2 - VOLUME I

One(1) set (common to two(2) units) of temporary steam blowdown cover plates for main steam stop valves, reheat stop valves and HP turbine exhaust non return valves shall be provided. All required gaskets shall be supplied. 6.5.6.4 Steam strainers Each main steam stop valve and reheat stop valve shall be equipped with permanent, integral strainers made of radial flow blade type elements for normal operation. Strainer screens shall be removable without disturbing steam piping. 6.5.6.5 Control valves Multiple speed and load governor-controlled, hydraulically operated turbine control valves.

Provisions for sequential remote testing while turbine is in

operation shall be provided. In addition, linear variable differential transformer(LVDT)s shall be equipped for each control valves. 6.5.6.6 The Bidder shall provide the design requirements of the non-return bleeder trip valves and isolation valves. 6.5.7

Turbine bypass system

6.5.7.1 A complete low pressure bypass system shall be provided by the Bidder. The equipment furnished by the Bidder shall include, but not necessarily be limited to, the following ; A.

Low pressure bypass control valve with emergency quick closing function, its motorized drain valve and piping to the flash tank and necessary appurtenances.

B.

Desuperheating spray water control valve, desuperheaters with orifices and necessary appurtenances.

C.

Pressure and temperature control system to operate the bypass control valves and spray water control valves shall be controlled and monitored in the PCS.

D.

Hydraulic power units and control fluid piping to the actuators. Hydraulic power units shall be operated and monitored on the plant OIS.

E.

Instrumentation to operate the bypass control valves, spray water control valves.

F.

Devices for turbine startup and protection system.

6.5-10 KHABAT TPP UNITS 1&2 - VOLUME I

1) Power operated non-return valves at high pressure turbine exhaust, pre-heating valve, pressure release valves, piping and orifice to the condenser. 2) Instrumentation to operate the power operated non-return valves, preheating valve and pressure release valves. 6.5.7.2 The low pressure bypass system shall be designed for the capacity of 40% of VWO rating of the turbine. The bypass control valves shall be provided with low velocity trim. The low pressure bypass system will dump steam from the hot reheat system into the condenser and be controlled by the pressure in the hot reheat system. Spray water for desuperheating will be supplied from the discharge of the condensate water pump. The bypass control valve shall be positioned by the control systems furnished with the turbine. The servo valve unit for the low pressure bypass valves shall be installed separately from the low pressure valves to prevent damage due to vibration. 6.5.7.3 The high pressure bypass system will be 40% capacity of BMCR(VWO) rating of the boiler. The high pressure bypass system will dump steam from the main steam line into the cold reheat system and be controlled by the pressure in the main steam system. Spray water for desuperheating will be supplied from the boiler feed pump discharge to the spray water control valve. 6.5.7.4 The Bidder shall provide all necessary pressure/ temperature transmitters, smart positioner with transmitters and pressure switches and installation materials etc. 6.5.7.5 The low pressure bypass system shall be controlled and monitored in the PCS. 6.5.7.6 The Bidder shall recommend the detail features to control and monitor the bypass system in the PCS. 6.5.8

Lubricating oil system Complete lubricating oil system including, but not necessarily be limited to, the following shall be provided ;

6.5.8.1 A lube oil reservoir with top mounted relief and access doors and all associated instrumentation and controls specified in paragraph 4.8. The reservoir shall have a capacity equal to the quantity of oil circulated through the system in approximately 6 minutes. The reservoir shall have sufficient 6.5-11 KHABAT TPP UNITS 1&2 - VOLUME I

free volume operating level above the normal range to accommodate full system flowback without bringing in the high level alarm regardless of oil temperature. The Bidder shall furnish and install the following equipment on or close to the lube oil reservoir.. A. Two(2) identical AC motor driven lube oil pumps B.

A DC motor driven emergency bearing oil pump, including the DC motor starter panel. The starter panel shall be equipped remote control function(start/stop etc.) of starter shall be provided in the PCS.

C.

An AC motor driven turbine bearing lift oil pump

D. Two(2) 100% oil coolers for use with closed cooling water at the inlet temperature and pressure of 35oC /10kg/cm2g Oil side of the coolers shall be designed for maximum expected oil pressure. Coolers shall be complete with interconnecting oil piping and manual three-way valve with provisions for safe transfer of oil flow from one cooler to the other. The oil cooler materials shall be selected for resistance to corrosion and erosion and shall be fabricated, assembled and, if necessary, treated with a suitable coating to maintain such resistance. E. Two(2) 100% AC motor driven vapor extractors. F. Thermostatically controlled electric heaters. G. Special return compartment located at oil return to reservoir. H.

Mesh or plate type lube oil demisters.

6.5.8.2 A lube oil conditioner of coalescence type for the conditioning of main turbine lube oil. The oil conditioner capacity shall be enough to circulate 10% of total oil within one(1) hour.

The Bidder shall furnish and install the following

equipment on each oil conditioner. A.

One(1) 100% AC motor driven conditioner recirculation pump.

B.

Filter assembly with instrumentation and other accessories

6.5.8.3 A lube oil storage tank(clean/dirty oil tank, one(1) for four(4) units) with top mounted access doors and all associated instrumentation and controls specified in this specification The storage tank shall be of horizontal, cylindrical type consists of two(2) compartments for clean oil and dirty oil 6.5-12 KHABAT TPP UNITS 1&2 - VOLUME I

storage separated by division wall.

Each compartment of the storage tank

shall have a capacity enough to fill the whole lubrication system including the main turbine oil reservoir, main turbine oil conditioner at a time. Each compartment of the storage tank shall have sufficient capacity to accommodate full system drainage to a compartment of storage tank without bringing in the high level alarm regardless of oil temperature. The Bidder shall furnish and install a thermostatically controlled electric heater at each compartment.

Mesh or plate type lube oil demisters shall be installed

at the vent outlet. 6.5.8.4 Two(2) 100% clean & dirty oil transfer pumps with duplex strainers 6.5.8.5 Complete fire protection system for lube oil system. 6.5.8.6 Complete interconnecting stainless steel oil piping with hangers and supports for the equipment. In order to minimize the risk of fire, oil and steam piping are as far as possible routed separately on different sides of the turbine. Where pressurized oil piping is close to hot parts, protection shields will be provided. 6.5.8.7 The Bidder shall describe the proper measure, between each bearing inlet and main oil reservoir, to prevent damage of bearings resulting from influx of foreign materials that might be contain in the oil. 6.5.8.8 Jacking oil system A jacking oil system shall be provided to facilitate turning of the rotor for cooling down and during maintenance activities. It is preferable that the jacking oil system should only be required to assist starting of the barring motor and that normal barring speed should be high enough to establish hydrodynamic lubrication at the bearings using the main or auxiliary oil pumps. 6.5.8.9 Hydraulic control fluid system The Bidder shall provide complete high pressure hydraulic control fluid system including, but not limited to, the following ; A.

Two(2) AC motor-driven full capacity pumps with totally enclosed fan cooled type motor; one for normal use, the other for standby.

B. Two(2) full-capacity fluid coolers. C.

A Hydraulic accumulator with connection line, valves and gages.

6.5-13 KHABAT TPP UNITS 1&2 - VOLUME I

D. The above equipment shall be mounted on a hydraulic power unit which shall be complete with level indicator, high and low level alarm switches and low level trip, relief valves, filters, and controlled heater and other necessary instruments. E.

Complete system of interconnecting stainless steel piping and stainless steel tubing between the high-pressure fluid supply system and turbinegenerator and auxiliary equipment.

F. Thermometers and temperature detectors in the inlets and outlets of fluid coolers. G. Pressure gages in each pump discharge, relevant points in the hydraulic system, and test points. H.

Pressure switches as required for automatic start of standby oil pump on low fluid pressure with spare contacts.

I.

Fluid transfer and filtering system complete with motor driven transfer pump, filters, and flow controls.

J.

Pressure switches for hydraulic fluid pumps.

K.

Hydraulic fluid reservoir with access doors.

6.5.8.10 Gland steam sealing system A. The turbine shall be provided with steam sealed glands on packings to prevent steam leakage to the atmosphere or air leakage into the turbine. A gland seal regulator shall automatically control steam pressure to the gland seals over the entire load range. If applicable, gland seal steam pressure control shall be covered in the turbine control system. B. The gland exhausting system shall include a surface type seal steam condenser suitable for the inlet condensate temperature and pressure as approved by the KNOC, and two(2) 100% AC motor driven exhausters. C.

All interconnecting piping between the turbine, the gland seal regulator and condenser shall be furnished, including hangers and supports, relief valves, isolation valves, control valves, pressure gauges, strainers, steam traps, orifices, expansion joints, fittings, and instruments necessary for automatic operation of the system.

6.5-14 KHABAT TPP UNITS 1&2 - VOLUME I

D.

During hot startup and warm startup, gland seal steam sources will be cold reheat steam and/or auxiliary steam. If superheating of these steam are required for the operation of gland steam seal system, the Bidder shall provide an electric steam superheater.

E.

Means shall also be provided for manual operation of the gland seal system when the regulator is out of order. Any other devices deemed necessary to properly operate the Bidder system such as blowdown, diverting, or spillover valves shall be provided complete with all accessories.

F.

The drain from gland steam sealing system including gland steam condenser loop seal shall be drained to the condenser.

6.5.8.11 Turning gear An AC motor driven turning gear shall be furnished, complete with oil piping and all associated hangers and valves, and all necessary interlocks to prevent the turning gear from operating until proper oil pressure has been established in the turbine-generator bearings. The turning gear motor shall have provisions for rotating the motor shaft manually to engage the turning gear with the main turbine shaft. The turning gear shall be of automatic engaged and disengaged type with hand turning device. A local turning gear instrumentation, including control switches, indicating lights, speed indicator ammeter and current transformer shall be provided. The rotor turning speed will be 5 rpm or above.

6.5.8.12 Speed reduction gear (if required) The purpose of Speed Reduction Gear Unit is to permit generator and turbines to have different but optimized shaft speed and to transmit power from the turbines to generator. This Unit shall be a single stage parallel shaft gear with two horizontally offset shafts. The standard design of the gear unit is in accordance with AGMA 421.06. Single helical gears shall be used in standard arrangements. Depending on the overall turbine generator configuration, the gear boxes can be equipped with a thrust bearing on the low speed shaft. A.

Casing 6.5-15 KHABAT TPP UNITS 1&2 - VOLUME I

Inspection openings shall be provided to allow for easy inspection of the gears. Provisions for mounting of RTD's, vibration probes and speed transmitters(key-phasors) shall be provided B.

Gearing and shafts The pinion and the wheel shall be manufactured from high alloy, special quality steel and case hardened. The tooth flanks shall be precision ground with lead and profile correction to compensate for torsional and thermal deflections and to guarantee lowest vibration and noise emissions. In certain cases, depending on the tooth load and pitch line velocity, the tooth surface of the pinion will be copper plated. Angular and parallel misalignment shall be compensated by means of flexible shafts. Between the turbine and the gear box there shall be an external quill shaft, and between the gear box and the generator a quill shaft shall be used. The flexible shafts shall be made of forge, high quality tempered steel with solid flanges.

C.

Lubrication The bearings and the gear shall receive oil from the lubrication system through a central connection in the gear casing. The lube oil amount for each bearing and gear mesh shall be optimized in order to obtain the highest efficiency. The lube oil returns to the main oil tank through the oil drain openings in the bottom of the gear casing.

D.

Bearings The gear unit shall be equipped with hydrodynamic journal bearings, which are axially split and white metal lined. Depending on the various conditions of load and velocity and the required stability and damping, cylindrical, lemon bore, offset half, multi-lobe and tilting pad bearings will be used.

6.5-16 KHABAT TPP UNITS 1&2 - VOLUME I

If a thrust bearing is required, the axial forces will be absorbed either by a combined journal and thrust bearing or by a separate selfcontained flange mounted thrust bearing. The thrust bearing shall be designed as tilting pad thrust bearing. The sealings are non-contact, split labyrinth seals. E. Turning gear The Speed Reduction Gear Unit shall be equipped with a AC motor driven turning gear at the free end of the pinion, comprising an electric motor, a speed reduction gear and an overrunning clutch. Before a turbine start, the turning motor is started and the clutch engages automatically. After turning for required time (depending on cold, warm, or hot start), the turbine is started. The clutch disengages when the speed of the pinion exceeds the turning gear speed and the motor stops. At a turbine stop, the turning gear motor starts and the clutch engages automatically as the turbine is coasting down. The turning gear motor shall have provisions for rotating the motor shaft manually to engage the turning gear with the main turbine shaft.

The

turning gear shall be of automatic engaged and disengaged type with hand turning device. Turning gear instrumentation, including control switches, indicating lights, ammeter and current transformer shall be provided and turning gear shall be controlled and monitored by TCMS. The Bidder shall propose the rotor turning speed.

6.5.8.13 Other devices A.

Complete turbine exhaust water spray system for turbine exhaust, including piping with hangers, sensing elements, and water spray control valve with manual bypass valve and isolating valves. These facility shall be provided IP/LP casing hood. The water spray valve shall be an air diaphragm-operated control valve activated by a solenoid air pilot valve. Exhaust hood temperature controller shall be electronic type. (pneumatic controller is not acceptable) If applicable, exhaust hood temperature control shall be covered in the turbine control system. 6.5-17 KHABAT TPP UNITS 1&2 - VOLUME I

B. Vacuum trip function A vacuum trip shall be provided to trip the turbine in the event of the vacuum continuing to fall and reaching a predetermined low value. The vacuum trip is preferably to act directly on the turbine generator protection system to shut the turbine control valves and emergency stop valves. Simultaneously with closure of the steam supply valves, the device is to cause the HV generator circuit breakers to open. Provision shall be made to automatically inhibit the vacuum trip functions to facilitate the run-up of the turbine. The functions shall be arranged to activate themselves as soon as the pre-determined operating limits have been reached C. Turbine exhaust overpressure protection Protection against excessive pressure in the condenser is to be provided by replaceable exhaust rupturing discs or self re-seating diaphragms capable of discharging full load steam flow. The materials used are to be capable of safely withstanding the temperatures reached during prolonged light load running. The discharge from the diaphragms is to be directed outside the turbine building to atmosphere at such a height as to avoid endangering any personnel. The diaphragms are to be suitably designed for the pressure differentials involved and adequately protected against corrosion. 6.5.8.14 Piping A. Turbine Integral Steam Piping (1) The Bidder shall supply all turbine integral piping, such as the piping between the main stop valves and the turbine ; between the combined reheat stop and control valves and the turbine. The

Bidder shall state the allowable forces and moments at the face of each piping connection on the turbine for the reactions from The KNOC's piping. The Bidder shall design and arrange for the transfer of these forces and moments from the face of pipe connections to an internal point of the turbine.

6.5-18 KHABAT TPP UNITS 1&2 - VOLUME I

(2) The operation of the turbine shall not be affected, in any manner, by the interconnecting piping and the reactions from the steam piping connected to the main and reheat stop valves and HP exhaust, provided that piping forces and moments on the turbine connections are not excess of the allowable forces and moments specified by the Bidder in this specification. (3) All hangers and supports, including travel stops, necessary to support valves and piping supplied with the turbine shall be furnished by the Bidder. B.

Drain & Vent Valves, Piping All drain and vent valves, piping (with hangers and supports) shall be furnished. A second manual lock-open shutoff valve shall be provided for each drain valve.

6.5.8.15 Thermal insulation The turbine casing, valves, piping and equipment shall be thermally insulated by

non-asbestos,

non-combustible

materials

to

obtain

the

surface

o

temperatures not to exceed 55 C. The top insulation blanket consist of mineral wool with a special designed glass fabric on both sides. The outside fabric is coated with silicone rubber to make the surface oil repellent. All insulation which is normally removed during routine turbine inspection shall be of the reusable "blanket" type.

All blankets shall be properly tagged and

identified on an insulation arrangement drawing supplied with the turbine. Aluminum jacketing on all pipe insulation shall be included.

6.5-19 KHABAT TPP UNITS 1&2 - VOLUME I

6.6

Condensate System

6.6.1

System Description The condensate system shall deliver the condensate from the condenser to the deaerator storage tank. The condensate shall be chemically treated by injecting ammonia and hydrazine to adjust the pH level, scavenge residual oxygen and thus minimize corrosion.

The condensate system also shall

provide water to various desuperheater, seal water to equipment, and makeup water to miscellaneous systems. The condenser air removal system shall be established and maintained the required vacuum in the condenser. The Demi, Water make-up system shall maintain normal levels in the condenser hotwell under all operating conditions and provide water to various desuperheaters, seal water to equipment, and makeup water to miscellaneous systems. 6.6.2

System Design Criteria A.

The system design is based on the heat balance for the maximum calculated load with valve wide open (VWO).

B.

The minimum flow recirculation line for the condensate pumps and the gland steam condenser will be provided down stream of the gland steam condenser.

C.

The main condensers shall be designed to prevent tube failures caused by steam impingement from the turbine bypass or exhaust.

D.

The tubes shall be expanded and seal welded to prevent the water leakage between tubes and tubesheets

6.6.2.1

Bypass design A.

The feedwater heaters No. 1, 2, 3, and the gland steam condenser shall have their individual bypass lines.

B.

Bypass line including bypass valve for low pressure feedwater heaters shall be sized for the same pressure drop as the total pressure drop in the heater and in the portions of the main condensate piping between the points of take-off and return of the bypass line. The maximum allowable pipeline velocity in the bypass line may exceed the recommended value of the design flow velocity.

6.6-1 KHABAT TPP UNITS 1&2 - VOLUME I

6.6.2.2

Start-up A.

Corrosion occurs in equipment in which water remains after shutdown, especially if it is exposed to air. Oxygen must be removed from the system because the corrosion rate is proportional to the Oxygen content.

B.

During the clean-up process, the vacuum pumps should be operated to evacuate air from the main condenser steam space to achieve a condenser vacuum corresponding to the condensate temperature.

C.

During start-up and low load operation, the normal condensate flow will not be adequate to meet the minimum flow requirements for the protection of the gland steam condenser. Therefore, a minimum flow recirculation line to the condenser will be provided downstream of the gland steam condenser.

6.6.2.3

Normal operation A.

During normal operating mode, the condensate feedwater system should be closely monitored and chemically controlled. This is achieved by analyzing adequate samples and compensating with appropriate chemical feeds.

B.

At partial loads there is higher possibility of air inleakage regardless of equipment air-proof design. Therefore, special attention is required to the parts which have possibility of air in-leakage : condenser connections, flanges, valve stems, gland turbine seals, etc.

C.

Make-up water to the condensers should be admitted into the steam space above tube bundle. This way, the make-up water temperature is increased close to that of the saturated steam and helps thermal deaeration of make-up water.

6.6.2.4

Abnormal operation A.

When conductivity of condensate water which exist in condensers, exceeds the allowable limit due to scooling water leakage caused by tube rupture, the hotwell and circulating water lines must be isolated and contaminated condensate water must be pumped to the waste water treatment system.

B.

The low pressure feedwater heaters will be designed to perform satisfactorily during system load transients as well as during abnormal

6.6-2 KHABAT TPP UNITS 1&2 - VOLUME I

modes of operation when various heaters are taken out of service for repair and maintenance. 6.6.2.5

Component description A.

Condensers 1) Quantity : Single(1) shell 2) Type : a) Single pressure, two pass(double) condenser. b) Tube arrangement : Traverse the turbine shaft 3) Design parameters : a) Tube velocity : 2.1 m/s b) Cleanliness factor : 90% c) Shell design pressure : Full vacuum and per the HEI standards for steam surface condenser. d) Waterbox design pressure : Per the HEI e) Hotwell storage : Seven (7) minutes of storage capacity at the normal water level and five(5) minutes minimum at the low water level, based on the design basis of the condensate flow. f) Oxygen content of condensate at outlet of condensers : 7 ppb g) Cooling Water temperature : [30℃] h) Cooling Water temperature difference : [Max 12℃ ] i) Materials : (1) Tube : Titanium (2) Tube sheet : Carbon steel plate covered with titanium (3) Tube plate : Titanium or carbon steel plate covered with titanium cladding

B.

Condensate pumps 1) Quantity : Two(2)×100% capacity 2) Type : Vertical can type, centrifugal, constant speed, motor operated 3) Design flow : the maximum continuous flow(VWO) plus a margin for control purposes and to cover for pressure changes during transient operating conditions plus a 5% margin to cover for pump wear between overhauls. 4) Design head : the rated total head shall include a 20% margin on the frictional resistance part of the total head at a flow corresponding to the normal maximum flow(VWO) plus the margin for control purposes 6.6-3 KHABAT TPP UNITS 1&2 - VOLUME I

5) Motor rating : a margin of at least 5% over the maximum power demand 6) One(1) condensate pumps shall be capable of continuous normal operation flow plus LP bypass spray flow. C.

Low pressure feedwater heaters 1) Quantity : a) LP feedwater No.1 and external drain cooler No. 1 : Each one (1)×100% capacity b) LP feedwater No.2 : One (1)×100% capacity c) LP feedwater No.3 : One (1)×100% capacity 2) Type and arrangement a) LP feedwater heater No.1 and external drain cooler No. 1 : Horizontal, U-tube, heater bay b) LP feedwater heater No.2 : Horizontal, U-tube, heater bay c) LP feedwater heater No.3 : Horizontal, U-tube, heater bay 3) Design requirement : a) Design performance : Based on VWO heat balance b) Design pressure (1) Tube : Total absolute pressure from the sum of the condensate pump shut off head with 5% margin. (2) Shell : 115% of extraction pressure based on VWO heat balance, but not less than 3.6kg/cm2.g, and also considering full vacuum condition. c) Design temperature (1) Tube : Saturated steam temperature corresponding to the shell-side design pressure. (2) Shell : Per HEI d) Tube material : stainless steel

D.

Gland steam condenser (steam packing exhauster) 1) Quantity : One (1)×100% capacity with Two(2)×100% steam packing exhausters 2) Type : Horizontal, single pass, shell and tube type 3) Design requirement a) Design performance : Based on VWO heat balance b) Design pressure and temperature : Same as the design parameters of the low pressure feedwater heaters 6.6-4 KHABAT TPP UNITS 1&2 - VOLUME I

c) Tube material : stainless steel E.

Piping 1) Design requirements a) Suction piping of condensate pump (1) Design pressure : Full vacuum and 10kg/cm2.g(150psig) (2) Design

temperature

:

Saturated

steam

temperature

corresponding to the maximum condenser pressure during operation (3) Flow velocity : maximum 1 m/sec b) Discharge piping of condensate pump (1) Design pressure : Total absolute pressure from the sum of the condensate pump shut off head with 5% margin (2) Design temperature : Temperature of condensate from last heater in condensate system of VWO heat balance (3) Flow velocity : 2.8 m/s - 4.6 m/s in NPS 50 mm thru NPS 175, 4.6 m/s in NPS 175 mm and larger F.

Condenser vacuum pumps 1) Quantity : Two (2) × 100% capacity for condenser 2) Type : Rotary liquid ring 3) Capacity : Per HEI standards 4) Accessories a) Seal water cooler (1) Type : Shell-tube type (2) Liquid : Cooling water (tube side), seal water (shell side) b) Moisture separator(Standard accessory)

6.6.2.6

The condensate rejection line shall be located downstream of the steam packing exhauster. The line shall contain a control station consisting of an air operating control valve with two isolation valves and a bypass valve.

6.6.2.7

The system minimum flow recirculation line shall provide a minimum flow recirculation protection for the condensate pump and the SPE. The line shall be sized for the minimum flow requirement of the condensate pump or the minimum flow requirements of the SPE, whichever is larger.

6.6.2.8

The minimum recirculation line shall contain a control station consisting of an air operated control valve with two manual isolation valves and a manual bypass valve. 6.6-5 KHABAT TPP UNITS 1&2 - VOLUME I

6.6.2.9

The low-pressure heater No.1 shall be provided with motor operated isolation valves at the inlet and outlet of the heater vessel and also in the vessel bypass line.

6.6.2.10 One(1) outdoor demi. Water storage tank per unit will be provided for makeup and initial fill of the condensate system. Makeup water to the demi & condensate storage tank will be provided from the demineralized water system. A motor operated control valve in the demineralized water makeup line control the level in the tank.

A condensate transfer pump will be located

in the makeup line to condenser hotwell. The condensate transfer pump will be used for the condensate system initial fill and the main boiler cold fill. 6.6.2.11 The demi. water transfer pump supply condensate from the demi storage tank to the following facilities and systems. A.

Feedwater storage tank

B.

Condenser hotwell

C.

Closed cooling water head tank make-up

D.

Condensate system header

6.6.2.12 The demi. water storage tank shall supply condensate to the condenser. 6.6.2.13 The gland seal steam concenser shall be a tube and shell heat exchanger which condensate the excess steam exhausted from the turbine highpressure shaft seals and the turbine control valve steam packings. 6.6.2.14 The gland seal steam concenser shall be provided with two isolation valves and a by-pass line with a normally closed valve. In case of a tube leak all condensate flow shall be bypassed. 6.6.2.15 The gland seal steam concenser shall be designed for full condensate flow passing through the inlet and outlet nozzles. 6.6.2.16 Downstream of the gland steam condenser a sub-header off the condensate supplies water to the following miscellaneous systems : A.

Makeup to auxiliary steam system

B.

Makeup to valve seal water

C.

Makeup to gland steam desuperheater

D.

Makeup to chemical feed system

E.

Makeup to L.P turbine exhaust hood spray

6.6-6 KHABAT TPP UNITS 1&2 - VOLUME I

F.

Makeup to waterbox vacuum pump and condenser vacuum pump seal water

G. Makeup to closed cooling water system H.

Makeup to chilled water system

6.6.2.17 The condenser and condensate system shall be chemically cleaned in the field prior to operation. 6.6.3

Condenser

6.6.3.1

Design conditions A.

The equipment will be located inside the turbine building and subject to the environmental conditions given in Volume Ⅱ,schedule A” Site Particulars “.

B.

The condenser shall be designed to operate in accordance with design requirements when receiving steam, moisture, condensate, feedwater and drains in the Valve Wide Open(V.W.O) Heat Balance.

C.

L.P Turbine Bypass 1) The condenser shall be designed to accept the flow from the low pressure turbine bypass system. Hot reheat steam flow will be discharged to the condenser shell, bypassing the low pressure turbine, during the bypass mode. The steam dumped to the condenser will enter condenser shell through a penetration which connect with the internal distribution piping within the condenser. The bypass steam flow and pressure, temperature shall be increased by 10 percent during abnormal condition. 2) The L.P turbine bypass steam inlet valve will automatically close when the condenser pressure reaches [127] mmHgA. 3) The L.P. turbine bypass discharge shall be designed to prohibit impingement on tubes and other components. 4) The two(2) measuring points of temperature instrumentation shall be fully engineered to ensure proper detection of the temperature inside of condenser to be caused by L.P. steam bypass operation.

D.

The condenser shall operate without noise and harmful vibration at all loads. It shall be designed to receive, distribute, and dissipate thermal and kinetic energy introduced by the conditions imposed during startup, shutdown, transient, and normal operation. And also during startup and/or

6.6-7 KHABAT TPP UNITS 1&2 - VOLUME I

cold season, one circulating water pumps will be taken out of service when not needed. One tube bundle of one shell may be out of service. E.

Hotwell condensate discharge temperature at the design condition and 50% through 100% load range shall be equal to the saturation temperature of the steam in the shell.

F.

The dissolved oxygen content of condensate shall not exceed 7 ppb for the design condition in condenser.

G. The temperature of the gas/vapor mixture being extracted from the condenser air cooling section shall be at least 4.2 deg. C(7.5 deg. F) less than the saturated steam temperature corresponding to the condenser pressure at design load. 6.6.3.2

Performance The Bidder shall guarantee that all equipment and materials will comply with all applicable code. The following performance factors are to be specifically guaranteed in writing for the condenser. A.

Condenser pressure [3.6 inch(92.5mm)]Hg A measured in accordance with ASME performance Test Code 12.2 for Steam Condensing Apparatus for the design condition shown in performance guarantee sheet.

B.

At the design condition the temperature of effluent condensate shall not be less than the saturation temperature for the pressure existing in the condenser shells.

C.

The dissolved oxygen in the condensate from the hotwell shall not exceed 7 ppb shown on HEI Standard

6.6.3.3

Design features A.

General 1) The condenser shall have ample space for the proper distribution of steam and water admitted to the shell, for the liberation and removal of air and noncondensable gases from the steam and water, and for the rapid and adequate drainage of condensate to the hotwell. Steam paths shall be designed to minimize quiescent zones at all operating conditions and prevent the excessive accumulation of condensate. 2) The internal parts of the condenser shall be arranged so that condensate leaving the hotwell shall approach the steam temperature 6.6-8 KHABAT TPP UNITS 1&2 - VOLUME I

with no observable difference. The condensate shall be deaerated to an oxygen content not to exceed that stated in Paragraph 6.6.3.2.C) under the restrictions listed in the Steam Surface Condenser Standard(HEI). 3) Lifting lugs shall be provided on all water boxes and wherever necessary

on

the

condenser

for

assembly,

installation,

or

maintenance. 4) All parts and components shall be capable of expanding and contracting through complete cycles of operating pressures and temperatures, including start-up, shutdown, pre-startup system cleaning operation, etc, without damage. B.

Condenser Shell 1) The condenser shall be adequately braced and stiffened to resist the specified design pressures without leaks or damage under all conditions of operation. The condenser shell shall be constructed of steel plate conforming to HEI standards . 2) Steam and drains at high temperatures and/or requiring deaeration should enter the condenser at a suitable elevation above the hotwell. Other steam and drain lines may enter into the condenser hotwell. All flows entering the condenser shall discharge through sufficient perforated pipes or against baffles as required to deflect the flows and eliminate the impingement on tube, shell and internal component. 3) The lines shall be arranged to ensure effective condensing in the tube bundle and to ensure that the exhaust hood temperatures will be kept within design limits. The design of perforated pipe or baffle distribution devices shall be in accordance with the principle of EPRI CS-2251. 4) Wherever possible, perforated spray pipe instead of the impingement baffles at high pressure drains shall be used. Impingement baffles, if any, shall be attached to the shell with full penetration welds and liquid penetrant tested in accordance with ASME Section VIII Division 1. 5) Special attention shall be given to shell connections handling high temperature steam. Thermal sleeves shall be provided to prevent shell cracking for piping that have temperatures of [149] deg. C and higher. 6.6-9 KHABAT TPP UNITS 1&2 - VOLUME I

6) The condenser shell shall be designed to allow for differential expansion between shell and tubes by a suitable method. All provisions to compensate for differential expansion between tube material and condenser shell material shall be based upon the circulating water temperature rise associated with operating at full load with one half of the specified circulating water flow. 7) The proper structures shall be furnished above the tube bundle to permit inspection of peripheral tubes in the bundle shoulders and other equipment in the steam space. The proper structures shall bridge across the center lane between bundles in condenser with divided waterboxes to permit access all around. At least two 500 mm x 600 mm(20 inch x 24 inch) openings with bolted and hinge covers shall be supplied in the shell to provide access to the proper structure. The two openings shall be in accessible location opposite each other. Similar access is also required in the hotwell. 8) Shell pressure boundary plates and welds shall be provided with a corrosion allowance of minimum 1.6 mm (1/16″) on each wetted side in contact with steam or condensate. 9) Ground pads shall be provided at two locations on each condenser shell for connection to ground grid. C.

L.P. Turbine Bypass Steam Distribution Piping. 1) The Bidder shall design the condenser to accommodate thermal and/or vibration stresses induced by the operation of the L.P. bypass system. 2) The Bidder shall furnish calculation to demonstrate that the location of the steam distribution piping within the condenser does not endanger the periphery of tube bundles and structure members. 3) The spray pattern of the steam distribution piping shall be designed in a such manner as to protect condenser tubes against direct contact of the spray. 4) The drain line for steam distribution piping shall be arranged for self drainage into hotwell.

Suitable provision for free movement of the

drain line shall be made.

6.6-10 KHABAT TPP UNITS 1&2 - VOLUME I

D.

Waterboxes 1) The single shell condenser shall have 2 tube bundles and that water boxes configuration must be designed to enable access for tube repair and manual cleaning for 1 side of condenser, while turbine is in operation 2) The condenser waterboxes shall be of welded steel lined with rubber and shall have ample strength to resist the external and internal pressures specified, mechanical forces due to expansion and contraction of the system as a whole including circulating water piping, and reactions that may be created by the expansion joints. 3) Waterboxes shall be supported off the condenser shell independent of the tube sheets in a manner that permits water box removal. All bolted joints shall be provided with full face asbestos free inserted rubber for waterbox side. 4) The internal design of the waterboxes shall be free of ribs and stays. Grab bars, ladders, brackets required at proper intervals to support temporary scaffolds, cathodic protection anodes, and other projecting members shall be designed to result a minimum interference with smooth flow. 5) The waterboxes shall be designed to receive and deliver water to and from the tubes and from and to the circulating water nozzles with minimum disturbance. For this purpose, the internal design, including ribs, access doors, handholes, stays, and all similar structures shall be arranged and streamlined to promote the natural flow of the water. Cavities, depressions, or low points that could accumulate debris will not be acceptable in the waterboxes. To ensure that air will not accumulate, the necessary external connections shall be provided for proper venting at the points where air could accumulate. 6) Waterboxes shall have suitable access doors (minimum 600 mm in diameter) with simplified closing devices including ladder so that tubes and tubesheets may be cleaned and inspected rapidly and conveniently. The access doors shall avoid possible interference with existing

installations

around

the

condenser.

Adequate

pipe

connections shall be provided for priming, venting, and draining the entire water system. 6.6-11 KHABAT TPP UNITS 1&2 - VOLUME I

7) Permanent provisions such as ladder, clips, support grids etc., shall be provided for frequent waterbox and tube cleaning. To prevent a hazard to personnel, the inlet and outlet connections shall have suitable protection, such as bars across the openings or removable safety grids. These shall be arranged so that they will not interfere with access for cleaning. 8) The circulating water passages shall be designed to prevent any damage to condenser tubes and tubesheets due to localized high velocities. The inlet waterbox design shall ensure adequate depth and suitable configuration so that a uniform velocity will be obtained as the water approaches and enters each tube. In addition, entrance velocity to the inlet waterboxes and exit velocity from the outlet waterboxes shall be considered in the design to obtain a uniform flow pattern to and from the tubes. 9) The Bidder shall furnish rubber expansion joints for the circulating water inlet and outlet pipes. Expansion joints shall have rubber flanges. They shall have individual solid steel ring reinforcement with a carcass of woven cotton or acceptable synthetic fiber. Joints shall be constructed to pipeline size and meet working pressures conditions, and face-to-face measurements as designated. Unless otherwise

specified,

flanges shall be of AWWA C207

CLASS D, Ring type. 10) The corrosion allowance shall be a minimum of 3.2 mm (1/8″) per side in contact with circulating water in the waterbox. 11) An adequate number of hinged manhole covers shall be provided in each condenser waterbox to give access including ventilation to the whole of the area of the tubeplates for inspection or cleaning. The doors shall be arranged so that they may be opened quickly without the use of lifting tackle or special tools. Where necessary for safe access to the manhole doors, galleries or platforms, complete with all necessary ladders and hand railing shall be provided. These galleries or platforms shall be arranged to include sections, which are easily removed to facilitate removal of the waterbox. If necessary, safety grates shall be provided over the waterbox/CW pipe connections. E.

Tubes

6.6-12 KHABAT TPP UNITS 1&2 - VOLUME I

1) Condenser tubes shall be made from annealed titanium strip and shall conform to the requirements of ASTM B338 Grade 2. The following impurity limitations shall not be exceed; - Oxygen Maximum 0.16 percent - Iron Maximum 0.15 percent 2) The tube size shall be 22.225 mm (7/8〃) O.D, and minimum wall thickness 25 BWG for condensing section and air removal section, minimum wall thickness 22 BWG for impingement zone respectively. 3) The number and arrangement of tubes in the exhaust impingement zone shall be designed to effectively protect all tubes from impingement damage caused by the flow of the exhaust steam and L.P. bypass steam dump. The Bidder shall submit tube arrangements for the condensing and impingement zone. 4) Careful consideration shall be given to the tube bundle design to effect free access of steam to the entire tube surface with minimum pressure drop. At the same time, adequate steam velocities shall be maintained throughout the tube bundle to prevent air blanketing of tubes. The arrangement of the condenser steam paths shall be designed so that all noncondensable gases shall be directed to the air cooler section. The arrangement shall also prevent damage to the tubes by steam impingement. The Bidder shall supply internal stainless steel pipes to convey vapors and non-condensable gases to the offtake to be located at the circulating water outlet end of the condenser. F.

Tube Support Plates 1) Tube support plates of the same material specification as the shell and proper thickness shall be spaced to reduce tube vibration and fretting with particular reference to resonance caused by mass flow of circulating water and steam. Maximum spacing between any two adjacent tube support plates or between a tube support plate and a tube sheet shall be complied with the method outlined in HEI standard. 2) Holes for the tubes shall be drilled and reamed to provide a free sliding fit for the tubes and shall be chamfered on both sides in such a manner as to remove all burrs which might score the tubes.

6.6-13 KHABAT TPP UNITS 1&2 - VOLUME I

3) Tube hole in the supporting plates shall be as small as possible, consistent with free lengthwise movement of tubes, slightly chamfered or rounded on both sides, and slightly offset vertically with corresponding holes in the tubesheet to provide for complete drainage of water. 4) Tube support plate shall be provided with minimum 1.6mm(1/16″) corrosion allowance on each side in contact with steam or condensate. 5) The preferred material for tube plates in contact with cooling water is solid titanium. Consideration will be given to titanium clad steel or other proven combinations providing satisfactory evidence of operating experience can be supplied]. If titanium clad tube plates are used, the cladding shall be applied by hot rolling or other approved method, and shall be of 5 mm minimum thickness. The clad tube plates shall be subject to full ultrasonic inspection to prove the integrity of the bonding in accordance with a recognized standard]. 6) The tubes shall be fixed into the tube plates by roller expansion followed by seal welding to the titanium surface of the tube plate at both ends of the tube. Sagging plates shall be supplied and arranged so that no periodic vibration of tubes shall be induced by the running of the turbine generator and its auxiliaries or by steam buffeting. The vertical location of the sagging plates shall be such that the condenser tubes are self draining when the machine is shut down. G. Tubesheets 1) The tubesheet cladding material shall be made from annealed titanium plate and shall conform to the requirements of ASTM B265 Grade 1. 2) The tubesheet backing material shall be made from carbon steel plate and shall conform to ASTM A516 Grade 70. 3) The tubes shall be expanded and seal welded at cooling water side of tubesheets. Joint between shell and tubesheet shall be welded. Waterboxes shall be bolted to the tubesheet. The titanium cladding on tubesheet shall be a minimum thickness of 6.4 mm (1/4″). The cladding shall cover 100 percent of the tubesheet backing plate. The plates after explosive bonding shall be press flattened. The cladding sheet shall be fabricated from one piece without welding. The 6.6-14 KHABAT TPP UNITS 1&2 - VOLUME I

deviation from flatness for each titanium clad tubesheet shall not exceed 3mm per 1500 mm, but bolting area shall not exceed 0.6mm per 300mm. Holes for tubes shall be accurately drilled in the tube sheets. Drilling and reaming of holes shall be performed in such manner as to ensure that the surfaces throughout the entire depth of the holes are smooth and free from any score marks. The shell side of all holes shall be chamfered.

Hole finish shall be 250 RMS.

Tube sheets shall be arranged for rolling at both ends. The explosive cladding process for joining of the titanium plate to the carbon steel backing plate shall be accomplished through the use of a proven procedure. 4) The corrosion allowance shall be minimum 1.6mm(1/16″) on each side in contact with steam or condensate. 5) Before fabrication of the tubesheet and waterbox, the Bidder shall submit a tubesheet stress analysis to prove adequacy of the tube sheet thickness under the specified design pressure. The analysis shall indicate the maximum tubesheet stresses and the maximum tube loads. 6) The tubesheets shall be connected to the condenser shell in a manner that permits the waterboxes to be removed without disturbing the tubesheets. H.

Hotwell 1) In hotwell, there shall be at least five(5) minutes of condensate retained below the low water level and two(2) minutes of storage capacity between the normal water level and the low water level for the normal operating range. The hotwell shall be fabricated of the same material specified for the condenser shell. 2) The hotwell shall include connections for gage glasses, level instruments, thermometers, and all other applicable instrumentation. 3) The hotwell condensate outlet box shall be suitably designed to eliminate vortexing. Access openings shall be provided to the hotwell. 4) The condensate flow path shall be designed so that the condensate is detained for a period of time as specified in paragraph 6.6.3.3.H) 1) before reaching the hotwell outlet box. This requirement is established so that a circulating water leak can be detected before contaminated condensate reaches the condensate pump. The point 6.6-15 KHABAT TPP UNITS 1&2 - VOLUME I

to which the condensate is directed prior to retention in each hotwell shall have a connection outside the condenser to allow a continuously flowing sampling stream to be automatically monitored for evidence of condensate contamination. The tube leak detection trough shall be provided beneath each tubesheet to detect tube-tubesheet leakage including connecting pipe from the trough to the outside of the condenser for connection to instrumentation. 5) The hotwell shall be provided with sufficient space between the water surface and the bottom of the tube bundle to permit steam flow under the tubes for condensate reheating and deaeration. 6) The hotwell shall be divided longitudinally to isolate each half from the other, so that the leak from any tube will contaminate only one-half of the hotwell condensate. The height of partition shall be adequate to preclude condensate overflow at maximum operating level. 7) Provide connections to gravity drain the hotwell from the normal operating level in 30 minutes or less. The design shall provide for complete drainage in case the water is contaminated. 8) The permanent, removal screen shall be provided in the hotwell at the entrance to the outlet well and also temporary screens for start-up operation condenser shall be provided. 9) The hotwell plates and welds shall be provided with a corrosion allowance of minimum 1.6mm(1/16") on wetted side in contact with steam or condensate. I.

Exhaust Necks 1) The exhaust necks shall be provided with all required openings, supports, and closure plates with provision for thermal expansion of feedwater heater and extraction piping located inside the exhaust necks. 2) The condenser neck shall have access manholes of sufficient size to pass the largest expansion joint of steam extraction piping through it. 3) Bracing shall be provided in the condenser neck to stiffen against vibration and vacuum loading. The condenser neck design shall be coordinated with the turbine and shall be compatible with the turbine exhaust nozzle to give minimum exhaust losses. Consideration shall 6.6-16 KHABAT TPP UNITS 1&2 - VOLUME I

be given to the turbine exhaust flow pattern at the exhaust flange. The distance piece and expansion joint for connecting the condenser to the turbine exhaust shall be streamlined where necessary to provide proper steam diffusion and to minimize exhaust losses. 4) The Bidder shall provide and be responsible for all design(supports, routing, stress analysis) and material of all extraction piping in the condenser neck. All piping within the condenser shall be designed, fabricated and erected in accordance with ASME B31.1.

All

extraction piping and expansion joints shall be completely covered with lagging and spacers to form a 25 mm deep insulating air space. Expansion joints shall be provided in both horizontal and vertical sections of piping as necessary to ensure that reactions on turbine connections as specified by the turbine manufacturer are within acceptable limits with piping anchored at neck penetration. 5) L.P. turbine bypass system as indicated on the condenser arrangement drawing shall be discharged into the condenser above the tube bundle. Condenser manufacturer shall be responsible for the analysis of the distribution of steam and the design and supply of the distribution devices. 6) The corrosion allowance in the exhaust neck shall be a minimum of 3.2 mm (1/8"). 7) Provide exhaust connection with an expansion joint. Expansion joint shall comply with the requirements

of the Expansion joint

Manufacturers Association Standards. 8) Performance test pressure connections and basket tips shall be provided for the condenser acceptance test, with location and number of connections in accordance with ASME PTC 12.2 requirements. 9) Structural members in the condenser neck shall be aligned with the turbine exhaust structural members provided by the turbine to the greatest extent possible without compromising integrity and strength of the condenser. 10) Bracing shall be provided in the condenser neck to stiffen against vibration and vacuum loading. 11) The bidder shall provide absorption for the expansion movement between the condenser and turbine by using a condenser neck expansion joint. The expansion joint connecting the turbine exhaust 6.6-17 KHABAT TPP UNITS 1&2 - VOLUME I

and the condenser shell shall be a stainless steel type having a welded/bolted connection to turbine exhaust and condenser neck. The end connection at the turbine end shall be compatible with the turbine exhaust details. A stainless steel liner shall be provided over the joint to prevent turbulence and direct impingement on the stainless steel expansion bellows J.

Distance Pieces 1) Distance pieces shall be provided with the exhaust neck expansion joint of the material specified in Paragraph 6.6.3.3 L). The distance piece landing bar shall be welded to the turbine casings.

K.

Connections 1) All necessary nozzles and connections shall be provided including, but not limited to, the following services : a) L.P. turbine bypass b) Removal of air, vapor and noncondensable gases c) Admission of makeup, normal and rapid d) Feedwater heater vents e) Normal and high level heater drains f) Condensate pump minimum flow recirculation g) Turbine stop valve and intercept valve before and after seat drains, similar returns and miscellaneous high energy drains to flash tank(flash box) h) Seal Steam i) Instrumentation required for operation of the condenser equipment per Paragraph 6.6.3.3 I) 2) and 6.6.3.3.I) 4) 2) Connections in the shell and on thermal sleeves 50mm (2inches) and smaller, except liquid level control, shall be of the socket weld type. Those 65mm (2-1/2 inches) and larger shall be of the butt-weld type. Connections in the waterbox shall be flanged and shall be large enough to be lined with rubber. 3) All test connections and basket tips, including pressure connections per each shell, shall be furnished by the Bidder for an ASME turbine acceptance test. 4) The Bidder shall provide a description and sketches of proposed methods of distributing the following flows ; a) L.P turbine bypass 6.6-18 KHABAT TPP UNITS 1&2 - VOLUME I

b) Main steam line warm-up drains c) Extraction steam line drains d) Condensate pump recirculation e) Makeup water f) Seal steam 5) Miscellaneous item as following; a) A direct reading level gauge for each condenser hotwell. b) A level transmitter for each hotwell with high and low level alarm and indication to the unit PCS c) A vacuum measuring grid of a design to be approved with four measuring connections (and four isolating valves) located within 150 mm of the condenser inlet flange level. d) Vacuum breaker valve e) Thermometer pockets in the steam space, air suction branches and hotwells. f) One 100 mm (minimum) bore branch and valve for draining each trough or reservoirs of the condenser hotwell. g) 100 mm (minimum) bore condenser shell steam space water filling connection with blank flange on each shell for hydraulic pressure test. h) 100 mm (minimum) drain valve and piping from each waterbox to nearest convenient floor drain. i) Plugged bosses; two on each circulating water inlet and outlet branch for pressure gauge connection. j) Two compound (combined pressure and vacuum) pressure gauges, one for each circulating water outlet branch. k) Thermometer pockets on the inlet, return end and outlet waterbox branches. Two pockets in each branch, one for thermocouple input to PCS and one a test pocket. l) Arrangement to allow chemical dosing of the inlet waterboxes. m) 80 mm (minimum) bore vent valves in each waterbox piped to a convenient drain via a tundish. n) Priming connection on each waterbox. o) One diffuser at each point of discharge into the condenser where impingement on tubes could occur. p) Condensate level control equipment. 6.6-19 KHABAT TPP UNITS 1&2 - VOLUME I

q) Condenser priming indicator on each cooling water discharge pipe. r) Hot well conductivity monitoring probes with associated continuous monitoring equipment. (manual sampling facilities shall be provided from each condenser half to enable rapid leak location). L.

Materials 1) The condenser materials shall be in accordance with the specified below and the requirements identified in data sheets. a) Exhaust neck expansion joint - Stainless steel : ASTM A240 Type 304L b) Metallic expansion joints and lagging for extraction piping - Stainless steel : ASTM A240 Type 304L c) Spacers for extraction piping - Carbon steel : ASTM A36 or equivalent d) Tubes - Titanium : ASTM B338 Grade 2 e) Tube sheet - Base : Carbon steel (ASTM A516 Grade 70) - Clad : Titanium (ASTM B265 Grade 1) f) Tube support plate - Titanium or titanium clad steel(A36) or equivalent g) Shell and hotwell, neck piece - Carbon steel : ASTM A285 Grade C or equivalent h) Waterbox and circulating water pipe - Carbon steel (ASTM A516 Grade 70 or equivalent) with rubber lining i) Impingement baffles/perforated spray pipes - Stainless steel : ASTM A240 Type 304L/ASTM A312 Type 304L or equivalent - Carbon steel : ASTM A285 Grade C/ASTM A53 Grade B or equivalent - Alloy steel : ASTM A335 Grade P11 or P22 or equivalent Material shall be selected according to the temperature-pressure rating. 2) Material certification of the chemical analysis and mechanical properties of the above materials shall be provided.

M. Cathodic Protection System 6.6-20 KHABAT TPP UNITS 1&2 - VOLUME I

1) The Bidder shall provide a cathodic protection system to minimize the galvanic corrosion attack of the condenser tube sheet. The cathodic protection system shall be designed in accordance with the following requirements. a) The control potential of the cathodic protection installation should be 700 millivolts SCE(Saturated Calumel Electrode) in order to ensure against titanium hydride formation. b) The electrode should be located to indicate maximum polarization potentials from the anode. Anode shall be treated MMO-Ti or equivalent, with space to provide protective current density to all interior surfaces as specified by the National Association of Corrosion Engineers Level of Protection Potential. Cathodic protection circuit shall be calculated with one Zn and two anode per one circuit. c) Individual anode output currents should be monitored. It may be necessary to add resistors to reduce the output from anodes whose output is higher than normal output of the others. d) A method of calibrating the electrodes should be established for

assurance that the critical potential for titanium hydride

formation is not reached. e) The anode entry stations should be built into the waterbox prior to the application of the waterbox lining. 2) The rectifier unit shall be complete with weather-proof enclosure (NEMA Type 4X) and shall be rated 400V AC 3phase 50 Hertz.The rectifier shall be properly protected on input and output sides against switching and lightning surges. 3) The rectifier control panel shall be equipped the transmitter port to be communicated with the main host computer of cathodic protection system to be provided by the Yard Island. 4) The impressed current system shall include zinc reference electrodes and auto controller to monitor the degree of protection. 5) The Bidder shall design and supply a complete impressed current cathodic protection system including, but not limited to anodes, rectifiers, local control panels including microprocessor based control and monitoring device, pull box, internal wiring, cables etc., all required for satisfactory operation of the entire system. 6.6-21 KHABAT TPP UNITS 1&2 - VOLUME I

Consideration shall be given to protect the condenser tube sheet made of clad plate. The Bidder shall also supply additional switches to annunciator system trouble in the main control room. The local control panels shall be enclosed type and will be located near the condenser water boxes. Size and location of openings shall be determined by the Bidder. Size of openings shall be adequate to allow proper application of the specified coating of the water boxes. N.

Manufacture 1) Shop Assembly The condenser shall be of welded construction and prefabricated into the largest sub-assembly that can be shipped to minimize field welding. The condenser shell and internals including tubes shall be completely assembled in the Bidder's shop. Condenser that can be shipped in sections shall be piece marked and provided with fit-up lugs to facilitate erection in the field. All nozzles, sleeves, baffles and thermal sleeves shall be welded to the condenser shell in the shop. The final field weld location shall be shown on the relevant condenser drawing. 2) Welding a) The Bidder shall provide written welding procedures, repair procedures and procedure qualification records. Each procedure shall be prepared and qualified in accordance with the requirements of ASME Section IX and this specification. Each procedure shall be reviewed and accepted by the KNOC before the Bidder or his Sub-Bidder may perform such welding. the KNOC's inspector will review performance qualification records for individual welders. Welding procedures and procedure qualification records shall be in the form of clear, sharp, reproducible prints and may be prepared on Forms QW-482 and QW-483 as shown in the ASME Code, Section IX, or similar. 3) Field Weld End Preparation The Bidder shall prepare the field weld sections of all condenser parts in such a way that the field weld will be done inside the condenser shell. This is to avoid possible interference with the existing 6.6-22 KHABAT TPP UNITS 1&2 - VOLUME I

installation around the condenser when performing field weld operation. Welding surfaces and heat affected zone that the field welding will be done shall not be painted with any paint or zinc primer to protect for zinc contamination. O. Cathodic Protection System 1) The Bidder shall provide a cathodic protection system to minimize the galvanic corrosion attack of the condenser tube sheet. The cathodic protection system shall be designed in accordance with the following requirements. a) The control potential of the cathodic protection installation should be 700 millivolts SCE(Saturated Calumel Electrode) in order to ensure against titanium hydride formation. b) The electrode should be located to indicate maximum polarization potentials from the anode. Anode shall be treated MMO-Ti or equivalent, with space to provide protective current density to all interior surfaces as specified by the National Association of Corrosion Engineers Level of Protection Potential. Cathodic protection circuit shall be calculated with one Zn and two anode per one circuit. c) Individual anode output currents should be monitored. It may be necessary to add resistors to reduce the output from anodes whose output is higher than normal output of the others. d) A method of calibrating the electrodes should be established for

assurance that the critical potential for titanium hydride

formation is not reached. e) The anode entry stations should be built into the waterbox prior to the application of the waterbox lining. 2) The rectifier unit shall be complete with weather-proof enclosure (NEMA Type 4X) and shall be rated 400V AC 3phase 50 Hertz.The rectifier shall be properly protected on input and output sides against switching and lightning surges. 3) The rectifier control panel shall be equipped the transmitter port to be communicated with the main host computer of cathodic protection system to be provided by the Yard Island. 4) The impressed current system shall include zinc reference electrodes and auto controller to monitor the degree of protection. 6.6-23 KHABAT TPP UNITS 1&2 - VOLUME I

5) The Bidder shall design and supply a complete impressed current cathodic protection system including, but not limited to anodes, rectifiers, local control panels including microprocessor based control and monitoring device, pull box, internal wiring, cables etc., all required for satisfactory operation of the entire system. Consideration shall be given to protect the condenser tube sheet made of clad plate. The Bidder shall also supply additional switches to annunciator system trouble in the main control room. The local control panels shall be enclosed type and will be located near the condenser water boxes. Size and location of openings shall be determined by the Bidder. Size of openings shall be adequate to allow proper application of the specified coating of the water boxes. P.

Foundations and Supports 1) The Bidder shall provide complete structural load information with the condenser outline drawings. Calculations shall be furnished with the structural load information. 2) The calculation shall include assumptions as to which loads are concurrent; tabulations of the combined loads to result in the maximum load for which the condenser is to be designed, and the magnitude, direction, and point of application of all loads for the condenser at the flooded test condition and for operating conditions of condensing and noncondensing, where both halves of the condenser are operating and where either half of the condenser is not operating. 3) The condenser outline drawings shall include location, dimensions, and details of all support plates attached to the condenser and furnished by the Bidder, including guide bars, Teflon sliding plates and anchor plates. Size, locations, and connection details of bolts and nuts shall also be included. 4) The effects of the following forces shall be considered by the Bidder a) Weights of condenser, appurtenances, and contents b) Vacuum and pressure loads c) Thermal expansion and contraction d) Hydraulic thrust at inlet and discharge connections e) Frictional resistances on sliding plates 6.6-24 KHABAT TPP UNITS 1&2 - VOLUME I

f) Seismic forces g) Hydrostatic test loads 5) The design will include the foundation and any connections for the purpose of transmitting vertical and horizontal loads.

6.6.4

Condensate pumps

6.6.4.1

Design condition A.

Type of Condensate Pump The pumps shall be the vertical in-barrel, centrifugal type with all necessary accessories for operable units.

B.

Operational Requirements 1) Each condensate pump shall meet the operating conditions. 2) The curve of total head vs. flow for the condensate pumps proposed shall pass through of all of the operating points. 3) The pumps shall operate free of cavitation over the entire range of operation. 4) Specific speeds and suction specific speeds shall be in accordance with those proposed in the Hydraulic Institute Standards. 5) The pumps shall be designed in accordance with the Hydraulic Institute Standards, vertical centrifugal pump section. 6) The critical speed of rotating elements including the effects of lubrication, bearings and bearing supports shall be at least 25 percent above the maximum expected operating speed. 7) The pumps shall be designed so that, at any system flow from zero to maximum flow, the total head developed by the pumps shall equal or exceed the system head requirements. The pumps will be required to operate at minimum flow for extended periods. 8) The pumps head-capacity curve shall be continuously rising from maximum flow to shutoff. Shutoff head shall be not less than 120 percent of rated pump head. 9) The pumps shall be capable of operating singly or in parallel combinations both intermittently and continuously at any rate from minimum flow to maximum flow under all operating conditions outlined herein without cavitation, undue noise, or vibration. Vibration 6.6-25 KHABAT TPP UNITS 1&2 - VOLUME I

shall be within the limits outlined in the ISO 10816 and ISO 7919. The Bidder shall supply all instrumentations and control systems which will be required to protect of pump system. 10) Pump casing design pressure shall be not less than shutoff head with the maximum suction pressure. 11) Equipment furnished shall be free from fault in design, workmanship and material. 12) Each set of pumps shall be identical in design with all replacement parts being interchangeable. 13) Strainers with the differential pressure indicating transmitter for indication of fouled shall be furnished by the Bidder. 14) The pump shall have clockwise rotation when viewed from motor facing pump. 15) The pumps shall be selected so that the best efficiency point occurs at design point. 6.6.4.2

Performance data A.

The Bidder shall design that the proposed apparatus will operate quietly without undue vibration or noise under the conditions outlined herein, that the apparatus will be capable of continuous and satisfactory operation supported on the proposed structure under all specified conditions of operation outlined herein, that the condensate pumps performance will comply with all requirements outlined herein.

B.

No minus tolerance shall be allowed with respect to capacity, total head or efficiency, and no plus tolerance shall be allowed for the vibration amplitudes. The total head at guarantee capacity may vary by plus 5 percent.

6.6.4.3

Design features A.

The pump design shall allow for dismantling the pump and removal of the rotating element without removing the pump from its base or disturbing the suction or discharge connections.

B.

Parts subject to substantial temperature changes shall be designed and supported to permit free expansion and contraction without resulting in leakage, harmful distortion or misalignment.

C.

Parts subject to wear, corrosion, or other deterioration,

requiring

adjustment, inspection, or repair shall be accessible and capable of 6.6-26 KHABAT TPP UNITS 1&2 - VOLUME I

reasonable convenient removal when required. Where practicable, parts subject of wear shall have means of adjustment. D.

Bolts, nuts, studs and screws shall have coarse threads conforming to ASME standards or equivalent, and shall be furnished in accordance with the latest approved practice for the duties involved. Only hexagonal nuts shall be used.

E.

The Bidder shall certify that the proposed piping arrangement will not cause or otherwise contribute to harmful pump vibrations.

F.

Lifting lugs or eyebolts with means of attachment shall be provided to aid in the handling of heavy parts. Support point provided by the Bidder shall be designed for convenient connection to the foundation or supports.

G. It is the Bidder's responsibility to advise his sub-bidder's of the relevant specifications, and to ensure that they are fully conversant with the requirements of the KNOC. H.

Pumps and all assembly joints or junctions shall include alignment or centering fits as required to ensure accurate reassembly or alignment of all parts.

I.

Running clearance shall meet the requirements of API 610, latest edition

J.

Casing Assemblies 1) Casing bowls shall be the diffuser type with hydraulic surfaces finished to a smooth surface. 2) The discharge head shall be fabricated of steel with flanged suction and discharge nozzles. Flanges shall conform to the requirements of ASME B16.5. 3) Casings shall be of uniform high quality and of the Bidder's standard thickness with a 10 percent allowable variation. 4) The suction can shall be suspended from a foundation base ring of ample thickness to prevent warping and shall provide a flat machined surface to carry the matching machined base on the nozzle head. The can shall be provided with a vent and its associated vent isolation valve. 5) Velocity in the suction barrel shall be between 1.2～2 m/s and flow shall be controlled at the lower end of the barrel or pump inlet.

K.

Rotating Elements 1) Shafts shall be of adequate size to withstand the forces resulting from starting and operating conditions to which the pumps will be 6.6-27 KHABAT TPP UNITS 1&2 - VOLUME I

subjected. The shafts shall have adequate fillets at all shoulders and shall have provisions for locking each impeller in the proper position. 2) Main coupling between the column shaft and drive motor shaft shall be the rigid, adjustable spacer type with provisions for vertical adjustment of the rotor in the inner casing and shall be provided to allow removal of the mechanical seal without removing the driving motor. Coupling pins, nuts, or bolts shall be recessed, and no part shall project past surfaces of revolution. 3) Column couplings shall be type that ensures positive alignment of the shafts. They shall be suitable for convenient disassembly and shall properly realign the shafts on reassembly. 4) Access holes to the shaft and coupling shall be covered with 50mm wire mesh or similar method. 5) Impellers shall be the single suction enclosed type, except the first stage which may be double suction. All surfaces shall be machined or hand finished to a smooth surface. Impellers shall be keyed and individually positioned on the shaft. Each impeller shall be dynamically balanced after any alteration. 6) Wear rings shall be replaceable. If impeller wear rings are not included, the impeller hub shall be of sufficient thickness to allow their future installation.

Wear rings shall be rigidly positioned and

attached to prevent loosening. The wear rings shall be suitably hardened for the service. L.

Bearings Bearings located in the casing bowls, in the suction bell and on the lineshaft shall be non-copper bearing metal, and shall be lubricated by the pumped water.

Column bearing centers shall be spaced so that the

shaft will have proper guidance to be free of harmful vibration. Axial pump thrust shall be absorbed by the motor thrust bearings. The Bidder shall state the maximum limits of vibration and the method of measurement that will be used to determine correct operation of the pump and coupling before shipment. In no case shall be acceptable operating limits or alarm limits exceed Hydraulic Institute Standards. M. Shaft Seals and Sleeves 1) The shaft shall be provided with a replaceable sleeve positioned against a shoulder on the shaft and held in place by a shaft nut or 6.6-28 KHABAT TPP UNITS 1&2 - VOLUME I

equivalent. The sleeve shall be suitably hardened for the service and keyed to the shaft. 2) Shaft seals shall be the cartridge mechanical type. Shaft seal shall be designed to operate in a liquid, and the seal faces must be immersed in a liquid from the very beginning to prevent dry running. Pump shaft shall be sealed by the pumped fluid during normal operation. The Bidder shall provide complete sealing system including restriction orifice, flow gauges, filters, solenoid valves and instrumentations. N.

Supports 1) The discharge head shall support the motor and shall take external forces, including vertical and horizontal thrust resulting from a suction expansion joint plus the nozzle loads Equipment Nozzle Loads and transmit them to the supporting foundation. 2) The suction barrel shall be of welded steel plate with provisions for mounting and supporting the complete unit on a ring base grouted into the supporting concrete. The ring base shall be supplied by the Bidder, Provisions shall be made for continuously venting the suction back to the condenser. 3) Support rings or gussets shall be provided in the suction barrel to limit pendular motion of the pump assembly. The rings or gussets shall be tapered to facilitate assembly. 4) Nozzle head/motor support shall have a natural frequency at least 20 percent above operating speed.

O. Strainer 1) Each condensate pump shall be provided with one 500 mm, nominal diameter basket strainer and temporary screen for start-up. 2) The Basket strainer shall be constructed of stainless steel and ASME Class 150 lb RFWN flanges with a quick opening cover for basket removal. The strainer body shall be ASTM A216 Gr WCB. A stainless steel basket shall be furnished for condensate water service with a minimum free area of four times pipe size with less than 0.07 kg/cm2 pressure drop. The strainer shall be furnished with a drain connection. The strainer shall be hydrostatically tested per ASME B16.5, or an equivalent code P.

Drivers

6.6-29 KHABAT TPP UNITS 1&2 - VOLUME I

The motor thrust bearings for the condensate pumps shall have a minimum rated capacity of 120 percent of the maximum pump down thrust and shall have the capability to accept a momentary upthrust of at least 30 percent of rated down thrust. Q. Instrumentation and Controls 1) Field Instrument Requirements a) All dial type pressure indicators and temperature indicators shall be of liquid filled type to protect from vibration of pumps b) Refer to Section 8 c) Instrument shall be supplied by one(1) recognized manufacturer having wide experience in the manufacture, application as possible. R.

Vibration Monitoring Devices 1) The Bidder shall provide the vibration monitoring devices consisting of probes with protective housing, extension cables and transducers with housing for accurate, reliable vibration monitoring. 2) The radial vibration probes shall be provided with two probes per bearing radially at 90 degrees (X,Y). The dual axial vibration/position probes and keyphaser shall be provided for each pump. The Bidder shall submit installation drawing and detailed specification of the proximitor and keyphaser transducer system for approval by the KNOC.

S.

Materials 1) All materials used in constructing the equipment shall be the best suitable for the specified service. For the specific materials identified in the following list, the base bid shall be predicated on their use and guaranteed by the Bidder to be suitable for the service intended. The Bidder may bid alternative materials of equal or superior properties. 2) Materials for the pumps shall be as specified below (ASTM Designation) a) Can(Barrel) : Structural Steel(A36 with Fiberglass Reinforced Plastic Lining or Polyethylene Lining) b) Casing or Bowl : Gray Iron Casting(A48 Class 35) c) Impeller : 13% Chrome Stainless Steel(A743 Grade CA15) d) Casing wear rings : 13% Chrome Stainless Steel, Hardened(A743 Grade CA40 or A582 Type 416) 6.6-30 KHABAT TPP UNITS 1&2 - VOLUME I

e) Shaft : 13% Chrome Stainless Steel(A276 Type 410) f)

Shaft sleeves : 13% Chrome Stainless Steel, Hardened(A743 Grade CA40 or A582 Type 416)

6.6.5

Low Pressure Feedwater Heaters

6.6.5.1

Design condition A.

Type of Feedwater Heaters The type of LP feedwater heaters shall be of the horizontal shell and Utube design with integral drain cooling zones.

B.

Performance Requirements The heaters shall be designed to accept the load variations at a minimum rate of [10%] of MGR per minute between [50% MGR and 100% MGR], and at a minimum rate of [3%] of MGR per minute between [20% MGR and 50% MGR] and also transients from turbine or steam generator unit trips.

C.

Tubeside Velocity The maximum water velocity through the tube shall be in accordance with the Heat Exchange Institute Standard at the normal full load operating conditions and shall not exceed 3 m/sec(10 ft/sec).

D.

Temperature Changes The heaters shall be designed to ensure continuous, safe and economical operation providing the maximum reliability under the following conditions of temperature changes : The low pressure heaters shall be designed for the instantaneous temperature drop from normal inlet temperature to [50 deg.C].

E.

Allowable Pressure Drops The tube side / shell side pressure drop shall submit the values for condensate pump's TDH and others.

F.

Nozzle and Support Loads Supports for the feedwater heaters shall be capable of withstanding the loads and moments calculated by the Bidder in addition to normal loads and moments and shall be provided for transfer of loads to the condenser neck and building foundation by positive means, respectively.

G. Overload and Abnormal Conditions 1) The feedwater heaters shall be capable of operating at the overload and abnormal conditions as specified below without malfunction or 6.6-31 KHABAT TPP UNITS 1&2 - VOLUME I

damage to the heaters. The Bidder shall determine the effects of removing heaters from service and provide for those effects in the heater designs. The Bidder shall supply calculations and complete Technical Data form for abnormal conditions in bid data form. 2) Abnormal condition occurs when heaters are bypassed. Extraction steam flows and drain flows of heaters in service proportionally increase, based on heater performance, over design flows. Extraction steam pressure will be increased. 6.6.5.2

Performance data The Bidder shall design for all equipment and materials to comply with all applicable code. Performance in accordance with all specified conditions without excessive noise and vibration, overheating or physical damage to the equipment. The heaters shall be operable under the rapid starting or load changing conditions without any limitation. The following performance data of LP feedwater heaters shall be submitted specifically.

6.6.5.3

A.

Terminal temperature difference

B.

Drain cooler approach

C.

Tubeside pressure drop

D.

Shellside pressure drop

Design features The feedwater heaters shall be designed in accordance with the requirements of ASME Section VIII, HEI standards and this specification. The heaters shall conform to ASME Section VIII Division 1 rules. The heaters shall be designed, certified and documented in accordance with code. A.

Shells 1) The No.1 low pressure heater & external drain cooler and No2, 3 shall have removable shells. 2) Feedwater heaters shall be equipped with fixed supports at the channel and wheels or roller supports for the removable portion of the shell. 3) The heaters shall have welded shell-to-tube sheet or shell- to-shell skirt joints. Shell covers shall be welded to the shells. Feedwater heaters with welded shell-to-tube sheet or shell-to-shell skirt joints shall be provided with a cutting line. Cutting lines shall be clearly indicated on the heater shells and cutting line location shall be shown 6.6-32 KHABAT TPP UNITS 1&2 - VOLUME I

on Bidder's drawings. A minimum 200 mm(8") wide stainless steel flame protecting band shall be provided around the tube bundle beneath the shell cutting line. 4) A shell corrosion allowance of 1.6 mm(1/16") minimum shall be used. 5) Lifting and pulling lugs shall be furnished with each heater. All lifting lugs shall be adequately sized for the empty weight of the heater. 6) The Bidder shall furnish insulation support clips and weld to the shells and heads. Externally mounted heaters shall be provided with insulation clips. Cylindrical surfaces shall be equipped with insulation clips spaced at 90-degree intervals, arranged along the long axis of the heater at 457mm(18") intervals. Clips may be threaded 6.4 mm(1/4") studs, flat tabs with hole, or 6.4 mm(1/4") machine nuts. Irregular surfaces of heaters, such as the shell end or forged heads, shall be similarly equipped with insulation attachment devices tackwelded at two points. Spacing shall be approximately 305 mm(12"). 7) Integral drain cooling zones shall be designed to allow satisfactory operation with a minimum level variation of condensate in the heater shell for both normal and abnormal conditions. On all heaters with integral drain coolers, a separate high level drain outlet bypassing the drain cooler section located in the condensing section of the heater shell and having at least the same capacity as the normal drain, shall be provided. Separate and independent levelsensing instrumentation connections shall be provided for normal level, high level and emergency high level. The

normal

heater

drain outlet from the drain cooling section shall be sized for the drain flow that occurs with maximum tube side flow. 8) Adequately sized venting orifices for removal of noncondensable gases shall be provided. Air vent limiting orifices for each heater shall be provided and will be installed in the external piping. B.

Channels 1) The channel heads shall be either one of the following three types : hemispherical head; elliptical head; bolted removable cover, full access head at Bidder's option. Channels shall be integral with the tube sheet or welded to the tube sheet.

6.6-33 KHABAT TPP UNITS 1&2 - VOLUME I

2) Heater channels(except for flat plate bolted cover type) shall be equipped with minimum 457 mm(18") ID circular manways, or elliptical manways with a minimum of 457 mm(18") ID major axis. Channel heads shall be of such configuration as to permit plugging of any tube without removing the entire head. C.

Tubes 1) Minimum allowable tube size shall be 15.88 mm(5/8") OD, and average wall thickness 20 BWG for U-tube type LP heaters. 2) Tubes for heaters and drain cooler shall be rolled into carbon steel tube sheets and shall be fabricated of ASTM A688 Type 304L. The Ubend portion of these heaters tubes shall be solution annealed after bending and cleaning in accordance with ASTM A688. 3) Tube plugging, following hydrotest due to tube failure during hydrotest and when location is either inaccessible or impractical for replacement as permitted by the HEI Standard, shall not compromise heater performance. The Bidder shall state the maximum percentage of tubes that can be plugged and still meet the specified heater thermal performance conditions. 4) All internal tube side heater surfaces will be chemically cleaned in the field prior to operation. The Bidder shall recommend the suitable cleaning solution. The heaters shall be designed for exposure to this solution, ease of flushing and cleanout of residue.

D.

Tube Sheets Low pressure heater tube sheets shall be ultrasonically tested to ASTM A-435 requirements.

E.

Tube Support Plates and Baffles 1) Tube support plates shall be spaced to prevent vibration induced damage to tubes during all operating conditions. 2) Support plate tube holes shall be deburred, with edges "broken"(or slightly chamfered) on both sides. 3) Larger diameter tube bundles shall be provided with support plates, or their equivalent, at the U-bends. 4) Impingement baffles of stainless steel shall be provided opposite all nozzle connections where impingement of steam or water might cause erosion of tubes. Baffles shall be designed to preclude transmission of vibration to the tubes and also to protect the tube 6.6-34 KHABAT TPP UNITS 1&2 - VOLUME I

bundle from rebound. Where necessary all impingement baffles shall be attached to the shell or appropriate parts with full penetration welds and liquid penetrant tested in accordance with Appendix VIII of ASME B & PV Code SEC. VIII. F.

Connections 1) In addition to the normal connections provided for steam inlet, drains, vents, feedwater inlet and outlet, the heaters shall be provided with connections for level controls, level alarms and indicators, chemical cleaning,

pressure

and

temperature

instrumentation,

nitrogen

blanketing, HEI and ASME test taps as required. 2) All connections shall be oriented radially and all connections for heaters except for the shell side safety relief valves, acid cleaning nozzle shall be welded. Connections 65mm(2-1/2") and larger shall be butt welded unless this specification states otherwise. Connections 50mm(2") and smaller shall be socket welded. 3) The shell side safety relief valve connections shall be flanged. The tube side safety relief valve connections shall be socket-welded type. 4) The incoming drain connection to heaters shall be on horizontal center line at the U-bend end, beyond the tube bundle. Stainless steel baffles shall be provided to protect the U-bend in the flash chamber. The incoming drain part of No. 1 heater shall be designed to drain enough and prevent from vibration, etc. in the condenser. 5) All connections shall extend beyond the insulation thickness. G. Accessories 1) The Bidder shall size a connection and provide a heavy duty thermal relief valve to protect the tube side of the feedwater heaters and external drain coolers. Valve size, type, and material shall comply with ASME and HEI Code requirements. 2) Safety relief valves shall be shop tested, set and tagged. The minimum tag information shall include identification number, set pressure and accumulation. The set pressure of valves shall be adjustable, without causing damage to the setting surface. H.

Materials All materials used in constructing the equipment to be furnished, but which are not specifically indicated in this specification, shall conform to HEI requirements, shall be the most suitable for the service intended. 6.6-35 KHABAT TPP UNITS 1&2 - VOLUME I

1) Carbon steel plate : ASTM A-516 Grade 70, ASTM A-283 Grade C for pressure containing parts, ASTM A-36 for nonpressure containing parts. 2) Carbon steel forgings : ASTM A-105 Grade II, ASTM A-266 Class 2 or ASTM A-350 Grade LF2, LF3 or equivalent. 3) Tubes : ASTM A688 Type 304L 4) Impingement plates : ASTM A-240 Type 304L and minimum 4.8 mm thickness. Internal impingement baffles in drains discharging into the shell shall be austenitic stainless steel. 5) Nozzles : ASTM A-106 Grade B or A-335 Grade P11 for all heaters. 6) Nozzle Liners : Fabricated stainless steel in accordance with ASTM A-240 Type 304, with a maximum carbon content of 0.03 percent. 7) Orifice plates : ASTM A240 Type 316L 8) Gaskets : Non-asbestos 9) The use of copper alloys in any part of the units is not acceptable. 10) Insulating shroud for heaters No. 1 shall be ASTM A-240 Type 304 stainless steel, minimum thickness 1.6mm. I.

Manufacture 1) Shop Assembly The feedwater heaters shall be completely assembled in the Bidder's shop for shipment to the field in one section. 2) Welding a) All welding, welding procedure qualifications, electrodes, preheat and postweld heat treatment, and welder performance tests shall be in accordance with ASME Section VIII and IX . b) Defects that require repair by welding shall be repaired in accordance with ASME Section VIII. A detailed repair procedure shall state the nature and location of the defect, method of repair, welding

and

nondestructive

examination

procedures,

and

subsequent heat treatment. 6.6.6

Condenser Vacuum Pumps

6.6.6.1

Design of condition A.

The condenser vacuum pumps will be used for initial evacuation of condenser and for continuous removal of noncondensibles from the condenser when it is operating at normal vacuum. The waterbox vacuum 6.6-36 KHABAT TPP UNITS 1&2 - VOLUME I

pumps will be used to remove gases separated at both inlet and outlet waterboxes of the condenser. B.

Start-up or hogging 1) During hogging operation, one(1) vacuum pumps are in operation evacuating the system from atmospheric pressure to 340mbar in 25 minutes. 2) Two(2) vacuum pumps will have to be operated to reduce the hogging time, any further.

C.

Normal (Holding) operation 1) During normal plant operation, one (1×100%) capacity condenser vacuum pumps will continuously remove the non-condensible gases to maintain the 92.5mm HgA condenser vacuum condition. 2) The air in leakage to the condenser is continuously monitored by the rotameter for leakage measurement.

D.

Abnormal operation In the event of excessive air in-leakage to the condenser, or when the dissolved oxygen level of condensate leaving the hotwell is too high, the standby vacuum pump can be activated automatically.

E.

The condenser vacuum pumps shall be sized for initial evacuation of the condenser and turbine in 25 minutes (hogging) and for continuous removal of noncondensable gases(holding) from the condenser in accordance with HEI Standards.

F.

The condenser vacuum pump data sheets will be included in technical bid form. The data contained in these sheets shall be incorporated in the equipment design.

G. The equipment shall be designed for continuous use and shall be capable of handling gases, entrained droplets and water vapor and slugs of water carried over from the condenser. 6.6.6.2

Performance The Bidder shall design that the supplied apparatus will operate quietly without undue vibration and noise, overheat and physical damage under the conditions outlined herein, that the apparatus will be capable of continuous and satisfactory operation supported on the proposed structure under all specified conditions of operation outlined herein, that mechanical vacuum pumps performance will comply with all requirements outlined herein. A.

Holding capacity at design suction pressure 6.6-37 KHABAT TPP UNITS 1&2 - VOLUME I

1) Dry air 2) Water vapor

6.6.6.3

B.

Evacuation time required.

C.

Maximum(Peak) shaft horsepower required.

Design features A.

100% capacity condenser vacuum pumps shall be provided for each unit.

B.

The condenser vacuum pumps shall be of the manufacturer's standard design, shall perform as specified in Paragraph 6.6.7.1 and shall meet the requirements of the HEI Standards for Steam Surface Condensers.

C.

The equipment shall be capable of withstanding forces resulting from all conditions of steady state and transient conditions which may occur during preliminary and routine startup and the normal continuous operation.

D.

The condenser vacuum pumps shall be capable of completely automated operation throughout both the hogging and holding ranges. In addition, they shall automatically transfer to the holding phase on completion of hogging, or from the holding to the hogging phase in the event of excessive air leakage into the condenser.

E.

Construction 1) The vacuum pumps shall be the liquid ring type and each pump and driver shall be mounted on a common fabricated steel base plate. 2) All vacuum pump heat exchangers shall be TEMA Class R and shall be constructed in accordance with ASME Section Ⅷ, Division 1. The heat exchanger shall be furnished of size and capacity to cool the water for their respective vacuum pumps. Each heat exchanger shall be furnished complete with all necessary control and appurtenances required. 3) The equipment shall be furnished with vents and drains to completely drain the equipment. 4) The Bidder shall include an air-water separator to retain the water and release the air to the ventilating system. 5) A Y-strainer shall be provided downstream of the seal water recirculation pump, or at the inlet from an exterior seal water source. 6) A level control valve shall be furnished to control the flow of make-up water to the seal water reservoir.

6.6-38 KHABAT TPP UNITS 1&2 - VOLUME I

7) External connections to the equipment (vacuum pump, water separator, seal water recirculation pump and heat exchanger, air ejector(if required)) shall be flanged. F.

All piping shall comply with the following : 1) Connections 65 mm and larger shall have flanged ends and shall be in accordance with ASME B16.5. 2) Connections 50 mm and smaller shall have socket-welding or thread ends and shall be in accordance with ASME B16.11.

G. The speed changer, if required, shall be of the industrial heavy duty type in conformance with American Gear Manufacturers Association(AGMA) standards with appropriate service factors for pump service. Gears shall be capable of continuous operation. Gear housing shall be totally enclosed with effective shaft seals to prevent oil leakage and entrance of moisture. H.

Coupling guards shall cover all moving external parts of the drive system and comply with OSHA standards.

I.

Materials 1) All materials used in construction the equipment shall be the best suitable for the specified service. The Bidder shall guarantee their use to be suitable for the service intended. 2) Materials for the mechanical vacuum pumps shall be as specified below (ASTM designation). a) Body : ASTM A48 GRADE 30 or EQ.(CAST IRON) b) Head : ASTM A48 GRADE 30 or EQ. c) Rotor : ASTM A536 or EQ.(DUCTILE CAST IRON) d) Ported cone/Plate : ASTM A48 GRADE 30 or EQ. e) Shaft : ASTM A576-1045 or EQ. f) Base plate : ASTM A283 GRADE D or EQ. (CARBON STEEL PLATE) g) Separator : ASTM A283 GRADE D or EQ. h) Silencer : ASTM A283 GRADE D or EQ

6.6-39 KHABAT TPP UNITS 1&2 - VOLUME I

6.6.7

Instrumentation And Controls A.

The Bidder shall design and supply all instrumentation and controls so as to insure accurate, safe and reliable operation under conditions of service.

B.

The Bidder shall design the condenser and condensate system to be started, stopped, controlled and monitored through the Plant PCS.

C.

The function for automatic startup and shutdown of the condenser and condensate system shall be considered in order to minimize operator intervention. All control equipment shall be capable of manual operation through the plant PCS.

D.

Two redundant instruments for system shall be supplied for following applications as a minimum. 1) Heater Level Transmitter : 2/heater 2) Condenser hotwell level transmitter : 2 3) COP discharge pressure transmitter : 2 4) Spray water pressure switch for LP Bypass attemperator : 2 5) Condenser vacuum pressure transmitter : 2

E.

The Bidder shall provide designated instrument type for the following BOP process. 1) LP heaters and hotwell level transmitter: displacement type 2) LP heater level gauge : magnetic type 3) Condenser makeup water, COP discharge, deaerator inlet flow transmitter : ultrasonic type(clamp on, accuracy: 1%)

6.6-40 KHABAT TPP UNITS 1&2 - VOLUME I

6.7

Feedwater System

6.7.1

System descrption

6.7.1.1 The feedwater system delivers heated feedwater, utilizing extraction steam for regenerative heating, from the feedwater storage tank to the steam generator at the required flow rate, temperature and pressure. A secondary function is to deliver water for superheater and reheater desuperheating, HP and LP bypass valve desuperheating, process steam desuperheating and other system when required for steam temperature control. 6.7.1.2 Feedwater system shall consist of the following equipment between the deaerator and feedwater storage tank outlet and the economizer inlet including all branches concerned with feed pump discharge pressure.

6.7.2

A.

One deaerator with feedwater storage tank (No. 4)

B.

Two feedwater pumps and motors

C.

Three high pressure feedwater heaters (No. 5, 6, 7)

D.

Minimum flow recirculation piping with control valves.

E.

Sampling for water analysis

F.

All associated piping, valves, instrumentation and controls

System design criteria

6.7.2.1 Feedwater system shall be designed for the flow based on the operation with turbine control valves wide open (VWO). 6.7.2.2 Hydrazine and ammonia are injected into the suction side of boiler feed pump. 6.7.2.3 Each pump draws suction from the feedwater storage tank for stable and simple operation of feedwater system. 6.7.2.4 For each pump, individual minimum flow line to feedwater storage tank shall be used to avoid overheating and unstable condition of pump, and flow meter shall control individual modulating control valve in recirculation line to feedwater storage tank. Minimum flow quantity will be determined by feedwater pump manufacturer. 6.7.2.5 During normal plant operation, warm water is supplied from the discharge lines of each feedwater pump in service to warm up the pump not in service so that water hammering and thermal shock shall be prevented when the pump is started.

6.7-1 KHABAT TPP UNITS 1&2 - VOLUME I

6.7.2.6 Sample for feedwater analysis will be extracted from the feedwater pump discharge header and economizer inlet. 6.7.2.7

Start-up A.

The demi water storage tanks will feed the 1 x 100% demi water transfer pump and this pump shall supply the make-up water requirements of the deaerators. Any upsurge from excess water will be routed to the drains system.

B.

Feedwater storage tank should be filled enough to operate the system before normal start-up of the system and warmed up by proper manner.

C.

Manually operated valves, such as feedwater pump suction shutoff valves, isolation valves in minimum flow recirculation line and feedwater pump balance leak-off valves which, if inadvertently closed during operation and would damage the pumps, shall be in a "locked-open" position.

D.

During cold start, feedwater system shall be cleaned with condensate and promote the removal of dissolved Oxygen and the deaerating. During hot restart, aux. steam should be supplied to maintain the feedwater temperature at the saturation temperature corresponding to deaerator pressure. Low temperature feedwater causes thermal fatigue when passed through the HP feedwater heater.

E.

During start-up and low load operation, feedwater temperature should be maintained at the temperature of deaerator by supplying the steam for feedwater heating from aux. steam header to deaerator. By this method, it should be possible to fill the steam generator with hot feedwater when the steam generator is on standby for hot restart.

F.

During start-up and low load operation, the flow should be recirculated to the feedwater storage tank through the minimum flow control valve to avoid overheating of feedwater pump and to avoid the unstable system condition due to the flow in the feedwater system being less than minimum flow requirements of the pump.

6.7.2.8 Normal operation A.

Boiler feedwater pumps and all H.P feedwater heaters should be used during normal operation. Feedwater pumps shall be controlled by the signal difference between feedwater flow corresponding to steam generator demand signal and measured feedwater flow. 6.7-2 KHABAT TPP UNITS 1&2 - VOLUME I

B.

Desuperheating water for superheat and reheat steam shall be supplied by individual steam temperature control.

6.7.2.9 Component description 6.7.2.9.1 Deaerator and feed water storage tank A. Quantity

: One (1)×100% capacity

B. Design performance

: Based on VWO condition

C. Design capacity

: The reserved capacity based on normal water level shall be possible to operate during min. 7 minutes

D. Design pressure

: The Sum of 115% of extraction pressure from VWO condition

E. Design temperature

: Maximum extraction steam temperature or pegging aux. steam temperature, which is greater

F. Type

: Horizontal

6.7.2.9.2 Boiler feedwater pump A. A.

Quantity Type

B. Design capacity

: Two (2)×100% capacity : Horizontal, Centrifugal, Multi-stage, Motor- driven : Flow for Boiler feeding plus 5% surge margin and 6% wear margin

C. Design head

: Based on required system head plus head margin corresponding to 5% flow surge margin.

D. NPSHav

:

Based

on

the

result

of

deaerator

decay

calculation 6.7.2.9.3 H.P heaters A.

Quantity

: Each One (1)× 100% capacity

B.

Design performance

: Based on VWO condition

C.

Design pressure 1) Tube

: 1.05 × (1.06 × Boiler Design Pressure + friction drop from No.5 HP heater to Boiler) or 1.05 × Pump discharge pressure at shutoff , whichever is greater

2) Shell

: Full vacuum and 115% of extraction pressure from VWO condition

6.7-3 KHABAT TPP UNITS 1&2 - VOLUME I

3) Design temperature for shell and tube : Per HEI standards, and the requirements for desuperheating section should be taken into consideration. D.

Tube material

:

ASTM A-213, type 304N or equal

E.

Type

:

Horizontal, U-tube

6.7.2.9.4 Piping A.

General Feedwater piping shall be from the deaerator outlet to the steam generator economizer inlet, divided into feedwater suction and feedwater discharge. Transient analysis required for suction piping for turbine trip condition.

B.

Design parameters

:

1) Suction Piping a) Pressure

:

Full vacuum and deaerator design pressure plus static head.

b) Temperature

:

Saturated temperature at 115% of deaerator

pressure

from

VWO

conditions. 2) Discharge piping a) Pressure : -

Upstream of feedwater pump flow control valve : 1.05 × Pump discharge pressure at shutoff

-

Downstream of feedwater pump flow control valve

:

1.25 × Boiler design pressure or Boiler design pressure + 225 psig, whichever is lesser b) Temperature : Last feedwater heater outlet temperature at 115% of HP extraction steam pressure for the last feedwater heater c) Piping sizing : 50mm-175mm ; for maximum velocity limit of 4.6m/s(50mm) and 7.3m/s (175mm)

above 175 mm ; for

maximum velocity limit of 7.3m/s d) Bypasses : Bypass pipeline including bypass valve for high pressure heaters shall be sized for the same pressure drop as the total pressure drop in the heater and in the portions of the main feedwater piping between the points of takeoff and return of the 6.7-4 KHABAT TPP UNITS 1&2 - VOLUME I

bypass pipeline. The maximum allowable velocity in the bypass pipeline may exceed the optimum value for pipe sizing 6.7.3

Deaerator and storage tank

6.7.3.1 Design condition 6.7.3.1.1 The power plant shall be designed to accept the load variations at a minimum rate of 5% of MGR per minute between 50% MGR and MGR, and 3% of MGR per minute between 30% and 50% MGR and also transient condition from turbine or steam generator unit trips. Supports for the deaerators shall be capable of withstanding the loads and moments calculated by the Bidder in addition to normal loads and moments and shall provide for transfer of loads to building structure by positive means. 6.7.3.1.2 The deaerator and feedwater tank shall be designed for quietness of operation and minimum vibration at all rates up to and including its maximum capacity, during rapid load changes and with the temperature of entering feedwater ranging from steady state to normal condenser hotwell temperature. The deaerator shall be capable of furnishing deaerated water continuously at the feedwater tank outlet at any rate from 10 to 100 percent of steady state maximum flow with a residual oxygen content not to exceed 7 ppb. The deaerated water shall be heated to the saturation temperature corresponding to the steam pressure maintained in the shell. Over the entire load range, the free carbon dioxide content shall be reduced to zero. 6.7.3.1.3 Feedwater Oxygen content, measured at the Feedwater storage tank outlet to boiler feed pump suction, shall not exceed 7 ppb and free carbon dioxide content shall be zero when the deaerator is operating 6.7.3.1.4 All components and component parts shall be designed so that safe working stresses are not exceeded during all modes of operation such as startup, steady state at any load from zero to full load, transient conditions, and forces caused by flashing of the liquid in the storage tank. The trays, tray enclosure, and support members shall be designed to withstand the maximum pressure differential across the trays and tray enclosure during any mode of operation. Among these modes, the Bidder shall consider the transient condition occurring upon sudden load rejection. For this condition it shall be assumed that all steam flow has stopped while condensate is still entering the deaerator at the maximum flow rate, for transient or condensate control valve failed wide open, resulting in a pressure differential across the 6.7-5 KHABAT TPP UNITS 1&2 - VOLUME I

tray enclosure. 6.7.3.1.5 The tray enclosure, either separate or combined with the vent condenser, shall preferably be bolted and not welded directly to the deaerator pressure vessel shell. Supports for the enclosure shall be of bolted design. Bolts shall be welded to one of the mating parts. After completion of assembly, all nuts shall be tightened and tack welded to the bolts. The entire internal structure shall be constructed to provide a limited freedom of movement through the use of bolted joints to eliminate residual stresses from welding, to mitigate thermal stress, and to promote damping of vibration. 6.7.3.1.6 The non-hydraulic loads that can be transmitted to nozzles by piping are not less than those which will cause a stress in the nozzle at the field welding joint. The Bidder's design shall be of such strength in the shell and in the nozzle that at no location will the combined load and internal design pressure result in a stress exceeding 90 percent of the ASME minimum yield strength. 6.7.3.1.7 The downcomers and equalizers shall accommodate the drainage of the heater section to the storage section under all modes of operation and particularly during transient conditions. Specifically the downcomers and equalizers shall be sized so that during a transient condition, except for an instantaneous and momentary condition, the flow of condensate through the downcomer is downward, and the flow of steam through the equalizer is upward.

The resulting pressure differences between the two vessels shall

be such that the equalizers will not become flooded, and the condensate level in the heater shall not impair the steam flow to the heater. 6.7.3.1.8 The downcomers shall be equipped with heavy deflector hoods to protect the trays against inadvertent upsurges of condensate. The equalizers shall also be equipped with heavy deflector hoods to divert the flow of steam and entrained condensate from the storage tank to the heater, away from the trays. 6.7.3.1.9 Each connecting nozzle between storage tank and heater shall require not more than one field weld. Nozzles shall be aligned in the shop to ensure a correct fit at field assembly. Any refabrication costs required at final field assembly due to shop misalignment shall be borne by the Bidder. 6.7.3.1.10 The spray valves distributing the condensate over the trays shall be designed for concurrent full internal vacuum and full exterior deaerator pressure to withstand the pressure resulting from liquid flashing in the pipe 6.7-6 KHABAT TPP UNITS 1&2 - VOLUME I

before the nozzles or spray holes, opening the control valve that supplies condensate to an empty spray pipe, or filling an empty system. In lines designed for full vacuum, methods may be employed for relieving vacuum. The trays shall be designed to safely withstand the impact energy of the condensate on the trays resulting from the above described pressure peaks. 6.7.3.1.11 Deaerator supports and nozzles shall be suitable to withstand the forces imposed on the deaerator by extraction steam and feedwater piping. Corresponding reactions and moments for these lines will be furnished to the Bidder after award of order. 6.7.3.1.12 The levels of feedwater tank shall be set as follows(shown as % of inner height) : A.

Low low level(for boiler feed pump trip) : 20%

B.

Normal level : 70%

C.

High level : 85%

D.

Overflow level : 89%

E.

High high level : 92%

6.7.3.1.13 The feedwater tank shall hold hot feedwater for min.7 minutes effective storage below the normal water level and above the low low level at V.W.O conditions. The deaerator and feedwater tank shell shall be designed for working pressure from full vacuum to design pressure. 6.7.3.1.14 A 1.6 mm corrosion allowance shall be provided over the calculated thickness for the deaerator shell, the feedwater tank shell, the connecting pipe, and the equalizing lines. 6.7.3.1.15 The deaerator and feedwater tank shall be designed to eliminate water hammer. 6.7.3.1.16 The feedwater outlets from the feedwater tank shall be designed for smooth flow and to prevent the formation of a vortex in the feed water pipe work to the boiler feed pumps. 6.7.3.2 Design Features 6.7.3.2.1 The deaerator shall be designed in accordance with the requirements of ASME Section VIII Div.1 and this specification. The deaerator shall be designed, certified and documented in accordance with the Code. 6.7.3.2.2 The vessels shall be constructed of welded, carbon steel plates. 6.7.3.2.3 Each section of the feedwater tank shall be designed to withstand the dead weight of the deaerating heater section when the deaerating heater section is placed on the upper half of the storage section during field installation. 6.7-7 KHABAT TPP UNITS 1&2 - VOLUME I

6.7.3.2.4 Tray Banks and Spray Nozzles A sufficient number of tray banks shall be assembled in the deaerator to demonstrate fit up before shipment. The banks shall be removed and shipped separately for field installation. All trays shall be self-draining. Trays shall be securely held in place, and deflectors shall be provided to protect the trays from direct impingement of steam and water entering the deaerator and from flash steam from the feedwater tank. Adequate spacing shall be provided between inlet fluid connections and deaerating components to prevent damage due to transient conditions, flashing, or high velocities. Spray nozzles shall be positively locked in place so as to prevent being dislodged under any and all operating conditions contained in this Specification. 6.7.3.2.5 Vent Condenser The vent condenser shall be capable of preventing undue loss of steam through the vent connection under all conditions of operation. 6.7.3.2.6 Impingement Baffles All steam inlet impingement baffles and their support shall be designed to withstand all forces resulting from an occasional water slug. 6.7.3.2.7 Manholes All necessary manholes and access doors for the deaerator and feedwater tank shall be provided. Manholes shall not be smaller than 600 mm I.D and shall be of adequate size to allow removal of all internal assemblies. 6.7.3.2.8 Screen (pump suction nozzle startup screen) A screen shall be installed at the pump suction nozzles of the feedwater tank. This screen will be removed after pre-operation. The screen shall be fabricated from stainless steel material. The opening shall be 60 mesh screen. This screen shall be removed through the tank manhole for flushing. 6.7.3.2.9 Steam inlet connections Steam inlet connections shall be located to provide a nearly uniform steam flow over the entire tray area. External or internal steam distribution pipe headers or internal baffles shall be provided to direct the flow to the tray face area. All nozzles distributing steam shall be on or symmetrically arranged about the midpoint of the deaerator vessel. 6.7.3.2.10 Tank drains Deaerator and feedwater tank drains shall be located to flush with the bottom of tank so that complete drainage can be assured. 6.7-8 KHABAT TPP UNITS 1&2 - VOLUME I

6.7.3.2.11 Pump suction nozzles Pump suction nozzles shall extend 75 mm up from the bottom of the feedwater tank section with a vortex breaker. Provisions shall be made, including suitable connections, to completely drain the deaerator and feedwater tank. The vortex breaker and suction nozzle entrance shall create minimum resistance. 6.7.3.2.12 Feedwater pump recirculation nozzles Boiler feed pump minimum flow recirculation nozzles shall have internal sparger pipe located above the feedwater tank water level. The sparger pipe shall have drilled holes with a max. allowable pressure drop in the feedwater tank, and the total area of the holes shall be at least three times the nozzle area. Special care shall be given to prevent steam dragging into the feed pump suction lines due to vortex formation by the high velocity water leaving the recirculation lines. 6.7.3.2.13 Safety relief valves Safety relief valves which are required for overpressure protection shall be sized in accordance with ASME Code, Section VIII, and shall be provided by the Bidder. Flanged safety relief-valve connections shall be sized and provided by the Bidder as required. Safety relief-valve discharge will be to atmospheric drains. The Bidder shall provide data for the proposed safety relief valves. Sizing of the deaerator safety relief valve shall be based on the following condition : - Auxiliary steam control valve failing open during control valve failure, the condensate flow entering and leaving the deaerator is assumed to be zero. Quantity of safety relief valve shall be determined by the Bidder. 6.7.3.2.14 Materials A.

Materials for pressure boundary applications shall conform to the requirements of ASME Code, Section VIII or ANSI Code B31.1 as applicable. Material for parts not specified shall be subject to KNOC's acceptance. Material certifications of critical component materials shall be furnished to KNOC.

B.

Materials for the deaerator, feedwater tank, and related components shall be as specified below. Where materials is not specified it shall be selected by the Bidder. Stainless steel materials shall be used for the appropriate internal parts or components of the deaerator including all 6.7-9 KHABAT TPP UNITS 1&2 - VOLUME I

areas from the point where the steam and water mix to the point where non-condensable gases are separated and vented through the vent condensing system. 1) Deaerator shell and feedwater tank shell - ASTM A285 Grade C, ASTM A516 Grade 70. 2) Spray valves and orifice plates - Spray valves

: Stainless Steel Type 316

- Orifice plates

: A240 Type 304L

3) Trays - ASTM A240 Type 430. 4) Tray stack enclosure, vent condenser enclosure and vent pipes, and distributing troughs(above tray stack) - ASTM A240 Type 304L 5) Impingement baffles - ASTM A240 Type 304L and minimum thickness 6mm 6) Piping - Size 600mm(N.D) and smaller : ASTM A106 Grade B - Size larger than 650mm(N.D) : ASTM A516 Grade 70 or equiv. 7) Nozzles(connections) - ASTM A105, ASTM A216. 8) Internal bolts, studs, and nuts - Bolts and studs : - ASTM A193 Type 304 - Nuts : ASTM A194 Type 304 9) Safety relief valve - Body & bonnet : - ASTM A216 Grade WCB or WCC 10) Flange - ASTM A181 Class 60 or 70. 11) Gaskets - Metal 12) Permanent support saddles(for the deaerator and feedwater tank) - ASTM A36, A283 Grade C or same as shell material. 6.7.3.2.15 Load criteria A.

Loads due to turbine trip (sudden load rejection) with condensate control valve wide open.

6.7-10 KHABAT TPP UNITS 1&2 - VOLUME I

B.

Equipment shall be designed for the seismic conditions given in Volume 2, Technical Schedule, Schedule A, Site Particulars. Seismic accelerations need not be combined with loads caused by transients.

C.

Internal temperature differentials as defined by the Bidder.

D.

Dead weight

E.

Other loads as determined to be critical by the Bidder.

6.7.3.2.16 Manufacture A.

Surface preparation All parts of the equipment shall be thoroughly cleaned of all mill scale, rust, grease and other foreign matter and the exterior surfaces shall be given one coat of inorganic zinc paint as specified. Interior of shells shall be thoroughly cleaned by using wire brushing so as to leave clean metal surfaces exposed. Inside surfaces shall not be painted or coated, unless otherwise specified. Accessories shall be painted with a "shop coat" of manufacturer's standard paint suitable for the service. No asphaltum paint shall be used. Before shipment, all exposed machined surfaces shall be coated with a suitable grease or anti-rust compound.

Before shipment, inlets and

outlets shall be blanked off or plugged. B.

The other manufacture requirements for deaerator and feedwater storage tank is same as that of LP heaters. Refer to LP heater's section

6.7.4

Boiler feed pumps

6.7.4.1 Design conditions 6.7.4.1.1 The boiler feed pumps shall be designed to ensure continuous, safe and economical operation providing the maximum reliability and without undue heating, vibration or noise. 6.7.4.1.2 Operational requirements A. The boiler feed pump head-capacity curve shall be continuously rising from maximum flow to shutoff. The pump shutoff head shall be no more than 20 to 30 percent higher than the total differential head(TDH) at the design point allowing for tolerances. The pressure pulsation shall be no more than 3% of the head produced by one pump stage (not whole pump TDH) as measured on the pump discharge. 6.7-11 KHABAT TPP UNITS 1&2 - VOLUME I

B. The boiler feed pumps shall be capable of operating continuously at any rate from minimum flow to rated flow under all normal conditions without cavitation or undue noise or vibration. The boiler feed pumps will be required to operate at minimum flow for extended periods. The Bidder shall indicate the minimum flow for continuous operation. C. Under severe transient conditions, the boiler feed pumps may

be

momentarily subject to moderately cavitation conditions. D. The boiler feed pumps at the rated speed shall not exceed the vibration and shaft movements specified hereinafter. The maximum vibration, as measured on the boiler feed pump shaft adjacent to all bearings, shall not exceed 42 microns double amplitude throughout the load range. The maximum vibration as measured on the boiler feed pump bearing pedestals, shall not exceed 21 microns double amplitude throughout the load range. Shaft movement in either axial direction shall not exceed 0.3 mm when measured from the center of the thrust gage clearance. The boiler feed pumps shall have a head capacity characteristic that will ensure satisfactory parallel operation of the pumps at any flow from minimum flow to run-out condition, with any combination of operating pumps. E. The boiler feed pump shall be capable of 'dry running', and of accepting a complete loss of water. In such an extreme case, it is recognized that the pump should be tripped and restarted after it has been reprimed. The pump must, however, be capable of being tripped and brought to restart safely in a short time. F. The pumps shall be designed for continuous unattended service while operating within the limits of the operating range, including runout and minimum flow. Maximum thermal shock is expected to occur on a complete loss of main turbine-generator load with resultant rapid feedwater temperature reduction from design temperature to "cold water" conditions at runout flow. G. The stand-by pump shall be capable of fast start to prevent load runback. H. Reheater attemperation water will be taken from the interstage of boiler feed pump.

6.7-12 KHABAT TPP UNITS 1&2 - VOLUME I

I.

The boiler feed pump shall be selected so that the best efficiency point occurs at the design point

J. The first critical speed of each pump shall exceed the operating speed of the pump by at least 25 percent. 6.7.4.2 Design and construction features 6.7.4.2.1 General A. The boiler feed pumps shall be the horizontal, centrifugal, double suction, barrel type, complete with all specified and required accessories for a complete installation B. The radial clearance between the diffuser vane or volute tongue and the periphery of the impeller blade shall be at least 3 percent of the maximum impeller blade tip radius for diffuser designs and at least 6 percent of the maximum impeller blade tip radius for volute designs. C. Running clearance shall meet the requirements of API 610 para 2.6.6. 6.7.4.2.2 Baseplate Baseplates shall be of fabricated steel with grout holes. They shall extend completely under all parts of the pump and accessories, and shall be positive slope drain rim type with the flat portion of the plate sloping continuously toward a drain connection at one end. The boiler feed pump and the common motor driver shall be provided with one pieces of baseplate. 6.7.4.2.3 Casing A. The outer casing shall be of forged low carbon steel.

Areas around the

discharge exit and at the seals shall be surfaced with an overlay of a metal alloy to resist erosion and corrosion. The inner casing cored water passages shall be machined or finished to smooth surfaces. The suction and discharge nozzles of the boiler feed pumps shall project upward from the pump casing. Design stress levels in the barrel, head, and bolting of the boiler feed pump shall not exceed the limits of the ASME Code for Pressure Vessels, Section VIII, or equivalent. Welding shall be in accordance with ASME Section VIII, IX or equivalent. B. Casing wear rings shall be of groove or serrated type and of hardened stainless steel alloy that will be compatible with the impeller material, will result in prolonged life, and will be free of galling tendencies. The ring shall be rigidly positioned to prevent rotation under any conditions of operation. Impeller wear rings shall not be acceptable. 6.7-13 KHABAT TPP UNITS 1&2 - VOLUME I

6.7.4.2.4 Impellers and diffusers A. Impellers shall be the single suction enclosed type, except the first stage which may be double suction. All surfaces shall be machined or hand finished to a smooth surface. Impellers shall be keyed and individually positioned on the shaft. Each impeller shall be statically balanced after completion of all machining and rebalanced after any alteration. After assembly, the complete rotating element shall be dynamically balanced. B. If the Bidder proposes diffuser type pumps, the Bidder shall propose pumps with enclosed type diffusers (the pumps with cantilever(semienclosed) type diffusers shall not be acceptable). The diffuser design shall be single precision casting where the vanes and shrouds are cast in one piece. Welding and soldering are not acceptable. 6.7.4.2.5 Bearing A. Thrust bearings shall be the tilting pad double action type. B. Sleeve bearings shall include "E" type thermocouples in contact with the bearing metal. Thrust bearings shall include "E" type thermocouples which, if design permits, shall make contact with one of the thrust shoes or shall be placed to give the most direct indication of actual bearing temperature. The Bidder shall submit a detailed description of how this will be accomplished.

Thermocouples shall be brought back to a

common terminal box mounted on the pump frame or off the baseplate of the pump. C. The Bidder shall state the method of measurement that will be used to determine correct balancing of the pump and coupling before shipment. The Bidder shall state the maximum limits of vibration that should be used for alarm and trip points during plant operation. In no case shall these limits exceed HI standards, or equivalent. 6.7.4.2.6 Lube oil system A. The Bidder shall provide a complete common forced feed lube oil system for the bearings of each boiler feed pump and common motor combination including, but not necessarily limited to the following : 1) A complete lube oil system and all associated instrumentation. The reservoir shall have sufficient free volume above the normal operating range level to accommodate full system flowback without bringing in the high level alarm regardless of oil temperature. The Bidder shall furnish and install the following equipment on each oil reservoir. 6.7-14 KHABAT TPP UNITS 1&2 - VOLUME I

a) One(1) shaft driven 100 % capacity main oil pump. b) One(1) AC motor driven 100% capacity auxiliary lube oil pump. c) One(1) 100% lube oil cooler for use with closed cooling water. The oil side of the coolers shall be designed for maximum oil pressure. d) Duplex type oil strainers with differential pressure indicating switch located at the outlet side of the lube oil cooler e) Pressure, flow, temperature, level and other instruments as necessary. f) Three(3) Pressure transmitters for sensing lubricating oil pressure shall be provided for pump start and stop, alarm interlock and trip. B. The auxiliary lube oil pump will be used to prelubricate the pump before starting and shall start automatically in the event of low oil pressure from the operating main lube oil pump. C. Lube oil system piping shall be designed with a minimum number of joints and the inside surfaces shall be essentially crevice free. All piping shall be concealed wherever practicable, and all exposed piping shall be arranged to present a neat appearance. Oil piping shall be welded steel, thoroughly cleaned, pickled and flushed.

Pipe ends shall be suitably

capped to prevent the entrance of dirt and moisture. Valves shall be forged steel and of an approved make with bronze bodies. Sight flow indicators shall be included for each bearing. 6.7.4.2.7 Shaft, sleeves, seals, and jacket cooling A. The boiler feed pump shafts shall be forged steel, accurately machined and ground, and of adequate size and strength to withstand safely and continuously all stresses resulting from startup, operating and transient conditions to which it will be subjected. The shaft extension shall be tapered to facilitate coupling removal. B. Shaft sleeves and bushings, as required for the proposed shaft seals, shall be of suitably hardened stainless steel materials in accordance with the Bidder's standard construction for the specified service. Materials shall be free of galling tendencies. C. Shaft seals shall be the cartridge mechanical type with pumping ring and external and internal shaft seal cooling water system. Also, shaft seals shall be designed to withstand the vapor lock tests. D. The jacket cooling water will be supplied from the closed cooling water system. 6.7-15 KHABAT TPP UNITS 1&2 - VOLUME I

6.7.4.2.8 Mechanical type seal water system A. The Bidder shall supply a complete shaft seal cooling water system for each pump. The internal system shall consist of shaft seal cooling water cooler, piping, valves, filter and temperature elements for a complete system. B. The shaft seal cooling water system shall, under all conditions of operation, maintain the outflowing seal water temperature sufficiently below 100 deg.C to prevent flashing. No cold injection water shall flow into the pump. C. The shaft seal cooling water will be cooled by the tube side cooling water. D. The shaft seal cooling water system shall include a magnetic separator or filter that will protect the seals from damage due to solids. The screen shall be of type 316 stainless steel, or approved equal, and shall be of a type that is readily cleaned by flushing. The differential pressure indicating switch for indication of a fouled strainer shall be supplied. 6.7.4.2.9 Couplings The coupling for the boiler feed pump shall be the non-lubricating flexible type. Coupling selection shall consider the vibration and thermal conditions. The coupling service factor shall be not less than two(2). 6.7.4.2.10 Strainers. A. Each boiler feed pump shall be provided with one basket strainer. The Bidder shall supply the suitable fine/coarse mesh size for start up and normal operation and the differential pressure indicating transmitter for indication of fouled. The basket strainer type shall be cross type and pressure drop for normal operation at clean condition shall be less than 0.07 kg/cm2. The basket strainer is suitable to be installed in a vertical pipe run. B. The strainer shall be constructed of stainless steel, and 300lb RFWN ANSI flanges. 6.7.4.2.11 Others A. Each pump, when in the stand-by condition, shall be warmed up to the feedwater temperature of the operating pump before being started. If the Bidder has a developed warm-up system which will provide the optimum design, it shall also be offered. The Bidder shall also submit a procedure for prewarming and post6.7-16 KHABAT TPP UNITS 1&2 - VOLUME I

warming after contract. Any instrumentation required for control and monitoring of warming, such as barrel differential temperature measurement, shall be supplied. B. A hydraulic balancing drum shall be capable to operate any condition and furnished with local pressure indicator and additional tap. The axial thrust of the rotor shall be carried by balance drum and external oil lubricated thrust bearing. The Bidder shall provide the pump speed vs balancing drum leak off outlet pressure and tie in point pressure with the balancing drum leak off line (New/worn condition). C. All hot surfaces of the pumps shall be insulated. Insulation shall be in removable sections of sheet metal lagging and shall provide a maximum surface temperature of 55 deg.C. The Bidder shall supply the pump bottom side insulation. D. The flow element, cone type meter, with three(3) flow transmitters shall be provided at each cross over line. E. Prior to chemical cleaning of the system, the pump rotor will be removed and a blanking off plate installed around the openings. The Bidder shall design and furnish the blanking off plates and companion gaskets to insure that when the chemical cleaning fluid is pumped through the pump, no leakage will occur into the pump internals. F. The Bidder shall provide complete reverse rotation senor shall provide dry contact to start oil pump and to close discharge valve when reverse rotating. 6.7.4.3 Electrical and instrumentation requirements 6.7.4.3.1 Drivers A. A common motor driver shall be provided for boiler feed pump. B. Motor rated horsepower shall not be exceeded at the specified pump rating by the impellers selected for the service. The service factor may be used infrequently, but it shall not be exceeded by any operating condition that can be developed by the installed impellers. C. The motor for the boiler feed pump shall endure the stress resulting from the cycling operation and shall be designed and manufactured to maintain high reliability during life expectancy. 6.7.4.3.2 Vibration monitoring devices

6.7-17 KHABAT TPP UNITS 1&2 - VOLUME I

A. The Bidder shall provide the vibration monitoring devices consisting of probes with protective housings, extension cables and transducers with housing for accurate, reliable vibration monitoring. B. The radial vibration probes shall be provided with two probes per bearing positioned radially at 90 degrees (X,Y). The dual axial vibration/position probes and keyphaser shall be provided for each pump. C. The Bidder shall provide complete reverse rotation detector to start oil pump and to close discharge valve when reverse rotating. 6.7.4.4 Manufacture 6.7.4.4.1 Fabrication A. Written welding and heat treatment procedures are to be submitted to KNOC for acceptance prior to use. B. Defects that require repair by welding shall be repaired in accordance with the applicable Code. A detailed repair procedure shall be submitted to KNOC for acceptance prior to performing the repair. The procedure shall state the nature and location of the defect, method of repair, welding and nondestructive examination procedure, and subsequent heat treatment. C. All equipment shall be neatly finished and free of burrs and fins. D. All casting surfaces shall meet visual examination acceptance standards contained in MSS SP-55. Impregnated castings are not acceptable. Repair of faulty castings shall be subject to acceptance by the KNOC. E. Interior surfaces shall be thoroughly cleaned of all mill scale, cuttings, oil, weld spatter, and other foreign matter. 6.7.4.4.2 Materials A. For the specific materials identified in the following list, the base bid shall be predicated on their use and guaranteed by the Bidder to be suitable for the service intended. The Bidder may bid alternative materials of equal or superior properties for KNOC's consideration. B. Materials for the pumps shall be as specified below (ASTM Designation) 1) Outer casing, Barrel

Forged 0.25% Carbon Steel with Overlay of Stainless Steel.(A105or Equivalent)

2) Inner casing or Volute 13% Chrome Stainless Steel (A743 Grade CA6NMor Equivalent) 3) Impellers

13% Chrome Stainless Steel 6.7-18 KHABAT TPP UNITS 1&2 - VOLUME I

(A743 Grade CA6NMor Equivalent) 4) Shaft

13% Chrome Stainless Steel (A276 Type410 or Equivalent)

C. The Bidder shall identify the materials used at all interface connections and on major parts as to the ASTM Specifications, or equivalent code. 6.7.5

High pressure feedwater heaters

6.7.5.1 Design condition 6.7.5.1.1 Type of Feedwater Heater All feedwater heaters shall be of the horizontal shell and U-tube design with integral drain cooling zones. The high pressure heaters shall also be equipped with integral desuperheating zones. 6.7.5.1.2 Tubeside velocity The maximum water velocity through the tube shall be in accordance with the Heat Exchange Institute Standard at the normal full load operating conditions and shall not exceed 3 m/sec(10 ft/sec). 6.7.5.1.3 Temperature changes The feedwater heaters shall be designed to ensure continuous, safe and economical operation providing the maximum reliability under the instantaneous temperature drop from normal condition inlet temperature to saturated temperature corresponding to deaerator pegging steam set pressure and to endure the inlet temperature changes on various load change cycles. 6.7.5.1.4 Nozzle and support loads Supports for the feedwater heaters shall be capable of withstanding the loads and moments calculated by the Bidder in addition to normal loads and moments and shall provide for transfer of loads to building structure by positive means. 6.7.5.1.5 Overload and abnormal conditions A. The feedwater heaters shall be capable of operating at the overload and abnormal conditions as specified below without malfunction or damage to the heaters. The Bidder shall determine the effects of removing heaters from service and provide for those effects in the heater designs. 6.7-19 KHABAT TPP UNITS 1&2 - VOLUME I

The Bidder shall supply calculations and complete Technical Data form for abnormal conditions in bid data form. B. Abnormal condition occurs when heaters are bypassed. Extraction steam flows and drain flows of heaters in service proportionally increase, based on heater performance, over design flows. Extraction steam pressure will be increased. 6.7.5.1.6 The Bidder shall perform a life time cycle fatigue analysis for the high pressure heaters based on all conditions and the unit mode of operation. The cycle service life for the following conditions shall be determined: - Hot start and regular shutdown - Warm start and regular shutdown - Cold start and regular shutdown - Turbine trip and hot restart 6.7.5.2 Performance requirements The Bidder shall design that all equipment and materials will comply with all applicable code. The following performance of each feedwater heater shall be specifically satisfied. A. Terminal temperature difference B. Drain cooler approach C. Tube side pressure drop D. Shellside pressure drop 6.7.5.2.1 Performance in accordance with all specified conditions without excessive noise and vibration, overheating or physical damage to the equipment. The heaters shall be operable under the rapid starting or load changing conditions without any limitation. 6.7.5.3 Design features 6.7.5.3.1 The feedwater heaters shall be designed in accordance with the requirements of ASME Section VIII, HEI standards and this specification. The feedwater heaters shall conform to ASME Section VIII Division 1 rules and the fatigue analysis for high pressure heaters shall conform to Division 2 rules. The feedwater heaters shall be designed, certified and documented in accordance with code. 6.7.5.3.2 Shells A. The high pressure heaters 5, 6 & 7 shall have removable shells.

6.7-20 KHABAT TPP UNITS 1&2 - VOLUME I

B. Feedwater heaters shall be equipped with fixed supports at the channel and wheels or roller supports for the removable portion of the shell. C. All heaters shall have welded shell-to-tube sheet or shell- to-shell skirt joints. Shell covers shall be welded to the shells. Feedwater heaters with welded shell-to-tube sheet or shell-to-shell skirt joints shall be provided with a cutting line. Cutting lines shall be clearly indicated on the heater shells and cutting line location shall be shown on Bidder's drawings. A minimum 200 mm(8") wide stainless steel flame protecting band shall be provided around the tube bundle beneath the shell cutting line. D. A shell corrosion allowance of 1.6 mm(1/16") minimum shall be used. E. Lifting and pulling lugs shall be furnished with each heater. All lifting lugs shall be adequately sized for the empty weight of the heater. F. Integral drain cooling zones shall be designed to allow satisfactory operation with a minimum level variation of condensate in the heater shell for both normal and abnormal conditions. On all heaters with integral drain coolers, a separate high level drain outlet bypassing the drain cooler section located in the condensing section of the heater shell and having at least the same capacity as the normal drain, shall be provided. Separate and independent level-sensing instrumentation connections shall be provided for normal level, high level and emergency high level. The normal heater drain outlet from the drain cooling section shall be sized for the drain flow that occurs with maximum tube side flow. G. Adequately sized venting orifices for removal of noncondensable gases shall be provided. Air vent limiting orifices for each heater shall be provided and will be installed in the external piping. 6.7.5.3.3 Channels A. The channel heads shall be either one of the following three types : hemispherical head; elliptical head; bolted removable cover, full access head at Bidder's option. Channels shall be integral with the tube sheet or welded to the tube sheet. B. Heater channels(except for flat plate bolted cover type) shall be equipped with minimum 457 mm(18") ID circular manways, or elliptical manways with a minimum of 457 mm(18") ID major axis. Channel heads shall be of such configuration as to permit plugging of any tube without removing the entire head. 6.7-21 KHABAT TPP UNITS 1&2 - VOLUME I

6.7.5.3.4 Tubes A. Tubes for heaters 5, 6 & 7 shall be rolled full depth into the tube-sheet and welded to the stainless steel clad tube sheet. The tubes for the high pressure heater shall be ASTM A-213 Type 304N or equivalent. The Ubend portion of these tubes shall be solution annealed after bending and cleaning in accordance with ASTM A688. B. Tube plugging, following hydrotest due to tube failure during hydrotest and when location is either inaccessible or impractical for replacement as permitted by the HEI Standard, shall not compromise heater performance. The Bidder shall state the maximum percentage of tubes that can be plugged and still meet the specified heater thermal performance conditions. C. All internal tube side heater surfaces will be chemically cleaned in the field prior to operation. The Bidder shall recommend the suitable cleaning solution. The heaters shall be designed for exposure to this solution, ease of flushing and cleanout of residue. 6.7.5.3.5 Tube sheets A. High pressure heater tube sheets shall be ultrasonically tested to ASTM A-388 requirements. Tube sheets for the high pressure heater shall be provided with stainless steel cladding. The tube sheet, if forged, shall have been machined sufficiently to remove any skin effect prior to applying the cladding material. The stainless steel cladding shall be applied to the tube sheet by weld overlay in accordance with ASTM A-264. The overlay shall consist of Type 309L stainless steel for first layer and type 308L for the second layer. Roll bond cladding is not acceptable. The Bidder shall submit his procedure for applying the weld overlay for The KNOC's review.

After

the overlay material is applied, the tube sheet shall be stress relieved. Then the cladding shall be machined to a minimum thickness of 6.4 mm (1/4"). B. Welding, rolling procedures and joint configuration are subject to approval by KNOC. 6.7.5.3.6 Tube support plates and baffles A. Tube support plates shall be spaced to prevent vibration induced damage to tubes during all operating conditions.

6.7-22 KHABAT TPP UNITS 1&2 - VOLUME I

B. Support plate tube holes shall be deburred, with edges "broken"(or slightly chamfered) on both sides. C. Larger diameter tube bundles shall be provided with support plates, or their equivalent, at the U-bends. D. Impingement baffles of stainless steel shall be provided opposite all nozzle connections where impingement of steam or water might cause erosion of tubes. Baffles shall be designed to preclude transmission of vibration to the tubes and also to protect the tube bundle from rebound. Where necessary all impingement baffles shall be attached to the shell or appropriate parts with full penetration welds and liquid penetrant tested in accordance with Appendix VIII of ASME B & PV Code SEC. VIII. 6.7.5.3.7 Connections A. In addition to the normal connections provided for steam inlet, drains, vents, feedwater inlet and outlet, the heaters shall be provided with connections for level controls, level alarms and indicators, chemical cleaning,

pressure

and

temperature

instrumentation,

nitrogen

blanketing, HEI and ASME test taps as required. B. All connections shall be oriented radially and all connections for heaters except for the shell side safety relief valves acid cleaning nozzle shall be welded. Connections 65 mm(2-1/2") and larger shall be butt welded unless this specification states otherwise. Connections 50 mm(2") and smaller shall be socket welded. C. The shell side safety relief valve connections shall be flanged. The tube side safety relief valve connections shall be socket-welded type. D. The incoming drain connection to heaters shall enter the next heater shell on horizontal center line at the U-bend end, beyond the tube bundle. Stainless steel baffles shall be provided to protect the U-bend in the flash chamber. E. All connections shall extend beyond the insulation thickness. 6.7.5.3.8 Accessories F. The Bidder shall size a connection and provide a heavy duty thermal relief valve to protect the tube side of the feedwater heater. Valve size, type, and material shall comply with ASME and HEI Code requirements.

6.7-23 KHABAT TPP UNITS 1&2 - VOLUME I

G. The Bidder shall size a connection and provide safety relief valves to protect the shell against tube breakage in accordance with the HEI Standards, Paragraph 6.1.2. H. Safety relief valves shall be shop tested, set and tagged. The minimum tag information shall include identification number, set pressure and accumulation. 6.7.5.3.9 Materials All materials used in constructing the equipment to be furnished, but which are not specifically indicated in this specification, shall conform to HEI requirements, shall be the most suitable for the service intended and shall be subject to approval by KNOC. Material certifications of all materials tests for chemical analysis and mechanical properties of the tubes, tube sheet, channel, and shell shall be furnished to KNOC for review. A. Carbon steel plate : ASTM A-516 Grade 70, ASTM A-283 Grade C for pressure containing parts, ASTM A-36 for nonpressure containing parts. B. Carbon steel forgings : ASTM A-105 Grade II, ASTM A-266 Class 2 or ASTM A-350 Grade LF2, LF3 or equivalent. C. Tubes : ASTM A213 304N for heaters 5,6,7. D. Impingement plates : ASTM A-240 Type 304L. Internal impingement baffles in drains discharging into the shell shall be austenitic stainless steel. E. Nozzles : ASTM A-106 Grade B or A-335 Grade P11 for all heaters. F. Nozzle Liners : Fabricated stainless steel in accordance with ASTM A240 Type 304, with a maximum carbon content of 0.03 percent. G. Orifice plates : ASTM A240 Type 316L H. Gaskets : Carbon steel, metal jacket type for heaters 5,6,7. I.

The use of copper alloys in any part of the units is not acceptable.

J. The material of shroud and baffles for heaters 5,6,7 desuperheating zone shall be selected considering the high temperature and high pressure steam. 6.7.5.3.10 Manufacture Refer to LP heater's section(Same as that of LP heater)

6.7-24 KHABAT TPP UNITS 1&2 - VOLUME I

6.7.6

Instrumentation and controls A. The Bidder shall design and supply all instrumentation and controls so as to insure accurate, safe and reliable operation under conditions of service. B. The Bidder shall design the feed water system to be started, stopped, controlled and monitored by the PCS. C. Instrumentation and controls shall be designed in accordance with the section 8 of this technical specification. D. Dual redundant instruments shall be supplied for following applications as a minimum. 1) Feedwater storage tank temperature transmitter : 2 2) BFP suction temperature transmitter : 2/pump 3) BFP suction pressure transmitter : 2/pump 4) BFP suction flow transmitter : 2/pump 5) BFP discharge pressure transmitter : 2/pump 6) Economizer inlet feedwater pressure transmitter : 2 7) Economizer inlet feedwater flow transmitter : 2 8) Feedwater storage tank level transmitter : 2 9) Feedwater Heater Level Transmitter : 2/heater E. The Bidder shall provide designated instrument type for the following BOP process. 1) HP heater and FW storage tank level transmitter : differential pressure type 2) HP heater, FW storage tank level gauge : magnetic type

6.7-25 KHABAT TPP UNITS 1&2 - VOLUME I

6.8

Main and Reheat System

6.8.1

System Description

6.8.1.1 The main steam and reheat steam system transfers steam from the steam generator to the turbine-generator. 6.8.1.2 The main steam and reheat steam system consists of the main steam system, the cold reheat steam system and the hot reheat steam system, including each instrumentation and controls. A.

The main steam system starts from the superheater outlet nozzles of the steam generator through [1] main steam lines. The main steam lines, which are separated to [2] lines near the main steam stop valve, are connected to the main steam stop valve inlets.

B.

The cold reheat steam system starts from the [1] exhaust lines of the high pressure turbine and are connected to the 1st stage reheater inlet header of the steam generator.

C.

The hot reheat steam system starts from the [1] lines of the last stage reheater outlet and the hot reheat steam lines, which are separated to [2] lines near the reheat steam stop valve, are connected to the hot reheat steam stop valve inlets.

D. 6.8.2

Drain line with MOV, bypass line and steam trap.

System design criteria

6.8.2.1 General 6.8.2.1.1 Main and hot reheat steam lines and other lines with special schedule use the pipe bends with minimum radius of five (5) diameters. The pipe bends with radius of three (3) diameters shall be used for convenient pipe routing so long as they don't affect the system or equipment. 6.8.2.1.2 The main and hot reheat steam temperature at the steam generator discharge is 541/541 ℃. 6.8.2.1.3 The nozzle load of pipes connected to each equipment shall be designed within the allowance provided by the equipment Tender. 6.8.2.1.4 For the preparation of a long-term shutdown, the main and reheat steam system shall be designed so that inert gas blanketing or wet lay-up might be available.

6.8-1 KHABAT TPP UNITS 1&2 - VOLUME I

6.8.2.1.5 Drains and vents Proper drainage and venting of the steam lines is essential during startup to prevent accumulation of water in these lines. The design criteria for drain line and drain pot sizing and venting system of main and reheat steam system shall be described in the Design Criteria for Main and Reheat Steam System. A.

The main steam piping shall be designed with adequate drainage to prevent water entering the turbine.

Danger of water entering the turbine

from the main steam piping is greater during startup or shortly after shutdown of a unit because of steam condensation. B.

A drain shall be installed at each low point of main and reheat steam system

C.

All the drain lines and drain pot of main and reheat steam system shall be sized adequately according to applicable code.

D.

The power-operated drain valves open automatically on turbine trip and can also be remotely operated from the control room.

E.

The drains arrangement must satisfy the turbine water induction prevention requirements of ASME Standard No. TDP-1.

F.

The automatic venting system for start up shall be installed to warm up the main and reheat steam line in front of each turbine stop valve.

6.8.2.2 Main steam system 6.8.2.2.1 Main steam design pressure shall be matched with turbine and boiler design pressures so that steam generator safety valves may protect main steam piping in accordance with ASME Boiler and Pressure Vessel Code and ASME B31.1. 6.8.2.2.2 Component description A. Flow rate

: Flow rate calculated with the heat balance diagram at valve wide open

B. Design pressure

: Pressure calculated per ASME B31.1 Paragraph 122.1.2(A.4)

C. Design temperature

: Temperature range recommended by the

Steam

generator

and

turbine

generator D. Maximum flow velocity

: About 60 m/s against the noise and vibration (Design 50 m/s) 6.8-2 KHABAT TPP UNITS 1&2 - VOLUME I

E. Pressure drop

: Pressure drop designed for 95% of the pressure

differential

between

the

steam generator superheater outlet design pressure and the turbine main stop valve inlet design pressure F. Pipe material

: ASME SA-335, Gr. P91

6.8.2.3 Cold reheat system 6.8.2.3.1 Piping The cold reheat system shall be designed to transport the cold reheat (CR) steam from the high pressure turbine exhaust to the steam generator reheater. Connections shall be provided on the CR piping for blowing out all foreign materials after piping installation. A reheat hydro-test isolating provision(blind flange) may be provided in the CR piping for isolating the HP turbine exhaust during hydrostatic-testing of the reheat system. 6.8.2.3.2 Component description A. Flow rate

: Flow rate calculated with the heat balance diagram at valve wide open

B. Design pressure

: The higher of the two values of : 1.15 times

the

high

pressure

turbine

exhaust pressure based on valve wide open heat balance diagram and 1.15 times the pressure due to fail-open condition of the high pressure turbine bypass valve. Full vacuum condition also to be considered as a design parameter. C. Design temperature

: Temperature range recommended by steam generator and turbine vendors

D. Maximum flow velocity

: 75 m/s (Design 40 m/s) The system shall be designed such that it is not damaged due to transient forces caused by steam or saturated water. 6.8-3 KHABAT TPP UNITS 1&2 - VOLUME I

E. Pressure drop

: The system shall be designed for about 40% of the pressure drop between high pressure turbine exhaust and intermediate pressure turbine inlet. The pressure drop to be calculated based on heat balance diagram at valve wide open and with safety margin of 5%, excluding the pressure drops due to reheaters and the turbine exhaust check valves.

F. Pipe material

: ASTM SA-335, Gr. P11

6.8.2.4 Hot reheat system 6.8.2.4.1 Piping The hot reheat system piping shall be designed to convey hot reheat system steam from the steam-generator reheater outlet to the T-G Combined Reheat Valves(CRV) for all flows from startup to maximum load conditions through a double header system. The reheat valve assembly shall be supplied by the turbine manufacturer as a combination of a strainer and two valves in series, an intercept valve (IV) and a reheat stop valve(RSV). The IVs and RSVs provide a double line of protection. The reheat valve assemblies pass steam into the intermediate pressure turbine.

Reheater stop valves close on turbine trip and intercept

valves modulate after the trip to prevent turbine overspeed. 6.8.2.4.2 Component description A. Flow rate

: Flow rate calculated with the heat balance diagram at valve wide open

B. Design pressure

: Pressure not less than the lowest setting pressure of the reheater safety valve and to be considered full vacuum condition as a design parameter

C. Design temperature

: Temperature range recommended by the

Steam

generator

and

turbine

vendors D. Maximum flow velocity

: 100 m/s (Design 55 m/s) 6.8-4 KHABAT TPP UNITS 1&2 - VOLUME I

E. Pressure drop

: The system shall be designed for about 60% of the pressure drop between high pressure turbine exhaust and intermediate pressure turbine inlet. The pressure drop to be calculated based on heat balance diagram at valve wide open and with safety margin of 5%, excluding the pressure drops due to reheaters and turbine exhaust of check valves.

F. Pipe material

6.8.3

: ASME SA-335, Gr. P91

Instrumentation and controls A.

The Tender shall design and supply all instrumentation and controls so as to insure accurate, safe and reliable operation under conditions of service.

B.

The Tender shall design the main and reheat steam system to be controlled and monitored through the PCS.

C.

Instrumentation and controls shall be designed in accordance with the section 8 of this technical specification.

D.

Redundant instruments for system shall be supplied for following applications as a minimum. 1) Main steam line temperature transmitter : 2 2) Main steam line pressure transmitter : 2 3) Cold reheat line temperature transmitter : 2 4) Feedwater Heater Level Transmitter : 2/heater

6.8-5 KHABAT TPP UNITS 1&2 - VOLUME I

6.9

Feedwater Heater Extraction, Drain and Vent System

6.9.1

System description The function of this system is to provide partially expanded steam from the turbines to the feedwater heaters in order to heat the feedwater entering the boiler for the purpose of increasing the thermal efficiency. A. Extraction steam The function of heater extraction system provides expanded steam from a number of stages of the turbines to low pressure and high pressure feedwater heaters. B. Heater drains The function of the heater drain system is to drain the condensate from the feedwater heaters to the next lower heaters or condensers. C. Heater vents The function of the heater vents system is to vent the air and noncondensable gases from the heater shells and channel to the deaerator, condenser or release to atmosphere. D. Pressure relief system The function of the pressure relief system is to protect the feedwater heaters from the over pressurization. Feedwater heater extraction steam vents and drains system consists of : extraction steam system, heater drains system, heater vents system and pressure relief system. The system design scope includes above items along with the associated piping, valves, instrumentation and controls.

6.9.2

System design criteria The design capacity of feedwater heater extraction, drain & vent system is based on the steam flow at turbine valve wide open (VWO) load. Design of the extraction steam system should be in accordance with ANSI/ASME TDP-1, "Recommended Practices for the Prevention of Water Damage to Steam Turbines Used for Electric Power Generation" to protect turbine damage caused by water induction. Feedwater will be heated 7-step feedwater heater composed of 3-step low pressure feedwater heaters, deaerator and 3-step high pressure feedwater heaters. All feedwater heaters excluding deaerator are equiped with internal drain coolers. 6.9-1 KHABAT TPP UNITS 1&2 - VOLUME I

Serial numbering of feedwater heaters shall be from low pressure feedwater heaters to high pressure feedwater heaters. That is, the lowest feedwater heater is No.1 and the highest feedwater heater is No.7. Feedwater heaters from No.1 to No.7. have one feedwater heater with capacity of 100% each. Design pressure for shell side of feedwater heaters is the pressure at heat balance VWO plus 15% margin considering the pressure fluctuations like misstaging of turbine. Also full vacuum should be considered. Design temperature of closed feedwater heaters shall be determined by HEI standards. Design temperature of deaerator shall be the maximum temperature between pegging steam temperature and normally supplied steam temperature. TTD (Terminal Temperature Difference) and DC (Drain Cooler Approach) of feedwater heaters will be as follows based on heat balance at VWO condition. Items No.1 ~ No.3 Feedwater Heater No.4 Feedwater Heater (Deaerator) No.5 & No.7 Feedwater Heater No.6 Feedwater Heater 6.9.3

TTD

DC

1.67 ℃ (3℉)

5.6℃ (10℉)

0℃ (0℉)

-

-1.67 ℃ (-3℉)

5.6℃ (10℉)

0℃ (0℉)

5.6℃ (10℉)

Extraction steam system

6.9.3.1 Design parameters A. Flow rate : Valves wide open heat balance flows. B. Design pressure : Extraction pressure from VWO, heat balance times 1.15, but not less than 3.5 kg/cm2(g). Also considering full vacuum condition in design. C. Design temperature : Steam temperature corresponding to design pressure based on the VWO heat balance with 15% margin. D. Maximum steam velocity : 75 m/s E. Maximum Allowable pressure drop (from turbine stage outlet flange to heater inlet nozzle) of feedwater heater extraction steam piping shall not exceed 5% pressure of turbine extraction steam point F. Extraction steam line size 6.9-2 KHABAT TPP UNITS 1&2 - VOLUME I

a) Steam velocity of extraction steam line shall not exceed 75 m/s. b) Design pressure drop shall be based on 90% of available pressure drop. 6.9.3.2 Bleeder trip valve Bleeder trip valve shall be installed in the extraction steam lines of feedwater heaters (Except No.1 heaters). Bleeder trip valves shall be in accordance with the recommendation of turbine manufacturer. 6.9.3.3 Shut-off valve of extraction steam line Shut-off valves shall be installed in the extraction steam line of feedwater heaters (Except No.1 heaters). Shut-off valve shall be installed to protect water induction to turbine, for which motor operated shut-off valves shall be installed. 6.9.3.4 Drain piping and valves for extraction steam lines Drain piping connected to condenser shall be installed in extraction steam lines to drain the extraction steam lines. Drain valves shall be operated through main control room, and shall open automatically when the turbine is tripped and bleeder trip valves of extraction steam lines are closed. 6.9.3.5 Extraction steam piping Extraction steam piping will be routed and supported in such manner as to provide for thermal expansion and to maintain end reaction forces and moments within allowable limits. All low pressure extraction piping inside the turbine exhaust hood will be provided with sleeved stainless steel bellow expansion joints. Extraction steam piping installed inside the condenser shell shall be fixed at the condenser shell. 6.9.4

Drain system All the necessary drains from pipework, steam chests, turbine cylinders etc, shall be led separately by gravity to a flash vessel discharging to the condenser through a system of continuously falling drain pipes, valves and orifices. Drain vessels shall be designed in accordance with PD 5500 or equivalent internationally recognized standard. The design and operation of the drains system shall ensure that during start6.9-3 KHABAT TPP UNITS 1&2 - VOLUME I

up air is not introduced into the condenser. Drains that are normally at atmospheric pressure during start-up shall be vented to atmosphere via the atmospheric drains vessel. The drains vessel and valves shall be located for ease of access and maintenance. Each drain shall be provided with a remote temperature indication monitored upstream of each drain control position. The temperature indications shall be displayed on a suitable PCS format in the CCR. Drain cooling/desuperheating sprays shall be provided as appropriate in the drains flash vessel. 6.9.4.1 Design parameters A. Drains : The following two kind of drains shall be provided : primary drains to next lower pressure feedwater heaters and emergency drains to condenser hotwell. In low pressure feedwater heater drain system feedwater heater drain pump shall not be installed. B. Design pressure : Feedwater heater shell side design pressure (upstream of control valve) C. Design temperature : Based on VWO, heat balance D. Flow velocity : Within the 2.5 m/s (upstream of control valve) E. Control valve type : Two valves in series shall be provided for each operational drain, the upstream or isolating valve being of the parallel slide type and lockable in the open position. The downstream or regulating valve shall be preferably of the globe type. All drain valves shall be conveniently grouped together where practicable. Regulating drain valves shall be motorized to aid automatic plant operation. F. Control valve capacity 1) Primary drain valves : VWO heat balance flow at a nominal 80% valve travel. Valves to be suitable for control at minimum flow at which cascading to next lower pressure heaters is still possible. 2) Emergency drain valves : The emergency drain control valves (drains to condenser) shall be capable of handling, with valves in fully open position, the total drain flow with one (or more, as required) upstream heaters out of service. G. Control valve size : Valve body size shall not be less than nominal pipe size which is one step smaller than inlet pipe size. H. Location of control valves

6.9-4 KHABAT TPP UNITS 1&2 - VOLUME I

1) Primary drain valves shall be installed near the inlet nozzle of the next lower feedwater heaters in order to minimize the piping connections affected by flashing. 2) Piping affected by flashing in the direction changes more than 45† between primary drain valves and feedwater heaters shall have tee fittings having the blind flange on one side. 3) Emergency drain valves shall be installed near the inlet nozzle of condensers and inline to minimize the piping area affected by flashing. 4) Piping installed between emergency drain control valves and condensers shall not have any vents. I.

Block valves: Block valves shall be installed at the upstream and downstream of primary drain valves and emergency drain valves, but bypass valve shall not be installed. During the operation of feedwater heaters, one of the primary drain lines and emergency drain lines must be used for drain.

6.9.5

Vent system A. System design 1) Follow the recommendation of feedwater heater manufacturer 2) Noncondensable gas of high pressure feedwater heaters shall be drained to deaerator or condensers through the flow restriction orifices, and noncondensable gas of low pressure feedwater heaters shall be drained to condensers through the flow restriction orifices. 3) If the vacuum ratio of condenser is normal, noncondensable gas of deaerator shall be drained to condenser but in abnormal conditions the noncondensable gas shall be drained to atmosphere though the orifices in each case. 4) All heaters except deaerator and No.1 heaters shall be provided with vent lines which will be used during start-up operations only. B. Maximum flow velocity : Within the 40 m/sec C. Design pressure : Feedwater heater shell side design pressure D. Design temperature : Feedwater heater shell side design temperature E. Shell side vent size: The shell vent line will be sized for venting approximately 0.5 percent of the extraction steam entering the heater.

6.9-5 KHABAT TPP UNITS 1&2 - VOLUME I

6.9.6

Pressure relief system Feedwater heater relief valve capacity : Relief valve shall be designed in accordance with hydraulic institute standards and considering the condition of upstream drain valve trouble. Deaerator shell side relief valve :Relief valve shall be designed considering the problems caused by the following valves : valve for pegging steam, drain valves for No.7 Feedwater heater and drain valves for feedwater storage tank.

6.9.7

Instrumentation and controls

A. The Bidder shall design and supply all instrumentation and controls so as to insure accurate, safe and reliable operation under conditions of service. B. The Bidder shall design the main and reheat steam system to be controlled and monitored through the Plant PCS. C. Instrumentation and controls shall be designed in accordance with the section 8 of this technical specification unless otherwise specified in this section.

6.9-6 KHABAT TPP UNITS 1&2 - VOLUME I

6.10

Auxiliary Steam System

6.10.1

System description During normal operation, the auxiliary steam requirements of the plant will be supplied from an operating boiler. The auxiliary steam supply system shall be arranged to have sufficient redundancy and isolation points to enable maintenance of any valve or other component in the system to be carried out safely without requiring the shut-down of the Unit. The function of the auxiliary steam system is to provide a supply of low pressure superheated steam for various plant uses, as required, during plant operation. Auxiliary steam is supplied from the cold reheat system, the steam generator superheater outlet and auxiliary bolier. The primary source depends on the operating mode of the plant and the load carried on the unit.

6.10.2

System design criteria

6.10.2.1

General description A.

Auxiliary steam header consists of [9]bar.g of superheated steam.

B.

During shutdown of the one unit, auxiliary steam header should be supplied the steam from other unit connecting cross tie between other units.

6.10.2.2

Facilities to be provided auxiliary steam A.

Auxiliary steam header supplies to the following services : 1) Turbine gland steam seal system 2) Deaerator pegging 3) Boiler, EP, Ash handling system 4) Atomizing steam 5) Fuel tank heating 6) Water treatment system 7) Aux. steam header by other unit 8) Miscellaneous outside building steam supply 9) All other equipment as identified in auxiliary steam

6.10-1 KHABAT TPP UNITS 1&2 - VOLUME I

B.

Maximum flow velocity 1) Superheated steam piping - 25 ~ 200 mm - More than 200 mm

: 45 ~ 76 m/s : 76 m/s

2) Saturated and wet steam piping (More than 1.75 bar.g) - 25 ~ 200 mm - More than 200 mm

: 30 ~ 48 m/s : 40 m/s

3) Saturated and wet steam piping (Less than 1.75 bar.g) - 25 ~ 200 mm - More than 200 mm 6.10.2.3

: 18 ~ 31 m/s : 31 m/s

Pressure control valve shall be provided to control pressure of steam supply from superheater outlet or cold reheat line.

6.10.2.4

Flow control valve and shut-off valve shall be provided to control flow of process steam supply to other site and to protect disturbance flow from other site abnormal condition.

6.10.2.5

Check valves shall be provided in the superheater aux. steam outlet header and in the cold reheat system aux. steam supply line in order to prevent aux. steam from entering the main boiler when it is shutdown.

6.10.2.6

Desuperheaters shall be provided in the line from main header to process steam line and required lines in order to reduce the aux. steam temperature to be compatible with the design condition of user equipment.

6.10.2.7

Steam flow measuring system shall be provided in the lines between the power plant units and none power plant systems to be monitored by PCS the steam consumption at each usage ends

6.10.2.8

System Operation Requirements A.

Start-up and shutdown The auxiliary steam supplied to the unit during plant shutdown shall come from the aux. steam header of the normal operating unit, or auxiliary boiler.

B.

Normal operation During normal power operation, the auxiliary steam source will changes as plant load changes. This operation will be able to be performed automatically or by operator action from the main control room.

6.10-2 KHABAT TPP UNITS 1&2 - VOLUME I

C.

Capacity : Operating requirements of "user" system plus 10% spare capacity for possible future use.

D.

Design pressure and temperature 1) Design pressure

: [20] kg/cm2.g

2) Design temperature

: Correspond to design pressure and

enthalpy supplied steam Instrumentation and controls

6.10.3 A.

The Bidder shall design and supply all instrumentation and controls so as to insure accurate, safe and reliable operation under conditions of service.

B.

The Bidder shall design the auxiliary steam system to be started, stopped, controlled and monitored through the Plant PCS.

C.

Instrumentation and controls shall be designed in accordance with the section 8 of this technical specification unless otherwise specified in this section.

D.

Two or triple redundant instruments for BOP shall be supplied for following applications as a minimum. 1) Aux. steam header pressure transmitter : 2 2) Aux. steam header temperature : 2

6.10-3 KHABAT TPP UNITS 1&2 - VOLUME I

6.11

Closed Cooling Water System

6.11.1

Extent of work A closed circuit cooling water (CCW) system shall be provided as part of the Works, to supply treated demineralized cooling water to the coolers associated with the plant.

The closed circuit cooling system shall be cooled

by the primary cooling water system, the closed circuit system receiving and discharging cooling water to the supply and return side of the main condenser. The scope of work for the closed circuit cooling water system comprises the complete system design and all related piping and equipment within the limits defined herein. It is not the intent to specify all details of design and construction, however, the main system components described below shall be provided, including, but not limited to: A. Two (2) 100% CCW heat exchangers for two(2) units B. Two (2) 100% CCW pumps for two(2) units C. One (1) CCW header tank with its related pipe work, valves and fill water connection for two(2) units D. Chemical pot feeders complete with inlet and outlet isolation valves, drain valve, vent valve and charging valve. The scope of supply includes all secondary coolers and related piping, valves and

operators,

hangers

and

supports

including

secondary

steel,

instrumentation and controls, miscellaneous equipment and piping specialities for the system. 6.11.2

General requirements The design, manufacture, installation and test of the materials, equipment and work shall be in accordance with all applicable HEI Codes and with the requirements of the Specification. All materials used in the system shall be suitable for use with river water and/or inhibited demineralized water as applicable throughout the full generating temperature range of the system. The demineralized water shall be dosed with a suitable corrosion inhibitor. 6.11-1 KHABAT TPP UNITS 1&2 - VOLUME I

The system shall include all instrument, vent and drain valves and pipework to suitable disposal points as approved by the KNOC. 6.11.3

System description The CCW system shall provide the cooling requirements for the auxiliary plant and equipment. The system shall be designed to ensure satisfactory distribution of water at the required temperature to all CCW users, and the coolers shall have sufficient capacity to dissipate the total heat generated with the plant operating at peak load at the maximum operating temperature. The CCW system design shall be capable for providing cooling requirements for all plant. The closed circuit cooling water system shall be arranged such that during normal operation, the cooling water cycle shall be supplied by one (1) operating (100%) cooling water pump circulating treated demineralized water through one (1) operating (100%) heat exchanger to all equipment consumers requiring a cooling medium for their operation. Either cooling water circulating pump should be able to operate with either heat exchanger. The header tank shall be located above the highest elevation of the closed circuit cooling water system, and shall be connected to the pump suction return pipelines. A make-up line shall be supplied to the header tank from the demineralized water supply system. The Tender shall provide valved connections on the CCW system for the introduction of a corrosion inhibitor into the system and for the downstream sampling of the cooling water. ‘Oil in water’ monitors shall be provided in the closed circuit cooling water returns and alarmed to the PCS.

6.11.4

System operation The first (duty) cooling water pump shall be started either automatically or manually via the PCS after the main cooling water flow has been established through one (1) of the cooling water heat exchangers.

The second

(standby) pump shall be started automatically on low flow in the cooling water supply header or on trip of the duty cooling water pump motor. An alarm shall 6.11-2 KHABAT TPP UNITS 1&2 - VOLUME I

be provided to announce automatic starting of the second (standby) pump. The auxiliary coolers shall be supplied with a manual flow control valve (with locking device) which shall be set during system commissioning and adjusted, as required thereafter, to give the required cooling water flow from the constant pressure source in the supply feed. These valves shall not be used as isolation valves. 6.11.5

CCW pumps Two (2) 100% capacity circulating water pumps shall be provided for the CCW system. The pumps shall be of the centrifugal, horizontally mounted, single stage, split casing type designed to give the specified output against all losses, including those relating to the pump. The delivery head of each pump shall be designed to meet the requirements of the closed circuit cooling water system, including a 10% margin on flow and a 5% margin on head. The pumps shall be identical and capable of parallel operation without throttling and as a single unit without cavitation or overload under all operating conditions with the pump characteristics matched to the relevant pipe system network to achieve the highest pump efficiency and reliability. The pumps and piping systems shall be capable of withstanding the transient pressure associated with a rapid closure of the discharge valves of a running pump or of a pump shut down. The Tender shall take all precautions in designing the system to limit system water hammer. The pumps shall have a non-overloading characteristic over the complete range of head and quantity delivered and the drive shall be capable of starting the pumps against a closed valve (ie maximum pump head conditions). The whole pumping unit shall be capable of withstanding, without detriment, reverse rotation to a speed that would occur if the pump were to stop when the differential head was at a maximum and the delivery and/or non-return valve failed to close. The pumps shall be standard units of a reputable manufacturer and shall conform to the requirements of standards as prescribed in the Specifications. Pump performance curves shall be submitted. 6.11-3 KHABAT TPP UNITS 1&2 - VOLUME I

6.11.6

Cooling water heat exchangers Two (2) 100% capacity cooling water heat exchangers shall be provided. Each heat exchanger shall be of the plate type using main circulating water as the cooling medium. The cooling water side shall be designed with low pressure loss so that design flow is achieved with the pressure differential between the supply and return circulating water at its lowest. The CCW heat exchangers shall be designed for satisfactory plant operation over the full range of cooling water temperatures and with a cleanliness factor whose arithmetic mean value is not greater than 0.9 or with a 10% margin on the surface area. Each heat exchanger shall be sized to cool the entire flow from one (1) CCW pump at the calculated temperature differential of the closed circuit before adding the flow margin. The frame of each heat exchanger shall be designed to permit the future installation of a minimum of 20% additional plates. Fouling factors will be as recommended by TEMA. Each heat exchanger shall be designed with the plate pack mounted between a stationary frame plate and a movable pressure plate. The plates shall be compressed by the tightening of longitudinal bolts connecting the moveable pressure plate to the stationary frame plate. The design of the unit shall be such as to enable the plates to be removed for cleaning and inspection without the need to disconnect the supply and return piping. The heat exchangers shall be complete with vents, drains, and all necessary connections, studs and bolts, venting shall be completed without the intermixing of the cooling media. The plates shall be designed for the shut-off head of the cooling water pump plus the header tank static head, rounded up to the nearest 1.0 bar gauge. The plates shall be manufactured from titanium with gaskets of nitrile rubber or other material designed for a life time of not less than 10 years. Two (2) strainers shall be provided, one at the river water inlet to each heat exchanger, in order to protect the heat exchanger from blockage/fouling due to particles within the river water. Each strainer shall include differential pressure indication and alarm, with automatic back flushing (self-cleaning) facility designed to allow uninterrupted 6.11-4 KHABAT TPP UNITS 1&2 - VOLUME I

flow to the heat exchanger. Backwash flow from the strainer shall be returned to the condenser CW outlet pipework. 6.11.7

Cooling water header tank One (1) CCW header tank shall be provided, to ensure a constant inlet head to the circulating water pumps. The tank shall include a make-up water connection from the demi-water supply system, complete with automatic water level control valve and integrating flow meter. The tank shall be equipped with a level indicator and with high and low level alarms. The make-up connection shall be equipped with a flow alarm announcing high make-up flow. The cooling water header tank shall be large enough to compensate for level variations during the start-up (heat up) and shut-off (cool down) of the CCW system and designed to provide for system leakage for a 24 hour duration when the system is at operating temperature. The header tank shall be manufactured from mild steel with a minimum corrosion allowance of 1.5 mm. An overflow shall be furnished, piped via a tundish to the nearest floor or equipment drain, with inspection facility for monitoring flow. The head tank shall operate at atmospheric pressure and shall be located at the highest point in the system.

6.11.8

Chemical dosing The system for corrosion prevention in the CCW system shall be based on the use of an oxygen scavenger and a pH buffer. The operational pH shall be between pH 9.3 and pH 9.5. Other chemical dosing regimes can be offered subject to the approval of the KNOC. Injection of the dosing solution shall be by a bypass pot feeder. Chemical pot feeders shall be of an appropriate size. They shall be complete with inlet and outlet isolation valves, drain valve, vent valve and charging valve. Charging shall be manually through a purpose designed charging funnel. Means of ensuring that the intended volume of dosing solution can be measured shall be included. The position of the pot feeder shall be such that 6.11-5 KHABAT TPP UNITS 1&2 - VOLUME I

the valves are readily accessible. The point of entry into the CCW system shall be such that adequate dilution and mixing of the charge takes place when the valves are operated. 6.11.9

Instrumentation and controls A. The Bidder shall design and supply all instrumentation and controls so as to insure accurate, safe and reliable operation under conditions of service. B. The Bidder shall design the closed cooling water system to be started, stopped, controlled and monitored through the PCS. C. Instrumentation and controls shall be designed in accordance with the section 8 of this technical specification unless otherwise specified in this section. D. Two or triple redundant instruments for system shall be supplied for following applications as a minimum. •

CCWP discharge pressure transmitter : 2

•

CCW tank level transmitter : 2

6.11-6 KHABAT TPP UNITS 1&2 - VOLUME I

6.12

Circulating Water System

6.12.1

General Prior to design the Bidder shall undertake a comprehensive survey and analysis of the intake water source to ensure that all necessary design parameters are accurately defined. The Bidder shall, taking into account all relevant environmental restrictions, establish the optimum location for the intake and outfall, and shall construct appropriate intake and outfall structures complete with all necessary, pumping, filtration and maintenance facilities. The selection of pumps, pipework and valve equipment shall take into account the possible presence of high suspended solid burden in the water. These items shall be specifically designed to withstand erosion arising from the presence of suspended solids over the lifetime of the project. All suspended solids that might otherwise damage or impair the operation of the remainder of the cooling system shall be removed from the make-up water. The cooling water shall be chemically dosed to mitigate biological growth. The Bidder shall undertake sufficient sampling to ensure all system materials shall be suitable for use with the source of make up water. Copper alloys shall not be used in the manufacture of components in contact with cooling water.

6.12.2

System description

6.12.2.1 The primary function of the circulating water system is to provide cooling water to the main condensers for the purpose of condensing the turbine exhaust and L.P bypass steam for reuse in the turbine cycle. In addition, the circulating water system provides cooling water to the closed cooling water heat exchangers for removing heat from various plant components. It also provides cooling to the condenser vacuum pump seal water coolers. 6.12.2.2 The circulating system shall be designed on the basis of recirculated system with cooling towers. An evaporative-type, mechanical-draft cooling tower shall be provided to dissipate the heat to the atmosphere. Bidder is required to show by suitable analysis that his proposed design of circulating system shall meet the circulating requirements of the power station and environmental requirements at all times. 6.12.3

System design criteria

6.12.3.1 The Bidder shall optimize the circulating water system establishing the circulating water flow rate and temperature range. The optimization shall be 6.12-1 KHABAT TPP UNITS 1&2 - VOLUME I

carried out in association with the condenser and steam turbine's design condition. Bidder shall fully demonstrate an economic optimization of the circulating water system and its performance, and its effects on condenser and steam turbine performance and their optimization. 6.12.3.2 The circulating water system shall be designed to ensure that failure of any single plant component does not result in the shutdown of a steam turbine. 6.12.3.3 Common line should be installed between CWP discharge lines so that circulating water can be supplied to all condenser shells during some CWP trip. 6.12.3.4 System design and pump control system should be designed so as to protect against the peak transient resulting from unit start, stop and trip. 6.12.3.5 Piping design pressure A.

Minimum : Full vacuum

B.

Maximum : Peak transient analysis pressure or 1.5 times of circulating water pump shutoff pressure, which is greater

6.12.3.6 The circulating water pump shall be used to circulate water through the main condenser, which services a turbine-generator unit, for the transfer of waste heat to the heat sink. 6.12.3.7 Condenser tube cleaning system should be operated to maintain cleanness of the condenser tubes. 6.12.3.8 The Bidder shall provide the following information. A.

Details of the system resistance (head & flow) for all possible flow and operational configurations and variation in pump suction levels.

B.

System water velocities.

C.

System pressure rating.

D.

Detailed hydraulic steady state and transient analyses of the circulating water system shall be carried out during the detail design stage.

6.12.3.9 Component description A.

Circulating water pumps 1) Quantity : Two (2)×50% capacity + 10% margin capacity / unit 2) Type : Vertical mixed flow type or horizontal double suction type

6.12-2 KHABAT TPP UNITS 1&2 - VOLUME I

3) Design

capacity

:

Sum

of

the

flow

requirements

of

the

condenser(VWO condition) and all equipment requiring circulating water. 4) Design Head : The system head based on the highest point on energy gradient including cooling tower. B.

Cooling tower 1) Quantity : One (1)×100% capacity / 2unit 2) Type : Evaporative, Multi-cell mechanical-draft

C.

Condenser tube cleaning system 1) Quantity : Two (2)×50% capacity / unit

D.

Circulating cooling water pumps 1) Quantity : Two (2)×50% capacity + 10% margin capacity

6.12.4

Circulating water pumps

6.12.4.1 Design of condition A.

The pump shall be designed in accordance with the recommendation of the design standard of the Hydraulic Institute Standards. Pumps are required to discharge condenser design cooling water flow when the water level is at the lowest level and the cooling tower basin screens are in maximum allowable foul condition.

B.

For system designs which include pumps in parallel operation each pump shall be capable of continuous operation at maximum run-out condition

C.

The pump head-capacity curve shall be continuously rising from the maximum flow to shutoff.

D.

Pump design pressure shall not be less than the shutoff head.

E.

The first critical speed of the pump shall exceed the operating speed of the pump by at least 25 percent. Critical speed shall include effects of lubrication, bearings and bearing supports.

F.

The pump and motors shall be capable of withstanding without failure such design conditions including reverse rotation due to power failure.

G. The Bidder shall perform the vibration analysis of pump station and shall have responsibility to modify any harmful effect from vibration. The vibration analysis for each pump shall include the analysis for the operating conditions of starting, stopping and trip. H.

Circulating water pumps operation 6.12-3 KHABAT TPP UNITS 1&2 - VOLUME I

1) The pump shall be capable of operating over the complete range with efficiencies as high as possible, and be free of harmful effects from vibration, cavitation, or recirculation. The startup mode shown in curves is of short duration. 2) During startup and/or cold winter season, One(1) circulating water pump shall be taken out of service when not needed. In this case, one(1) circulating water pump shall discharge through a common line to one(1) condenser shell for each condenser shells. 3) The circulating water pump discharge shall be manifolded on the downstream side of the pump, and thus shall be subject to parallel operation. Each pump shall be capable of withstanding the reverse rotational speed caused by the head of the operating pump(s) at its discharge flange if the motor of the pump is deenergized. 4) The pumps and drive motors shall be suitable for continuous operation at any flow from shut off point to maximum runout flow. The Bidder shall state any limitations on the runout flow and shall also state the minimum continuous flow allowable. 5) The Bidder shall be provided the automatic air release valves in the pump's internal surface for the protection of circulating water system whenever the pump discharge conduit is under positive pressure. 6) The system shall include valves at the discharge of each pump and at the inlet and outlet waterbox of each condenser shell. 7) The circulating water pumps shall be started under two modes of system operation. One method of starting shall be when the circulating water system is empty and the adjacent circulating water pumps are not operating. The pumps shall also be started when the circulating water system is full of water and the adjacent circulating water pumps are operating. The circulating water pump starting sequence shall be designed to start the pumps under both modes of operation. a) The method of starting the pumps(with the system either empty or full) shall be as follows : The pump starting sequence shall take into consideration the inertia of the water mass in the circulating water system. The method of starting the pumps shall be designed to minimize the motor torque requirement and to optimize the

6.12-4 KHABAT TPP UNITS 1&2 - VOLUME I

motor efficiency at the pump rated conditions by timing the discharge valve opening with the pump/motor acceleration. b) The method of pump starting shall also be designed to prevent pump or motor damage in the event the discharge valve inadvertently fully opens during startup due to failure of the discharge valve control sequence. The Bidder shall state any limitations on the starting of the pumps in the event of a possible failure of the discharge valve control sequence. c) The starting sequence shall also be designed to prevent damage to the pump and motor during shutdown of the circulating water pumps. The shutdown of the circulating water pumps can occur when the circulating water system is empty and adjacent circulating water pumps are not operating or when the system is full and adjacent circulating water pumps are operating. The Bidder shall describe the required pump discharge valve closing sequence, and the effects if the control sequence fails and the valve becomes inoperative. 6.12.4.2 Design and construction features A.

General 1) The pump shall be designed for disassembly and assembly as they are being withdrawn or replaced in the cooling tower structure. 2) All assembly joints or junctions shall include alignment or centering fits as required to ensure accurate reassembly or alignment of all parts. 3) The pump construction in contact with riverwater shall be designed to avoid crevice corrosion. 4) The assembly such as joints, flanges, bolts and nuts shall be treated with anti-crevice corrosion sealant.

B.

Instrumentation and Controls 1) Field Instrument Requirements a) All dial type pressure indicators and temperature indicators shall be of liquid filled type to protect from vibration of pumps b) Instrument shall be supplied by one(1) recognized manufacturer having wide experience in the manufacture, application as possible. 2) Vibration Monitoring Devices 6.12-5 KHABAT TPP UNITS 1&2 - VOLUME I

a) The Bidder shall provide the vibration monitoring devices consisting of probes with protective housings, extension cables and transducers with housing for accurate and reliable vibration monitoring of pumps. b) The radial vibration probes shall be provided with two probes per bearing positioned radially at 90 degrees (X,Y). The dual axial vibration/position probes and keyphaser shall be provided for each pump. C.

Valve and pipework 1) The circulating water pump discharge valves should be capable of modulation in order to limit surge effects during opening and closing and attention shall be paid to the flow and modulation characteristics. The valves and their actuating equipment shall be capable conditions of CW pressure and flow, including operation against CW pump shutvalve pressure. 2) The CW pump discharge valves shall be arranged to open on remote manual control from the main control room. Consideration shall be given in the design to the rate of valve opening during filing of the discharge line and culverts. Main CW pump inlet valves shall be provided with motor actuators. The rates of closure for the valves shall be determined by the surge study and shall be selected to minimize hydraulic surge and prevent possible damage to the pump resulting from reverse rotation.

6.12.5

Cooling tower system

6.12.5.1 General A.

The cooling tower shall be designed as wet cooling tower.

B.

The cooling water shall be conveyed on both sides of the cooling tower through an appropriately designed inlet pipe to the heat exchanger bundles, where part of the heat is transferred to the cooling air flowing across. The water leaving the bundles flows into the water distribution by pipes and spray assemblies over the cooling fill.

C.

Cooling tower system shall be automatically operated.

D.

Materials containing asbestos shall not be used.

E.

Operation and maintenance of the tower should be as convenient as possible. Particular attention shall be also paid to the arrangement of the 6.12-6 KHABAT TPP UNITS 1&2 - VOLUME I

mechanical equipment(e.g. valves and motors) as well as platforms and workways, etc. F.

For operation in cold-weather, anti-ice formation measures shall be provided to protect the cooling tower and cold water basin from threatening performance and damage so that allow the cooling tower to be safely operated.

G. Anti-fouling type of fill media shall be used in the cooling tower and to minimize windage losses spray eliminators shall be fitted to the cooling tower air outlets. Specific attention shall be paid to the elimination of drift. 6.12.5.2 Structure A.

The cooling tower shall be induced draft type, with multi-cell arranged in one row. It consists of exterior walls, partition walls, fan deck, fan stack, internal and external supporting structures and the water basin.

B.

The fan stack shall be of a divergent type for velocity pressure recovery and shall have a rounded inlet shape to avoid air turbulences.

6.12.5.3 Cooling fill of wet section The heat exchange surface in the wet section shall be of the film flow type. Water shall be distributed above the fill covering the surfaces with a thin film of water.

Heat is transferred to the passing air by evaporation of water from the

film surface.

The cooling fill material shall be capable to withstand water

temperatures up to 60℃ without damage or permanent distortion.

The

cooling fill shall be the best heat transfer possible and minimize the air side pressure loss. 6.12.5.4 Water distribution The hot water shall flow in riser pipes at each side of the cells to the headers of the wet section arranged horizontally along the cell. To these headers distribution pipes shall be connected, which are arranged inside of each cell above the cooling fill. Each distribution pipe shall be equipped with an easily removable sealing cap for cleaning purposes. 6.12.5.5 Spray system At certain distances the water distribution pipes shall be equipped with screwed flanges acting as supports for the sprayers. The sprayers in their spraying arrangement shall ensure a uniform distribution of the water to be cooled. 6.12-7 KHABAT TPP UNITS 1&2 - VOLUME I

6.12-8 KHABAT TPP UNITS 1&2 - VOLUME I

6.12.5.6 Drift eliminator In order to reduce drift losses by entrained water droplets to the maximum possible a drift eliminator shall be arranged above the spray area. 6.12.5.7 Mechanical equipment A.

Axial-flow fans The impellers shall consist of the hub and blades connected to each other by means of clamping bearings. The surface of the steel hubs shall be protected by paint coats depending on their application.

B.

Fan driving motors The electric motors shall be surface cooled three-phase squirrel cage motors and appropriate for the drive of fans. A motor protection and an out-of-service heating shall be installed for application at very low ambient air temperature.

C.

Gearbox (bevel spur gear) The casing shall be of oil and dustproof design.

The shafts shall be

supported by largely dimensioned oil-lubricated anti-friction bearings. The design of the gear surfaces shall allow rejection of the heat produced not requiring the installation of oil cooler. Oil level indicator, drain and filler sockets shall be mounted at the exterior of the fan stack. D.

Drive shaft Power transmission from motor to gearbox shall be effected by means of a torsionally stiff flexible coupling : very long shafts shall be equipped with an intermediate bearing.

If necessary, connection between electric

motor and/or gearbox shall be made by means of flexible couplings. E.

Each cell has its own fan deck which is equipped with vibration monitoring equipment as well as oil-level gauge, temperature sensors, etc.

F.

The fan and other equipment shall be operated smoothly and without vibration.

6.12.5.8 Access to the tower and supporting structures All elevations shall be accessible via stairways and walkways to facilitate inspections and maintenance work.

6.12-9 KHABAT TPP UNITS 1&2 - VOLUME I

6.12.5.9 Piping system The necessary cooling system piping of the tower shall be designed and routed as to ensure a safe operation. Thermal expansion due to varying temperatures shall be compensated for by appropriate expansion joints. 6.12.5.10 Valves A.

The manual valves to isolate individual cells of the cooling tower shall designed as butterfly valves.

Casing and sealing disk and endless

sectional sealing ring shall be provided fastened to the valve disk by means of a retaining ring. The valve shaft shall be made from stainless steel complete with an o-ring sealing of shaft passage. B.

An electric actuator drives the valve through a self-locking gear. The limit switches for open and closed position shall be connected to plant control system(PCS).

6.12.5.11 Cooling tower cold water basin The Bidder shall design the cold water basin and submit the engineering and construction drawing for installation. The size of the storage (between normal and minimum level) must be sufficient for an operation of the system with nominal quantity for 30minutes without make-up water supply. Furthermore, the surge of water level in case of shut-down of all circulating water pumps has to be considered also for the design of the storage (maximum level). The normal level shall be controlled by the make-up water flow into the storage. 6.12.5.12 Chemical injection system A.

A non-chromate corrosion inhibitor, a microbiological growth control and an antiscalant chemical program shall be utilized to avoid corrosion, fouling and scale accumulation in the circulating water system. The chemicals used shall not require post treatment of the circulating water blowdown, and the blowdown shall comply with the applicable effluent water quality standards. The following chemicals shall be used.

B.

Corrosion Inhibitor Non-chromate corrosion inhibitor shall be injected into the circulating water system to control and minimize corrosion of the piping and heat exchangers. The liquid inhibitor shall be fed continuously, by a positive 6.12-10 KHABAT TPP UNITS 1&2 - VOLUME I

displacement metering pump, into the cooling tower basin. Proper inhibitor residual shall be monitored and maintained based on selected vendor's recommendation. C.

Sodiumhypochloride The control of microbiological fouling in the circulating water system shall be

accomplished

by

the

addition

of

sodiumhypochloride.

The

sodiumhypochloride shall be fed continuously, by a positive displacement metering pump, into the cooling tower basin. Dosage shall be maintained based on selected vendor's recommendation. 6.12.5.13 Cooling tower blowdown A.

The Bidder shall propose concentration ratio and blowdown rate for the cooling tower to meet the local regulation and/or World Bank environmental guidelines in his tender. The cooling tower blowdown shall be discharged to the river via a discharge basin, buried pipe and outfall also to be provided under this Contract. Two × 100% capacity blowdown pumps complete with isolation and non-return valves shall be supplied. The discharge shall have a residual chlorine level that is within the authorized environmental limits. A system shall be included to control the free chlorine content to this level if required.

B.

The temperature of the blowdown from the cooling circuit shall be compliant with World bank Environmental guidelines for pollution prevention and abatement in new plants. Redundant online temperature and pH monitoring of the discharge shall be provided and the information transmitted to the PCS. Flow measurement equipment to record the total volumes of water discharged to the river shall be provided.

6.12.5.14 Control and instrumentation A.

The complete instrumentation and control system shall be provided to control and monitor the cooling tower system.

B.

The cooling tower system control shall be implemented in the PCS.

C.

The normal operation of the system shall be operated from central control room.

D.

Instrumentation and controls shall be designed in accordance with the section 8 of this technical specification unless otherwise specified in this section.

6.12-11 KHABAT TPP UNITS 1&2 - VOLUME I

6.12.6

Condenser tube cleaning system

6.12.6.1 Description of condition A.

The condenser tube cleaning systems maintain condenser efficiency at design levels by removing bio-fouling, sediment, corrosion products and scaling. The condenser tube cleaning systems shall be located inside the turbine building.

B.

The riverwater may contain sand and debris of a size that shall pass through the 9.5mm(3/8inch) mesh travelling screens.

C.

The design data of condenser shall be incorporated in the condenser tube cleaning system design and the circulating water design/low flow condition.

6.12.6.2 Design features A.

Two(2) condenser tube cleaning systems shall be provided for each unit, and shall be required to operate at circulating water flow for plant load and seasonal variations.

B.

The system shall be designed to operate and function automatically to produce a clean interior surface in each tube.

C.

Rotating parts shall be provided with guards in accordance with OSHA standards.

D.

Components shall be designed to permit frequent repetitive cycling and required flow of the system without harmful effect.

E.

Condenser Tube Cleaning Systems 1) The strainer design pressure shall be determined by circulating water system transient analysis. 2) The strainer section including screen angle and screen bar spacing shall be selected, condenser tube cleaning system performance are satisfied for proper function during each flow conditions. The screen angle shall be optimized to assure proper sponge ball movement against the resulting screen pressure drop and screen bar spacing shall be optimized to prevent sponge ball penetration while minimizing pressure drop at the highest expected 'design' circulating water velocity. 3) The ball strainer section shall as a minimum contain the following components. The number of components shall be determined by the size of the strainer section. 6.12-12 KHABAT TPP UNITS 1&2 - VOLUME I

a) Screens to direct balls to the extraction tube. b) Drive mechanisms with motor operators for screens. c) Ball type, size and hardness for ball recirculation ability. 4) Motor actuators shall be of sufficient rating to rotate the screens against the circulating water flow for backwash purposes, i.e., to wash off the debris retained on the screens. 5) The balls shall be non-unicellular elastomeric and, when wetted, shall be of specific gravity nearly equal to but slightly greater than that of the circulating water for homogeneous distribution through the water passages. 6) The Bidder shall select the total quantity of balls so that each condenser tube shall receive a ball on an average of every 5 minutes and the ball shall have an excellent recovery rate more than 95% and effective tube cleaning to meet condenser performance. To be considered, the Bidder shall submit technical data. 7) The Bidder shall be considered such as inlet waterbox design with regard to uniform distribution of balls to all tubes. The ball shall be of the correct size to insure cleaning of the condenser tubes without excessive tube wear. 8) The Bidder shall provide the ball monitoring devices to automatically indicate required ball charge and recirculating ball quantity. 9) The Bidder shall provide the ball sorting devices to automatically sort the worn balls to be replaced by new ones. 10) The Bidder shall recommend if any abrasive balls should be included in initial charge or first year's supply and shall specify the quantity. 11) The ball recirculating pump shall be the non-clogging centrifugal type with wide clearance between impeller and housing to prevent damage to the balls. 12) The ball recirculating pump shall have sufficient capacity and head to ensure proper recirculation of the complete ball charge under all modes of operation. Pump speed shall be selected by the Bidder to minimize ball damage. 13) Each electric motor driver shall be rated so that the motor is not overloaded over the entire pump performance range.

6.12-13 KHABAT TPP UNITS 1&2 - VOLUME I

14) The ball collector shall be provided with motor actuated ball catching flap or valve. 15) Distributors shall be provided to equalize ball flow through individual lines. 16) A sight glass shall be provided to observe ball flow through the distributor. 17) The ball shall be guaranteed a lifetime long enough to maintain the appropriate tube cleaning performance. The abrasive ball shall be determined to be most suitable to remove any kind of deposits without damaging the tube surface. F.

Materials 1) All materials used in constructing the equipment shall be the best suitable for the service intended.

6.12-14 KHABAT TPP UNITS 1&2 - VOLUME I

6.13

Compressed Air Systems

6.13.1

General A compressed air system shall be provided to accommodate the requirements of both instrument and service air as appropriate for the complete power station. The compressed air system shall be capable of meeting all plant requirements during any operating condition, including start up, shutdown and trip. The standby compressor shall start up automatically in case of air pressure abnormally decreasing. Moreover, a valve in the service air supply main header shall shut automatically in case of very low air pressure to ensure continuity of instrument air supply which has priority over service air supplies. The air quality for the control air systems shall be filtered to 5 microns, with a dewpoint of -40°C. The air pressure in the pipe distribution system shall be [7 barg]. The filter/dryers supplied as part of the instrument air system shall be sufficient to condition the air required by the plant whilst the second train of filter/dryers is in standby mode. Air storage volume, compressor running periods and compressor control method are closely interdependent. The system designs shall be optimized for minimum total costs. The optimization calculations shall be submitted to the KNOC for approval. System design and equipment shall conform to the requirements and recommendations of the appropriate Codes and Standards.

6.13.1.1 Instument air system Instrument air system is provided compressed air from air compressors and supplies instrument air to the instruments. Instrument air system is composed of two (2) 100% capacity instrument air receivers, two (2) 100% instrument air filters, two (2) 100% instrument air dryers and instrument air distribution system, including instruments, valves, piping and supports. 6.13.1.2 Service air system Service air system supplies compressed air to instrument air system and consuming utilities. Service air system is composed of two (2) 100% capacity air compressors, 6.13-1 KHABAT TPP UNITS 1&2 - VOLUME I

one (1) service air receiver and service air distribution system, including instruments, valves, air-line couplings, piping and supports. 6.13.2

Scope of work Main equipment shall include, but not be limited to the following: A.

Two (2) 100% capacity air compressors, designed to operate on a duty/standby basis, each complete with suction air sand separator and filter/silencer, intercooler and aftercooler with moisture separators;

B.

one (1) general service air receiver of sufficient capacity to facilitate safe shut- down in the case of emergency, with all other provisions considered;

C.

two (2) 100% capacity instrument air receivers of sufficient capacity to facilitate safe shut-down in the case of emergency, with all other provisions considered;

D.

two (2) 100% instrument air filters;

E.

two (2) 100% instrument air dryers;

F.

instrument air distribution system, including instruments, valves, piping and supports;

G. Service air distribution system, including instruments, valves, air-line couplings, piping and supports. A ‘priority’ valve shall be included, operable from the CCR, to shut off the supply from the air compressors to the service air system in the event of low pressure in the instrument air header. 6.13.2.1 Sand separators Dust and sandstorms may occasionally occur at site. Occurrence of dust and sandstorms must not compromise compressor operation. One cyclone or equivalent inertial type sand separator per compressor shall be installed. A special motor driven valve for releasing the dust out of the collector and a collecting drum with a minimum volume of 1 m3 shall be furnished with each dust collector. Indication of the dust level inside the sand separator and pressure differential indication shall be supplied. The sand separators and the suction duct shall be installed in such a way that neither dust from ground nor rain water can be drawn into the separator. 6.13.2.2 Suction air filters/silencers

6.13-2 KHABAT TPP UNITS 1&2 - VOLUME I

The suction air filters on each compressor suction side shall retain all dust and sand not collected in the sand separator. They shall be designed for low pressure loss and the compressor design shall be on the basis of the filter being obstructed up to the maximum allowable differential pressure. The suction air filters shall be of the single element dry type. Filter screens shall be quickly changeable or cleanable. Means to indicate when cleaning or replacement is needed shall be provided. The silencers shall be the manufacturer’s standard, specially designed to dampen the low frequency compressor intake noise. The suction air filter/silencers shall be designed for low pressure loss. The compressor design shall be based on the filter being 50% obstructed. 6.13.2.3 Air compressors The compressors shall be of the electrical, direct driven, multi-stage rotary screw type. Oil lubrication of the instrument compressor parts in contact with compressed air is not acceptable. Each compressor shall include a motor, coupling, base plate, lubrication system, water cooling system and all appurtenances. One (1) set of special maintenance tools for compressor overhauling shall be provided. Each compressor shall have the following design features: A.

The period between two inspections for maintenance shall be not less than 10,000 operating hours.

B.

The compressors shall be of heavy duty construction and designed for continuous and intermittent operation at full and low capacity.

C.

The compressors and associated equipment shall be mounted on a fabricated skid base. All piping leaving the skids shall have flexible connections to approval and the piping shall be adequately supported to prevent transmission of vibration and noise.

D.

The compressors shall be of two or three stage configuration water cooled type with intercoolers.

E.

The impeller shall be manufactured from stainless steel.

F.

Bearings shall be lubricated with oil. A lubrication system with a shaft driven pump and an electrically driven pre-lubrication pump shall be supplied.

G. Modulating control shall apply over the full operating range.

6.13-3 KHABAT TPP UNITS 1&2 - VOLUME I

H.

The noise level of the compressors shall not exceed 85 dB(A) at 1 m from the source

6.13.2.4 Air compressor control Each compressor shall have automatic start and stop controls which shall include an unloading device to unload the compressor when it is stopped and maintain that condition until the motor is again up to speed. The compressor shall also be provided with controls which shall unload the compressor when the pressure in the receiver reaches a predetermined level and load the compressor when that pressure drops below a predetermined level without stopping the motor. The pressure controls shall be adjustable over a wide range and shall operate with a maximum pressure change of 0.2 bar. 6.13.2.5 After-coolers One pipeline type after-cooler per compressor with cyclone type water separators shall be provided. The approach temperature, i.e. difference between outlet air temperature and inlet water temperature shall be 6°C for the after-coolers. Cooling water will be inhibited demineralized water of the closed cooling water system. Easy access for inspection and cleaning shall be provided. Drains shall be provided. Each cooler shall be equipped with a relief valve. The after-coolers shall be suitably mounted so as to be accessible for maintenance and inspection. Fouling factors shall be as recommended by TEMA 6.13.2.6 Air receivers The air receivers shall keep an ample amount of air available during short time air consumption peaks to reduce the frequency of compressor cycling whilst maintaining air pressure supplies at or above an acceptable minimum level. Each instrument air receiver will be designed for a storage capacity, without any additional air makeup supply, which is the larger of: A.

Ten minutes storage on normal plant operation or,

B.

The capacity to run down the generating units and station service auxiliaries from full load operating condition to non-operation condition.

Each receiver shall have a pressure gauge and code stamped relief valve(s). 6.13-4 KHABAT TPP UNITS 1&2 - VOLUME I

Design temperature shall be compressor discharge temperature without aftercooling. Each receiver shall be furnished with one (1) snap-action type moisture trap. Each trap shall be provided with a bypass valve. Easy access to the drain valve shall be provided. The bottom of the vessel shall be at least 300 mm above the floor. Each receiver shall conform to the appropriate Codes and Standards and shall be suitable for the site ambient condition specified in Schedule A. 6.13.2.7 Instrument air dryers Two 100% capacity air dryers shall be provided to dry the instrument air. The dryers shall be of the dual tower, regenerating desiccant type each capable of meeting the requirements of the unit instrument air demand and of removing moisture from the instrument air over the range of design ambient conditions specified in Schedule A for the following design instrument air dewpoint: Outlet dewpoint

-40°C

Visual indication of dewpoint shall be given by means of colour change indicators. The dryers shall be packaged self-supporting units, shipped completely piped and wired. The dryer shall have a control cabinet and multiport valves for automatic transfer of air between towers. Each drying vessel shall have a drying capacity equal to ten hours at the rated output and regeneration, including vessel cooling, shall not be more than 6 hours. Moisture shall be removed during regeneration by internal electric heaters and/or purge air and expelled from the vessels to atmosphere by a stream of purge air. The towers shall be fully insulated. In the event that a dryer is supplied without heaters the compressor capacities shall be adjusted for the increased purge air flow. No provision shall be made for by-passing the air dryers. The pressure drop at full load conditions and across the complete dryer/filter package shall not exceed 0.5 bar when clean. 6.13.2.8 Pre and after-filters Each instrument air dryer shall be provided with a pre-filter and after-filter. The pre-filter shall protect the desiccant of the dryer from contaminants such a liquid (water), pipe scale and dirt; while the after-filter shall prevent desiccant 6.13-5 KHABAT TPP UNITS 1&2 - VOLUME I

fines of the dryer from entering the instrument air supply headers. The filters shall be compatible with the dryers in all respects. The water mist removal capacity of the pre-filter shall be not less than 99% and the after-filter shall removal all particles greater than 1.0 micron in size. The pre-filters shall have coalescing elements which will concentrate water mist to bulk liquid for removal by traps. The filters shall have sufficient area so that replacement of cleaning shall be required only at reasonable intervals. Each filter shall be provided with a differential pressure gauge. 6.13.2.9 Drains The compressed air systems shall have drains on all low points. Snap-action type traps with inlet strainers shall be provided. The minimum size shall be 20 mm. Drains from all low points in headers, water separators and air receivers shall empty into waste funnel connections.

6.13-6 KHABAT TPP UNITS 1&2 - VOLUME I

6.13.2.10 Instrumentation and control A. The Bidder shall furnish a complete package of instrumentation and controls necessary to meet the requirements of this specification, and that shall offer a high degree of reliability and safety to both personnel and apparatus. The control system shall include all permissives and interlocks required to ensure safe and proper operation of the compressed air system under all expected normal and abnormal conditions. Abnormal conditions shall be alarmed for operator attention. Instrumentation and controls shall be designed in accordance with the section 8 of this technical specification. B. PLC based control cubicles and complete field instrumentation for the automatically controls and monitoring shall be provided. C. Minimum one(1) operator interface station with dual LCD monitor(21” min.) and printer shall be provided. D. E. The control system shall be designed to enable the operator to supervise and operate the system by using LCD/keyboard in local and OWS in CCR. F. The control system shall be provided with the data communication interface devices with PCS for the supervisory control and monitoring in the central control room.

6.13-7 KHABAT TPP UNITS 1&2 - VOLUME I

6.14

Water Supply and Treatment Systems

6.14.1

Conditions of service

6.14.1.1 Description of service The raw water supplied from great ZAB River is supplied to trash rack. The trash rack shall be installed at the raw water intake structure and discharge structure so as to eliminate foreign matters such as papers, leaves, other refuses from the water channels. The traveling screen removes debris from the influent river water to prevent fouling of the raw water pump. The stop gate is provided for blockade of river water flow at the influent side for the purpose of periodical inspection and maintenance of equipment behind the above equipment. The raw water for the plant shall be supplied by 100% x two(2) raw water pumps into raw water storage tank(30,000m3) in the site. Raw water in the raw water storage tank shall be transferred to the cooling tower make-up by 30% x three(3) cooling tower make-up pumps and transferred to the water treatment system by 100% x two(2) raw water transfer pumps. The pipe line size is 150mm nominal diameter and the flow rate is approximate 140m3/hr. The raw water in the raw water storage tank is transferred to clarifier by raw water transfer pumps and is pretreated with chemicals to remove suspended and dissolved solid. the pretreated water by gravity filters is stored in the filtered water reservoir. The filtered water in filtered water reservoir is transferred to the make-up demineralizer system by Demi. Water supply pumps and that is demineralized by the make-up demineralizer system and stored into the demi. water storage tank. Also, the potable water will be supplied by the potable water pumps from the filtered water reservoir. The raw water, make-up demineralizer, potable water & service water system shall be incorporated in the drawings and requirements specified in this specification. A. Normal Operation 1) The raw water in the raw water storage tank is transferred to the clarifier by the raw water transfer pumps. The floc. in the clarifier shall be created by the clay and the chemical which is included in alum, alum aid, caustic and the clarified water shall be monitored by turbidity control and removed suspended and dissolved solid in the clarifier. 6.14-1 KHABAT TPP UNITS 1&2 - VOLUME I

2) The slurry water on the bottom of clarifier shall be transferred to waste water treatment system by sludge transfer pumps. 3) The clarified water is delivered into three(3) 50% capacity gravity filters. 4) The bypass line to avoid clarifier shall be considered. 5) Filtered water to be used for the make-up demineralizer system is stored by gravity in the underground filtered water reservoir. 6) The water in the filtered water reservoir is transferred to demineralizer trains by Demi. Water supply pumps. 7) Each of the demineralizer trains shall include an activated carbon filter to remove any trace of organic matters and residual chlorine. The activated carbon filters shall be backwashed by back washing pumps. 8) The pretreated water from activated carbon filter shall flow through cation exchanger, degasifier, anion exchanger and mixed bed exchanger. The demi. water supply pumps and the degasified water transfer pumps shall be sufficiently designed to deliver the pretreated water into the demi. water storage tank . 9) Potable water shall be supplied to the activated carbon filters by potable water pumps from filtered water reservoir and it shall be removed color, taste, turbidity, organic matters by the activated carbon filters. Potable water chlorinated by sodium hypochlorination feed pumps will be stored in the hydropneumatic tank and supplied to demand area. 6.14.1.2 Design conditions A. Design Parameters 1) General a) General design conditions Pressure, kg/㎠.g

10.0

Temperature, ℃

Max 66.0

b) Auxiliary steam conditions Pressure, kg/㎠.g

6

Temperature, ℃

180

2) Raw Water Supply System a) Raw Water Pumps 6.14-2 KHABAT TPP UNITS 1&2 - VOLUME I

•

Quantity : Two (2)×100% capacity / 2unit

•

Raw water pump shall be capable of pumping one(1) day required water for two(2) units within 8hrs.

•

Design Head : The system head based on the highest point on energy gradient for the minimum depth of the liver condition.

b) Raw Water Storage Tank •

One(1) 100% capacity / 2 unit

•

Carbon steel construction with painting

•

SP-10 inter surface treatment and epoxy coating

•

Outside painting

•

30,000m3 capacity available

•

All required instrument and level control equipment

c) Intake equipment (for 2Units) •

Intake structure

•

Traveling screen : Two (2) sets

•

Trash rack : Two (2) sets

•

Stop gate : Two (2) sets

•

Embedded Guide for future units : Three(3) sets

d) Screen wash pumps •

Quantity : Two (2)×100% capacity / 2unit

•

Type : Centrifugal

e) Cooling tower make-up pumps •

Quantity : Two (2)×100% capacity / 2unit

•

Type : Centrifugal

f) Raw water transfer pumps •

Quantity : Two (2)×100% capacity / 2unit

•

Type : Centrifugal

3) Raw Water Pretreatment System and Potable Water System a) Clarifier •

Upward velocity of effective

2.44

area, at max. flow ,㎥/hr.㎡ •

Flow rate, ㎥/hr

•

Minimum detention time at

140 60

maximum flow, minutes. •

Number of clarifier

1

6.14-3 KHABAT TPP UNITS 1&2 - VOLUME I

b) Gravity Filters •

Capacity each of filter, ㎥/hr

70

•

Linear velocity of filter cross-

7.32

sectional area, ㎥/hr.㎡ •

Backwash linear velocity of filter

29.4

cross-sectional area, ㎥/hr.㎡ •

Number of filters

•

Design pressure, kg/㎠.g

Atm

•

Minimum depth of media

m

3

media : Amthrecite, Sand c) Activated Carbon Filters for Potable Water •

Number of filters

•

Linear velocity of filter

2 12

cross-sectional area, ㎥/hr.㎡ •

Flow rate, ㎥/hr./filter

20

•

Backwash linear velocity of filter

24.4

cross-sectional area, ㎥/hr.㎡ •

Design pressure, kg/㎠.g

10

d) Hydro-Pneumatic Tank for Potable Water •

Type

•

Number of tank

•

Material

•

Capacity, ㎥

Horizontal 1 STS or equal 15

e) Hydro-Pneumatic Tank for Service Water •

Type

•

Number of tank

•

Material

•

Capacity, ㎥

Horizontal 1 Carbon steel 20

4) Makeup Demineralizer System a) Activated Carbon Filters •

Number of filters

2

•

Linear velocity of filter

11

cross-sectional area, ㎥/hr.㎡ •

Flow rate, ㎥/hr./filter

32

•

Backwash linear velocity of filter

24.4

cross-sectional area, ㎥/hr.㎡ 6.14-4 KHABAT TPP UNITS 1&2 - VOLUME I

•

Design pressure, kg/㎠.g

10

b) Degasifiers •

Number of degasifiers

2

•

Capacity, ㎥/hr/ea

32/ea

•

degasifier air blower (q'ty)

2

c) Exchangers •

Ion Exchange Using Exchange Capacity and Chemical Consumption Anion

Cation Exchanger Minimum exchange ability,

Exchanger

-

Mixed Bed Exchanger

-

-

g as CaCO3/l-resin Maximum dosage of 100% HCl, -

-

g/l-resin Maximum dosage of 100% NaOH,

-

-

g/l-resin Minimum ion exchanger

768

768

768x5

unit capacity, ㎥/regeneration Minimum resin depth, m •

0.91

0.91

0.91

Resin Inventory The primary resin beds shall be designed based on the maximum water analysis for 24 hour runs between regenerations. The mixed-resin bed strong-acid to strongbase resin stoichiometric ratio shall be 1 : 1. The minimum resin depth shall be 0.91m. o Cation Exchange Resin Strong acid, gel type, cation resin is required having a polystyrene-DVB copolymers matrix and sulfuric acid functional groups. The resin shall be standard Dowex HCRS or Amberlite IR-120 or Duolite C-20 or equal, shipped in the hydrogen form. o Anion Exchange Resin Strong base, gel type, anion resin is required with polystyrene-DVB

copolymers

matrix

and

quaternary

6.14-5 KHABAT TPP UNITS 1&2 - VOLUME I

ammonium functionality. The resin shall be standard Dowex SBR-P or Amberlite IRA-420 or Duolite A-101 or equal, shipped in the chloride form. o Flow rate, ㎥/hr,㎡ - Cation

:

20

- Anion

:

10

- Mixed Bed

:

30

o Product flowrate, ㎥/hr.train

:

32

o Design pressure, kg/㎠.g

:

10

o Minimum diameter of demineralizer vessel - Cation, diameter, mm

:

- Anion, diameter, mm

:

- Mixed bed, diameter, mm

:

6.14.1.3 Performance A. The Bidder shall Performance the following effluent qualities by treating the raw water. 1) Clarifier - Flow rate, ㎥/hr

140

- Turbidity, NTU

< 5.0

2) Gravity Filters - Flow rate, ㎥/hr.filter

70 X 3(1 Stand-by)

- Turbidity, NTU

< 1.0

3) Activity Carbon filter fo Potable Water System - Flow rate, ㎥/hr.filter

20

4) Makeup Demineralizer System - Flow rate, ㎥/hr.train

32

- Accumulated flow rate, ㎥/regen

768(32 x 24h)

5) Quality of Make-up Demineralizer Water The quality of demineralizer water shall be as follows : Anion Exchanger

Mixed Bed Exchanger

(Effluent)

Constituents Total suspended solids, ppm

0.1

Max. 0.1

Total hardness, ppm as CaCO3

0.0

0.0

Carbon dioxide, ppm

0.0

0.0

Total silica, ppm as SiO2 +

Sodium, ppm as Na

Max.

(Effluent)

Max. Max.

0.2

Max. 0.02

0.9

Max. 0.01

6.14-6 KHABAT TPP UNITS 1&2 - VOLUME I

Conductivity ,

Max.

10

Max. 0.2

Micromhos/cm at 25 ℃ pH at 25 ℃

6.5 - 7.5

6) The ion-exchange resins in the demineralizer system shall be guaranteed not to have lower than a capacity at the maximum chemical dosages specified in this specification. However, the regeneration system shall be enough designed so that the chemical dosages could be doubled at operator's option. These guarantees shall be based on the influent water analysis specified in design data and shall consider the additional ionized salts which is caused by chemical addition through pretreatment. 6.14.2

Design and construction features

6.14.2.1 General A. The raw water pretreatment and makeup demineralizer system shall be designed so as to insure continuous, safe, and economical operation providing the maximum reliability without vibration or noise. B. Duplication of components shall be maximized to the greatest extent possible such that similar components shall be interchangeable. C. Each item of raw water, potable water, service water and makeup demineralizer system equipment shall be shop assembled, properly aligned, and, if required, match-marked and disassembled for shipment. D. The equipment and all assembly joints or junctions shall include alignment or centering fits as required to ensure accurate reassembly or alignment of all parts. E. The Bidder shall make any provision for the future area of the water treatment system supplied by KNOC. 6.14.2.2 Raw water supply sytem and intake equipment A. Raw Water Pumps 1) The river water may at times contain sand, shells, marine life and debris of size that will pass through the 9.525mm (3/8 inch) mesh travelling screens for the raw water pump. 2) The pump shall be designed in accordance with the recommendation of the design standard of the Hydraulic Institute Standards. The Bidder shall design the pump and motor selected to meet the

6.14-7 KHABAT TPP UNITS 1&2 - VOLUME I

specified intake structures and cooling tower structures design conditions. 3)

For system designs which include pumps in parallel operation each pump shall be capable of continuous operation at maximum run-out condition

4) The pump head-capacity curve shall be continuously rising from the maximum flow to shutoff. 5)

Pump design pressure shall not be less than the shutoff head.

6)

The first critical speed of the pump shall exceed the operating speed of the pump by at least 25 percent. Critical speed shall include effects of lubrication, bearings and bearing supports.

7)

The pump and motors shall be capable of withstanding without failure such design conditions including reverse rotation due to power failure.

8) The Bidder shall perform the vibration analysis of pump station and shall have responsibility to modify any harmful effect from vibration. The vibration analysis for each pump shall include the analysis for the operating conditions of starting, stopping and trip. B. Intake Equipment 1) The traveling screen remove debris from the influent river water. The trash rack shall be installed at the riverwater intake structure, circulating water intake structure and discharge structure so as to eliminate foreign matters such as papers, leaves, other refuses from the water channels. 2) The stop gate is provided for blockade of riverwater flow at the influent side for the purpose of periodical inspection and maintenance of equipment behind the above equipment. The equipment shall conform to the design and arrangement indicated on the drawings and requirements specified in specifications. The Bidder shall supply and install the embedded guide materials for future units. a) Through-flow type traveling screens complete with all accessories : •

Splash housing

•

Head shaft drive

•

Screen wash spray system

•

Screen frame and embedded guides

•

Baskets and carrying chains 6.14-8 KHABAT TPP UNITS 1&2 - VOLUME I

•

Screen drive motor and reducer

b) Trash rake complete with all accessories : •

Traversing head frame and dead plate

•

Hopper

•

Hoisting mechanism

•

Motors and gear reducer

•

Cable reels and cable

•

Motor starters, switch-gear and wiring

•

Runway rail

c) Trash racks complete with all accessories. •

Trash racks

•

Embedded materials

d) Stop gates complete with all accessories. •

Stop gates

•

Guide ways

3) The equipment shall not require service water. If service water is required, the equipment shall be designed to use source water as service water. 4) Travelling screen a) The screen shall be the vertical, traveling basket, through-flow type of the manufacturer's proven design and construction, modified to meet the requirements of the specified service and this specification. The screen shall be situated with the main bearings and shaft above the mean low water level, shall be of the selfcleaning, two speed type, suitable for unattended operation. b) Allowable stress in structural members, screen frames, or panels shall not exceed AISC values for the material used. These shall be based on the load corresponding to a combination of maximum upstream water depth, the differential head obtained at stalled motor torque, and a coefficient of friction for carrying chain rollers of 0.13. Spray header piping and connections shall conform to ANSI Standards. Drive gearing shall conform to AGMA Standards. c) Screen drives shall be designed for continuous operation at all specified speeds under the loading imposed by rated upstream water level and the head differential across the screens. When subjected to the maximum breakdown(stalling) torque of the drive 6.14-9 KHABAT TPP UNITS 1&2 - VOLUME I

motor, all screen drive components, including screen carrying chains, shall have a factor of safety of not less than 3 based on the ultimate or fracture strength of the material. Allowance for failure of a shear pin shall not be included in this requirement except on written permission of the KNOC. d) The screen approach velocity shall not exceed 0.8 m/s with a corresponding pressure drop of not more than 150 mm water level across the screen, with a minimum water level in the screen forebay and with 30% of the screen blocked. e) Allowable stress in structural members, screen frames, or panels shall not exceed AISC values for the material used. These shall be based on the load corresponding to a combination of maximum upstream water depth, the differential head obtained at stalled motor torque, and a coefficient of friction for carrying chain rollers of 0.13. f) Spray header piping and connections shall conform to ANSI Standards. g) Screen panels shall include full width self draining rubbish elevators to be installed at intervals around the internal periphery of the screen. The rubbish elevators shall be manufactured from the same material as the screen panel. The screen panels shall be electrically isolated from the main structure. h) The traveling screen operation shall be controlled and monitored from the PCS. i) Drive gearing shall conform to AGMA Standards. 5) Trash Racks a) The trash rack shall be made by welding flat bars to horizontal beams at a specified pitch and the trash rack shall be hinged to the bracket in the screen wall. b) The trash rack shall consist of vertical steel bars with sufficient horizontal support structural beams and spacers. It is very important point in design to maintain the uniform space between the bar through entire trash rack to provide efficient collecting of refuses. 6) Trash rake

6.14-10 KHABAT TPP UNITS 1&2 - VOLUME I

a) The trash rake shall consist of a rake proper, hoist mechanism, mechanical or hydraulic system for positioning rake teeth, trash hopper, carriage drive and cable reel type power pickup. b) Trash rake shall be of the cable operated rake type, non guide design. Hoist and carriage drives shall be electrically operated. c) Trash pit will be installed at one side of each main intake structure. And a trash rack rake will remove its trash into this pit. The Bidder shall install necessary rail including embedded hardware and shall consider sufficient length of cable or travelling mechanism. d) The rake shall be raised and lowered through a suitable system of cables, sheaves, hoist drum, gear reducer and electrical motor. A suitable power-operated mechanism shall be provided to engage and disengage the rake teeth. The entire unit, including trash hopper, shall be electrically driven along rails by a suitable reversible gear motor drive.

A brake shall be provided to lock the

wheels when not in use. The rake shall be designed to be used and stored outdoors. 7) Stop Gate a) The stop gates shall be designed based on the water levels from bottom sill to H.W.L. b) Each stop gate shall be of welded construction and consist of a structural steel frame formed by 2 vertical end girders between which horizontal beams are properly spaced according to their individual capacity and design water pressure. The end girders shall be provided with substantial bearing plates to distribute the load to the embedded parts and with suitable adjustable guide shoes to position and guide the stop gates within the embedded parts. The end girders shall transmit the design loads to the embedded parts without warping or undue to deflection. c) The entire downstream face shall be covered with a heavy steel skin plate. d) Each stop gate shall be designed to close under its own weight with balanced no-flow hydraulic conditions. e) Bottom section stop gate shall be have gate valve to equalize hydrostatic water pressure prior to lift up stop gate. The valve

6.14-11 KHABAT TPP UNITS 1&2 - VOLUME I

should be installed at the appropriate at point of bottom section of stop gate. f) The valve shall be specified to be operated through the lifting beam that is controlled from the gantry crane. g) The stop gates shall be of the sliding vertical lift type with downstream seals. In these specifications, the downstream side of the stop gate refers to the unwatered side in the closed position. h) Drain holes to adequate size shall be located in the webs of horizontal beams to completely drain the water from these beams. i) Each stop gate shall be provided with lifting lugs to engage with the lifting hooks of the lifting device. j) Each stop gate shall be sealed at the downstream face with J-type neoprene seals & wedge seal between the stop gate and embedded material so that when properly in position the set of stop gates are free from leakage. k) The seals shall be in continuous lengths where possible and any necessary joints shall be properly made to be watertight and of adequate strength. The seals shall be fastened to the stop gate of stainless steel bolts and nuts to facilitate their replacement. The seals shall be positive in action and shall not unduly interfere with the placing and withdrawal of the stop gate. l) The guides shall be fabricated from suitable material of channel sections and fully grouted with the foundation by welded grouting lugs on the back of the channel sections. The channel sections shall be arranged to give an adequate and permanent location. The tops of the side guides shall be fabricated to give sufficient lead-in to enable the stop-gate to be correctly positioned over the guides. m) Where the rubber seals are located in the guide frame, stainless steel strips shall be provided, the strips may be welded to the channel section by an approved procedure. 8) Splash Housing a) Splash housing shall be provided to enclose the spray system and refuse trough. The housing shall be watertight and provided with hinged and gasketed inspection door.

6.14-12 KHABAT TPP UNITS 1&2 - VOLUME I

b) The rear of the housing shall be removable for access to the screen chain and baskets. c) The arrangement of the housing shall provide for the full opening of the inspection door between adjacent units. 9) Head Shaft Drive a) The head shaft drive shall be the roller-chain type, oil-bath lubricated, and located outside the splash housing in a suitable oiltight enclosure. The enclosure shall be provided with an oil-level sight gage and bottom drain cock. b) The driver shall be a two speed electric motor giving a speed ratio of no less than 2:1. c) A shear pin or approved slip type coupling device shall be provided on the reducer drive sprocket. If shear pins are used, 16 Set(s) extra pins for each size required shall be provided. d) The drive chain shall be furnished with a 12 gauge stainless steel protection guard. 10) Spray System a) The spray system shall be the single header type. b) The spray header shall terminate with a power-operated butterfly valve outside the splash housing for connection to wash water source. Wash water will be provided after having passed through a duplex basket strainer with perforations no larger than 4.5 mm. Valve connection shall be flanged per ANSI/ASME B16.5. 11) Frames a) Screen framework Sections shall be approximately the same length. The head shaft section shall have adequate lifting lugs to enable lifting of the entire assembly. b) The main frame of screen shall be of four(4) post construction with overlapping side guard seals to prevent debris from passing through the chain link and around the outside of the screen frame. c) The raw water pump area screen assemblies shall be designed and fabricated to permit installation and removal by using gantry crane. Bottom frame sections shall have supporting and lifting lugs as required for installation or removal. d) Frame sections shall be of welded and/or bolted construction insofar as practicable. All shop frame joints shall be continuously 6.14-13 KHABAT TPP UNITS 1&2 - VOLUME I

seal welded to eliminate crack corrosion. All field connections shall be bolted. e) Cross bracing shall be provided if required to maintain rigidity and running clearances under maximum differential level operation or to limit combined stresses to allowable limits. However, no material thickness shall be less than 10 mm. f) Renewable chain tracks or guides shall be provided on the ascending and descending side of the framework. g) If required by seismic design, the descending side of the framework may require a guide. h) The Bidder shall provide wall guide ways and anchors for placement in the screen structure wall at the time the structure is poured. The guides shall be transported to the jobsite before the screen assemblies in accordance with the delivery schedule. i) The screen frame shall be adequate to resist the maximum differential head necessitated by the Bidders design or 2 m differential head, whichever is greater. j) The screen panels shall provide for an easy assembly of kelp knives on alternate screen panels. No kelp knives shall be required initially with this equipment. 12) Baskets and Carrying Chains a) Screen mesh for baskets shall not be less than 14 Washburn & Moen wire gage with 10mm square clear openings. The loading that the wire mesh imposes on a basket-carrying frame shall be considered in the frame design. b) Basket frames shall be attached to carrying chains to transfer uniform loading to the chain rollers. c) Screen carrying chains shall be the hardened roller type with ground bushings and pins that have water-tight press fits into chain sidebars. Grease fittings shall be provided for lubrication of bushing wearing surfaces. The screen drive chain shall be heavy duty, steel, roller type. d) Head shaft sprockets for basket-carrying chains shall be provided with renewable, hardened inserts to absorb wear from chain rollers. The headshaft shall be provided with sleeve type bronze bearings mounted in guided ways arranged for adjustment of 6.14-14 KHABAT TPP UNITS 1&2 - VOLUME I

carrying chain tension. Grease fittings shall be provided for the lubrication of head shaft bearings. Foot shaft bearings shall be sleeve type, self-lubricated suitable for underwater service. e) Effective seals shall be provided to prevent passage of trash through or around carrying chains and chain guides also to prevent passage of solids as the screen baskets pass around the foot wheels. f) Shoes shall be provided on the basket framework if stress limitations require center support for the baskets. The shoes shall slide in guides to be provided on the main structural framework. g) Portable chain-tension indicators of the manufacturer's standard design shall be furnished as called for in the material requisition. The devices shall be calibrated for accurate indication. Calibration certificates shall be furnished by Bidder for each device. 13) Motor and Reducer a) The screen drive motor shall be in accordance with NEMA design "B". The motor enclosure shall be TEFC. All drive components shall be designed to withstand the full NEMA stalling torque of the motor without damage to any part of the drive or the foot shaft assembly. The drive shall be capable of starting the screen under a load equivalent to a 760 mm water pressure differential at the high water levels.

The drive unit shall be suitable for screen

travel speed of 3 m/min. b) The drive unit speed reducer shall be a fully enclosed helical gear type with anti-friction bearings. The speed reducing gear shall be connected to the drive motor by non-lubricated stainless steel, disk-type flexible coupling and through keyed shafts. c) Cover guards shall be provided for all motor and speed reducer couplings. 14) Trash Rack a) The trash rack and embedded material shall be designed as a normal load condition for the design differential head. b) The trash rack should be installed vertically at a slight angle of 5 deg from the vertical toward the pump and the discharge structure trash rack should be installed in same location of stop gate vertically. 6.14-15 KHABAT TPP UNITS 1&2 - VOLUME I

c) Trash rack shall consist of a series of equally spaced vertical flat bars supported by a structural frame consisting of two vertical end girders between which horizontal beam shall be located to meet the water pressure and flow conditions. d) The frame, end girders, beams and bars shall be welded together. e) The unsupported length shall be restricted by bar vibration. f) At the design differential head, stress in the trash rack bars shall not exceed 90% of yield stress. g) The trash rack guides shall be consist of vertical steel members embedded in concrete including all anchor bolts. 15) Trash rake a) Hoisting Machinery The hoisting machinery shall consist of a motor with motor brake, gear reducer, limit switch, line shaft, bearings and hoisting drums of sufficient size to store all required hoisting cable without overlap. Trash rake assembly shall be provided with two cast irons grooved hoisting drums and supported by self-aligning roller bearings. Each drum shall be provided with stainless steel wire rope cables. The hoisting cables shall have a minimum breaking strength of 5 times the design lifting capacity. The limit switch shall be mounted at one end of the shaft for automatically stopping the rake at the top and bottom of the travel. The motor brake shall hold the rake in any position when power is removed. Full personal protection cover guards shall be provided for all motor and speed reducer couplings. b) Raking Mechanism The raking mechanism shall be driven from the hoist through a suitable system of cables and sheaves. The support of the raking mechanism shall be by four(4) cables of stainless steel. The rake teeth shall be spaced to correspond with the spacing of the bar rack. The rotation of the rake teeth shall be accomplished by changing the effective length of the cables by a mechanical-hydraulic 6.14-16 KHABAT TPP UNITS 1&2 - VOLUME I

mechanism with this effective change in cable length, the mechanical linkage within the trash rake will rotate the teeth to the cleaning position. Reversing this cycle at the top of the run shall cause an effective discharge of the debris. The design of the tooth rotating mechanism shall also permit opening and closing of the rake teeth at any point in the raking cycle with the rake stationary or in motion. The rake shall have a load lifting capacity of 2600 kg and shall rake at a speed of approximately 9 m/min. The round bar rake teeth shall penetrate the upstream face of the trash rack by about 20mm and shall be of stainless steel. c) Traversing Mechanism The entire unit shall be electrically driven along the rails in a horizontal direction by a reversible drive unit. The wheels shall be cast iron and keyed to the shafts. Each shaft assembly shall be mounted to the shafts. Each shaft assembly shall be mounted to the main frame by two self-aligning roller bearings. The operation of the traversing drive shall be by means of holddown "forward" and "reverse" pushbuttons. Traversing motor shall be provided with a motor brake to stop and hold the drive unit when the pushbutton is released. The rails and rail clips upon which the trash rake equipment moves and operated shall be of carbon steel. The reducer for the traversing drive unit shall be a vertical worm gear type. The motor brake shall be dust-tight, waterproof magnetic disc type mounted to the motor, and shall be suitable sized to keep the unit stationary. The traversing speed shall be approximately 9 m/min. d) Framework The main frame of the trash rack shall be designed to fit the raking mechanism. The framework shall consist of the main frame, dead plate assembly, wheel guides, machinery platform, and debris Hopper. The dead plate located on the front of the main frame shall assure smooth transition of the rake mechanism from the bar 6.14-17 KHABAT TPP UNITS 1&2 - VOLUME I

rack to its discharge position. The design of the dead plate shall allow for operation over 90cm high pipe handrail at the edge of the operating floor, and discharge into the debris hopper. The debris hopper shall be of 2m3 capacity stainless steel and shall be of the hinge open type, for discharge into a refuse trough. e) Hydraulic Control System The hydraulic unit shall include a TEFC motor having class "B" insulation with hydraulic pump, reservoir, relief valve, solenoid valve, flow control valves, hydraulic tubing, piping, valves, etc., to provide complete hydraulic system. A relief valve in the hydraulic mechanism shall be factory set to open, allowing the rake teeth to open when the rake become jammed or otherwise overloaded. Each system shall be furnished with two cylinders for operation of the walking beams. C. Screen Wash Pumps and Equipment 1) Design of Condition a) Two (2) 100% duty/standby wash water pumps, together with auto clean strainers and associated interconnecting pipework and equipment shall be supplied and installed as part of the Works for each drum screen. b) The pumps shall be located adjacent to the drum screens. The pumps shall draw their water from the clean water side of the drum screens, and shall be designed to provide the spray/wash water requirements of the drum screen, with minimum water level in the suction chamber. c) The screen water jet system offered shall be capable of flushing all debris into a collecting trough and washing it away to the sea. The jets and isolating valves (one per jet) shall be readily accessible and easily removable for clearance of any blockage that may occur. Splashguards shall be provided over pipework and nozzles with doors or removable panels to allow viewing of each washwater jet and to provide access for maintenance. d) Nozzles for the wash water system shall be constructed from a suitable material to avoid corrosion. Nozzles shall be easily 6.14-18 KHABAT TPP UNITS 1&2 - VOLUME I

replaceable. Pumps, pipes and valves shall be in accordance with the general requirements of this specification. e) The debris collection trough system shall be fabricated from grade 316 stainless steel. The collection troughs supplied with the drum screen structure shall be securely supported and suitably designed to enable easy replacement. f) The debris collection trough from the screen shall direct the collected debris and wash water into a common disposal trough fabricated from 316 stainless steel and this debris shall discharge to an approved location. D. Instrumentation and Controls 1) General a) The Bidder shall design and supply all instrumentation and control system so as to insure accurate, safe and reliable operation under conditions of service. b) The Bidder shall be responsible for the design to meet the requirements of system performance. Any additional designs required to satisfy the high efficiency, equipment and system protection, safety and stability operation requirements shall be provided at no additional cost. c) All automatic and manual control action of intake equipment shall be possible through PCS (except for trash rake). d) All instrumentation and control equipment shall be supplied. If any requirements given in this specification, the instrumentation shall be supplied in accordance with in this requirements. 2) Scope The work to be furnished by the Bidder per Units shall include, but not be limited to the following; a) Local control station for TWS b) Level monitoring equipment with monitoring panel c) All instruments and related accessories, erection materials for installation of instruments, etc. d) Instrument cabinets to mount transmitters, switches and other local instruments.

6.14-19 KHABAT TPP UNITS 1&2 - VOLUME I

e) Two(2) channel signal distributers of level signals of after TWS, Two(2) channel signal distributer of common level signal of before TWS f) others 3) Design requirements a) General requirements The Bidder shall furnish a complete package of instrumentation and controls necessary for the TWS to function in a manner that will meet the requirements of this specification, and that will offer a high degree of reliability and safety to both personnel and apparatus. The sequencers shall have the capability of turning on and off on to four times each 24 hours for periods of time varying from 1-1/3 revolutions to continuous operation. The screen wash cycle shall be automatically initiated upon attainment of a preset differential level across to screens. The screen wash cycle shall be initiated automatically on high differential head across the screens, with automatic pump shutdown when the wash cycle is complete. Concurrently, the screen shall revolve at least 1-1/3 revolutions to provide complete basket cleaning and to prevent debris from standing and drying out on the screens. The wash cycle shall also be started and stopped manually. Local control stations shall be provided for each screen drive and for each power operated valve. b) Level measuring equipment with monitoring panel The Bidder shall furnish ultrasonic level measuring equipment with all necessary accessories of traveling screen control. Level monitoring panel shall indicate the level of sea water level and differential level between before and after screen. Level monitoring panel equiped with level measuring equipment and accessories hall be the self standing type and its enclosure type shall be above NEMA 4X. c) Field Instrument Requirements Instrument shall be supplied by one(1) recognized manufacturer having wide experience in the manufacture, application as possible. 6.14-20 KHABAT TPP UNITS 1&2 - VOLUME I

d) Local control station Local control station shall be the self standing type and its enclosure type shall be above NEMA 4X. The Bidder shall provide local control station of TWS to be controled by the operator locally. Local control station shall be equiped with control switchs and lamps for manual and jogging operation of TWS. 6.14.2.3 Raw water pretreatment system and potable water system A. Clarifier and Related Equipment. 1) One(1), 100% capacity clarifier shall be provided and shall be of the circular type, sludge recirculation and conical base. Appurtenances consist of chemical mixing zone and feed facility, sludge handling facility with mixing, reaction and separation compartments. Minimum detention time shall be 60 min. with upward velocity 2.44 ㎥/hr.㎡ of rise area. 2) The agitator mechanism shall be mounted on top of the clarifier and shall be complete with shaft, paddles, lubricated bearings, adjustable speed drive, gear reducer, and automatic torque releasing mechanism with alarms. The contents of the reaction zone must circulate to cause flocculation of all particles while they are kept in suspension. The large volume of floc previously formed from the stilling flocculation zone shall be recirculated. The system shall be designed so that all portions of floc are agitated to avoid the formation of cones or pockets. 3). Automatic blow-off equipment, actuated by flow or time for sludge removal shall be provided and furnished complete with adjustable timers by using program, control valves, tank dewatering provision. 4) A structural steel walkway and stairway shall be provided, and the walkway shall be extended to the full diameter of the clarifier. The walkway and stairway shall be provided with kick plates and handrails. 5) Two(2) 100% capacity sludge transfer pumps shall be provided. 6) The shell and bottom of the clarifier shall be fabricated of A 285 Gr.C or equal in accordance with API 650. The clarifier interior shall be coated with 0.3mm of polyamide epoxy. B. Gravity Filters 6.14-21 KHABAT TPP UNITS 1&2 - VOLUME I

1) Three(3), 50% capacity gravity filters shall be provided and shall be of the vertical type, skid mounted, preassembled, piped, wired and tubed. 2) The gravity filters shall contain multiple media and be furnished in accordance with AWWA standards for filtering material. Support media shall be provided, if required. Each filter shall be equipped with all automatic valves required to operate the unit. Service, backwash, rinse and drain valves shall be the automatic butterfly type. 3) Two(2), 100% capacity gravity filter back wash pumps shall be provided. 4) The gravity filter shells shall be fabricated of A 285 Gr. C or equal in accordance with API 650. The vessel interior shall be lined with 0.3mm of polyamide epoxy. The internal upper and lower distributors shall be constructed of extra heavy carbon steel lined with 0.3mm of polyamide epoxy and shall evenly distribute all flows. Internals shall be factory assembled. C. Chemical Feed System 1) The Bidder shall design that the alum aid with electric heater and the alum (solid drug) are melted by the agitator in the dissolving tanks. 2) The caustic(45% liquid) is diluted in the mixing tank. 3) Chemicals shall be delivered in site with bags or containers and dissolved or diluted in the chemical tanks by the agitator. 4) Each tank shall be provided with overflow, drain, and fill connections. and steel tanks shall be provided with hinged cover, bottom dished head etc. The tank capacity shall be sufficient for one day's usage. 5) Slow speed(75 rpm maximum) agitator shall be provided on the related tank. 6) Two(2) flooded suction positive displacement, diaphragm type pumps or KNOC approved equal pumps shall be provided for each chemical. 7) The feeder equipment shall be mounted above skid and assembled with suction and discharge piping. 8) The alum, alum aid and caustic tanks shall be constructed of 316 stainless steel(mininum 3.2mm thickness) or equal. Wetted parts of the alum, alum aid and caustic feed pump shall be constructed of 6.14-22 KHABAT TPP UNITS 1&2 - VOLUME I

316 stainless steel or teflon or equal. Piping shall be schedule 40, 316 stainless steel or hard rubber lined carbon steel or equal. The alum and alum aid tanks shall have a capacity included the usage of waste water treatment system and shall be supplied from branch lines by each feed pump. D. Potable water system 1) The chlorination system shall be able to chlorinate the potable water when the power plant is operating normal at a rate of 20 ㎥/h. Chlorine dosages of 0.2 to 0.1ppm of free available chlorine will be required. 2) Sodium hypochlorite will be supplied by sodium hypochlorite feed pumps from sodium hypochlorite feed tank. The Bidder shall supply discharge piping of sodium hypochlorite feed pumps and a mixing tee. Sodium hypochlorite feed tank shall be designed to include drug capacity of raw water pretreatment system. 3) The Bidder shall adequately size the hydropneumatic tank. 4) The Bidder shall furnish the instrument air piping and valves. 5) Hydropneumatic tank internal pressure shall be maintained by pressure regulation valve and non-slam check valve on the air line from service air header. The Bidder shall also furnish all necessary instruments and controls required for full automatic operations of this equipment. 6) Hydropneumatic tank shall be constructed by ASTM A240 type 304. 7) Two(2) 100% capacity activated carbon filters, the internal upper and lower distributors shall be fabricated of A240 type 304 in accordance with ASTM code. Internals shall be factory assembled. 8) The flow integrating indicator to be installed on the discharge of hydropneumatic tank shall be supplied by the Bidder. E. Service water system 1) The Bidder shall adequately size the hydropneumatic tank. 2) The Bidder shall furnish the instrument air piping and valves. 3) Hydropneumatic tank internal pressure shall be maintained by pressure regulation valve and non-slam check valve on the air line from service air header. The Bidder shall also furnish all necessary instruments and controls required for full automatic operations of this equipment. 6.14-23 KHABAT TPP UNITS 1&2 - VOLUME I

4) Hydropneumatic tank shall be constructed by carbon steel. 5) The flow integrating indicator to be installed on the discharge of hydropneumatic tank shall be supplied by the Bidder. 6.14.2.4 Makeup demineralizer system A. Makeup Demineralizer 1). The makeup demineralizer system shall consist of following components: a) Two(2) 100% capacity activated carbon filters b) Two(2) 100% capacity cation exchangers c) Two(2) 100% capacity degasifiers d) Four(4) 100% capacity degasified water transfer pumps (Two(2) 100% capacity per train) e) Two(2) 100% capacity anion exchangers f) Two(2) 100% capacity mixed bed ion exchangers 2) The two(2) train demineralizer system shall be capable of operating with one train in service while one train is regenerating. During normal operation, one train will be on line with the other on standby. During peak water demands, the system shall have the capability of operating two trains simultaneously. 3) All demineralizer vessel internals shall be designed to adequately distribute and collect the flow without channeling or bypassing and without loss of resin. All internals shall be designed to be removed through the vessel access manhole. 4) The under drain system shall be designed : a) To ensure that there are no inactive resin volumes b) To retain resin fineness less than 50 mesh c) Without sub fill 5) A resin trap shall be furnished in the effluent line of each ion exchanger. The trap basket shall be capable of withstanding a differential pressure of 10.0 kg/sq.cm.g without failure. The resin trap body shall be constructed of rubber lined carbon steel. The basket shall be stainless steel with 100 mesh effective screen size. 6) Each vessel shall be furnished with the following accessories : a) Structural support legs b) One access manhole, 500 mm minimum diameter c) Vent valve to vent the highest point in the tank or piping 6.14-24 KHABAT TPP UNITS 1&2 - VOLUME I

d) Drain valve e) Sight glasses in all backwash lines located down-stream of the rinse line connection f) 75 x 300 mm sight glass in all demineralizer vessels at the settled bed level and at the top of the bed for use during backwash and at mixed resin interface for mixed bed ion exchanger. g) 150 mm flange openings to enable sluice-out of resin h)

A

drain-down

connection

on

each

mixed

bed,

suitably

screened(316 stainless steel) located at the point of drain-down required for proper mixing. Minimum size of drain connection shall be 65 mm. Bidder shall provide a screened pipe probe internally, if required. i) A sampling point shall be provided for the effluent of each in exchanger vessel and activated carbon vessels. B. Regeneration 1) The Bidder shall furnish a complete system for automatic and counter current regeneration of the demineralizer system. The system shall include chemical storage and injection tanks, injection pumps, unloading and transfer pumps, piping, valves, instrumentation, mixing tees and steam water heater, and other components necessary for a complete operating system. 2) The regeneration system shall consist of the following components: a) One(1) 100% capacity acid day tank b) Two(2) 100% capacity acid injection pumps c) One(1) 100% capacity gas scrubber d) One(1) 100% capacity caustic day tank e) Two(2) 100% capacity caustic injection pumps f) One(1) 100% capacity steam water heater g) Two(2) 50% capacity acid storage tanks h) Two(2) 50% capacity caustic storage tanks i) Two(2) 100% capacity caustic unloading & transfer pumps j) Two(2) 100% capacity acid unloading & transfer pumps k) Two(2) 100% capacity mixing tees l) One(1) 100% capacity steam trap m) Two(2) 100% capacity regeneration water pumps

6.14-25 KHABAT TPP UNITS 1&2 - VOLUME I

3). Regeneration chemicals shall be 35 percent hydrochloride acid and 45 percent caustic soda. Dilution of these chemicals to the applicable concentrations and temperatures shall be accomplished at the time of use in closed pressure systems, employing in-line mixing. 4) The cation exchanger shall be regenerated with anion at a concentration of 5 percent. Anion resin shall be regenerated with caustic at a concentration of 5 percent at max. 50 deg.C. 5) Blocking water, acid & caustic dilution water and backwash water of anion exchanger & mixed bed ion exchanger shall be demineralizer water, supplied from demi. water storage tank by regeneration water pump. Generally, rinse water shall be from demineralized water, but filtered water can be used for rinse sequentially. 6) All regenerate system valves shall be spring-to-close except leak off which shall be spring-to-open. 7) Backwash and rinse controllers shall be provided for each equipment with backwash and rinse rates indicated. Equipment shall be designed to prevent excessive rates of flow during backwashing. 8) Acid day tank shall be provided for one regeneration of cation exchanger and mixed bed ion exchanger. Caustic day tank shall be provided for one regeneration of anion exchanger and mixed bed ion exchanger. 9) The concentration of chemicals shall be adjusted by manual setting. 10) An automatic control valve shall be provided on the water side of the mixing tee with the percent concentration indicated downstream of the mixing tee. 11) Acid day tank shall be made by FRP or equal and provided with gas scrubber. This gas scrubber shall also transact poison gas of acid storage tanks. 11) Caustic day tank shall be made by 316 stainless steel or equal. 12) The steam water heater shall consist of a steam shell and tube heat exchanger with 110 percent capacity. Hot water shall be used for the caustic injection and caustic displacement steps. The heat exchanger shall be capable of heating the caustic dilution water from 0 deg.C to 50 deg.C and have the sampling connection at the low point of shell-side and provision to drain the steam condensate to 6.14-26 KHABAT TPP UNITS 1&2 - VOLUME I

the waste system or recover the condensate to the demi. water storage tank. The shell shall be constructed of carbon steel or equal and the tubes shall be constructed of type 316 stainless steel or equal. 13) Two(2) acid and two(2) caustic storage tanks shall be provided and shall have a capacity of about one month consumption included the usage of waste water treatment system. Acid storage tank shall be made of rubber lined A285 Gr.C or equal. Caustic storage tank shall be made of A285 Gr.C or equal. 14) Acid and caustic drugs supplied to waste water treatment system shall be supplied by branch lines of each injection pump outlet. C. Degasifier 1) Degasifiers shall include a flange ring at the top, which will allow the removal of a top section of the degasifier. In addition, the degasifier will include a 300 mm diameter flange port opening, ANSI 150# flange connection, with blind flange, located at the bottom of the packing section, to allow removal of the packing. Air-inlet and airoutlet connections properly sized for the maximum air flow design shall be provided. 2) The clearwell shall be integral with the degasifier section, so designed as to provide complete support of the degasifier section. The clearwell section shall also be constructed of welded steel. The degasifier with integral clearwell shall be shipped in a single piece and be self-supporting. Where the clearwell is of larger diameter than the degasifier, preference shall be given to a clearwell with dish-shaped or flat top, which will aid in supporting the degasifier. 3) Plastic tower packing of polypropylene construction or equal shall be provided. Packing shall be shipped in bags or other suitable shipping containers for field installation. 4) The clearwell drain valve shall be diaphragm type with cast iron body, rubber lined, minimum size 75 mm. 5) Each air blower capable of delivering a minimum of 0.02 cu.m/min. of air per one(1) l/min water flow. The blower shall be properly designed to overcome the static pressure in the degasifier without causing flooding and to meet guarantees. The blower shall be completely packaged and include the motor, V-belt drive with pulley 6.14-27 KHABAT TPP UNITS 1&2 - VOLUME I

and belts assembled if required, belt guard, clear-out door, drain plugs, flange inlet and outlet. The air blower shall include an adjustable outlet damper. The blower shall be shipped and assembled with suitably sized air filter and damper attached. In addition, the Bidder shall provide piping or duct work from blower to the degasifier air inlet connection. The blower shall be mounted on a steel support stand on the side of the degasifier and, if possible, shall be assembled and braced to the degasifier, and shipped in place. The blower shall be provided with inlet silencer and inlet piping. 6) The clear-well shall have a 500 mm diameter or larger bolted manhole, attached with stainless steel bolts. All clearwell nozzles shall be flange, 10.0 kg/cm2 design and the minimum number of nozzles

shall

include

pump

suction,

drain,

level

controller

connections, and high and low-level connections. 7) The degasifier inlet distributor shall be of header lateral with spray nozzle design. The inlet distributor shall be installed and suitably braced at the factory and shipped in place. 8) A perforated packing support plate or grid suitably designed to support the required packing shall be supplied. The support plate or grid shall be factory-installed, suitably braced and shipped in place. 9) The downcomer pipe from the degasifier section to the clearwell section shall end approximately 150 to 225 mm above the bottom of the clearwell. The downcomer pipe shall be factory-installed, suitably braced and shipped in place. 10) Four(4) degasified water transfer pumps shall be provided complete with motors, baseplate, coupling and mechanical seal. Pumps shall be single stage, end or top suction, horizontal type with single-row or double-row bearings. Casing shall have a cover, which shall be easily removed for cleaning and impeller removal without disturbing pipe connections or in lieu of this cover a horizontally split casing shall be provided. The pumps shall be provided with isolating valves, check valves, pressure indicators and accessories on the discharge of each pump. 11) The degasifiers with integral clearwell shall be constructed of welded steel A285 Gr.C or equal. The degasifier shell and integral 6.14-28 KHABAT TPP UNITS 1&2 - VOLUME I

clearwell section shall be completely lined internally with 4.8mm hard rubber, vulcanized in place after the tank has been hydrostatically tested. 6.14.2.5 Piping & valves A. The Bidder shall supply all piping, valves, supports, fittings and appurtenances necessary to make a completely self supporting system. FRP and PVC piping shall be supported by 1.0 m interval. B. All piping shall be ASTM A106 Grade B or A53 Grade B seamless or welded pipe with butt weld fittings unless stated otherwise. Piping of 150 mm and smaller shall be the seamless pipe, 200 mm and larger shall be the welded pipe. All flanges shall be of the ANSI 150# weld neck or slip on type. C. The Bidder shall provide interconnecting piping and fittings, which shall be of welded carbon steel. Piping with diameters of DN 65 and over shall be prefabricated in sections at shop as required for shipment. Flanges shall be provided where required for connections to vessels and valves. D. Piping and fittings connected to the demineralizer shall be lined carbon steel or equal. Rubber or Polypropylene Lining shall be used in lined pipe runs. Before lining, internal surfaces and flanges surfaces shall be blast cleaned to white metal condition in accordance with SSPC-SP5. E. Demineralizer valves size DN 50 and smaller shall be austenitic stainless steel or lined cast iron or equal. Lined cast iron valves shall be the diaphargm type with a rubber or polypropylene lining and a rubber or ethylene polypropylene copolymer(white) diaphragm. Valves over DN 50 shall be flange and lined cast iron, with lining and diaphragm. F. Piping connections DN 50 and smaller shall be the socket weld type, DN 65 and larger shall be the butt-weld type. G. All piping and fittings in contact with demineralizer water, including lines between operating valves and demineralized vessels shall conform to the materials specified in this specification. H. The Bidder shall furnish all regenerate piping. All piping immediately adjacent for both strong and dilute acid shall be made by Schedule 40 polypropylene or rubber lined carbon steel. All piping in contact with caustic shall be Schedule 40 polypropylene or rubber lined carbon steel. The waste water drain piping of each filter (exchanger) shall be PVC or equal. 6.14-29 KHABAT TPP UNITS 1&2 - VOLUME I

I. The Bidder shall furnish all lined piping and fittings for the equipment specified herein which shall be fabricated into piping spools ready for installation. The lining shall be applied by an applicator approved by the KNOC. No welding shall be done on lined pipe. The KNOC will inspect the linings. J. Plastic piping, strainers, or screens used in demineralizer internal shall be subjected to the KNOC's approval. K. The design of all items specified shall conform to OSHA design requirements. L. All piping and fitting in contact with potable water shall be fabricated of A312 type 304 in accordance with ASTM code. M. All drain valve connections shall be located at least 200 mm above the floor. N. The Bidder shall be responsible for pipe sizing and subject to approval of KNOC . O. Insulating flange kits shall be provided where carbon steel piping is connected to stainless steel piping. P. Instrument air piping shall be constructed of STS 304 seamless pipe or equal. 6.14.2.6 Pumps and accessories A. Pumps shall be designed to receive and support all forces and moments associated with startup, normal operation, and temperature changes. Duplicate pumps for the same service shall be designed to operate in parallel, at reduced flows, and without undue noise and vibration and danger of shaft breakage. B. Pump casings, motor supports, and counter flanges or bases shall be sufficiently rigid to safely withstand the forces resulting at any flow obtainable or during startup or shutdown of pumps. C. The Bidder shall list the materials which he recommends and guarantees under the specified conditions of operation and shall completely describe the proposed material by specification and analysis. D. Impellers shall be of the enclosed type, keyed to the shaft. Pump rotating assemblies shall be dynamically balanced. E. Sealing shall be standard packing gland. The glands shall be constructed to permit their inspection and packing removal without disturbing other parts of the pump. Adequate provision shall be made to collect gland 6.14-30 KHABAT TPP UNITS 1&2 - VOLUME I

leakage and drain it from the pump. The Bidder may submit, as an a alternative to standard packing glands, a mechanical seal which he recommends for the service. Seal water shall be applied to all packed pumps. F. Pump shafts shall be provided with replaceable sleeves where they pass through the stuffing boxes. The sleeves shall be hardened and adequately sealed to prevent leakage of air or liquid between shaft and sleeve. Sleeves shall be rigidly positioned. Positioning by set screws will not be acceptable. G. Pumps shall be provided with replaceable wearing rings. H. All pump and motor bearings shall be heavy duty, oil or grease lubricated. Oil lubricated bearings shall be suitable for lubrication with turbine oil. Constant level oilers shall be provided for oil lubricated bearings. I. Flanges shall be faced and drilled according to ANSI B16.5 standards. J. Pump shafts shall be accurately machined and ground and of adequate size and strength to maintain all clearances and withstand safely all stresses resulting from weight to be supported. K. Pumps shall be horizontal, radially split, frame mounted, single suction type, complete with drive motor, base plate, and all required accessories for completely operable units. L. Baseplates shall be either fabricated steel or cast iron, with drip lips and 20 mm minimum drain connections. The baseplates shall extend completely under both pumps and drivers. M. Couplings shall be spacer type, where required, to allow dismantling of the pumps without disturbing the motors or the pump pedestals. Metal coupling guards shall be provided to cover couplings and exposed keyways. N. A completely self-contained priming system shall be provided for the pumps which take suction from the underground filtered water reservoir. The priming system shall include but not be limited to foot valves, vacuum pumps, solenoid valves and a complete valving arrangement to provide pump priming as required. O. Chemical feed pumps shall be the metering, positive displacement diaphragm type and shall be furnished completely with drive motors, reduction gears, stroke control devices, and guards, all mounted on a common baseplate. 6.14-31 KHABAT TPP UNITS 1&2 - VOLUME I

P. Pump capacity shall be determined by the Bidder and shall be of adequate capacity to allow the system to perform as specified. Q. The acid and caustic unloading and transfer pumps shall have capacity to fill feed tank in 10 minutes and also to include minimum flow in addition to the feed tank filling flow. Pumps shall be suitable for chemical application. These pumps shall be started locally. However, additional stop button station shall be provided to the feed tanks to remotely stop the pumps when the feed tanks have been filled. R. The pumps for acid shall be constructed of FRP wetted parts or equal, and the pumps for caustic shall be constructed of 316 stainless steel wetted parts or equal. 6.14.2.7 Instrumentation and controls A. The instrumentation and controls of the raw water and the potable system shall designed in accordance with the section 8 of this technical specification. B. PLC based control cubicles and complete field instrumentation for the automatically controls and monitoring shall be provided. C. The control system shall be designed to enable the operator to supervise and operate the system by using LCD/keyboard. D. The control system shall be provided with the data communication interface devices with PCS for the supervisory control and monitoring in the central control room. E. Minimum two(2) operator interface station with dual LCD monitor(21” min.) and printer shall be provided. F. The PLC shall be provided with redundant (hot back-up) CPUs, power supplies and data communication networks. G. Conductivity cells and pH meters at the outlet of each anion and mixed bed exchanger shall register and alarm a preset conductance on the control panel indicating High Conductivity and Low & High pH. H. Analyzers a)

Specific Conductivity Measurement

b)

pH Measurement

c)

Silica Measurement

I. The flow totalizer shall be provided at the outlet of anion exchanger and mixed bed exchanger.

6.14-32 KHABAT TPP UNITS 1&2 - VOLUME I

6.15

Chemical Feed and Sampling System

6.15.1

Chemical feed system

6.15.1.1 System description The chemical feed system shall conform to the design and arrangement indicated on the drawings and requirements specified in the specification. The chemical feed system shall be capable of providing oxygen scavenging and pH control at the specified locations to prevent corrosion and phosphate to drum scale inhibitor. The plant shall be equipped with chemical feed systems to control the boiler and feedwater chemistry. The system shall be complete in all respects including bulk chemical storage tanks, dilution equipment, feed solution tanks, feed pumps, control systems and all pipework. Each chemical feed system shall comprise all equipment for the safe, reliable and efficient operation of the feed systems, including bunds, segregated chemical drains, appropriate ventilation and emergency eye wash and deluge shower units. Operation Capacity; The chemical feed units and related equipment specified herein shall be located indoors. The units are to be designed for mixing, storage, and feed of chemicals for oxygen scavenging, pH control and scale control of the condensate and boiler feed water for the electric power generating units as detailed in the data sheets and elsewhere in this specification.

6.15-1 KHABAT TPP UNITS 1&2 - VOLUME I

6.15.1.2

Design condition A.

Design Parameters The chemical feed system shall be designed to satisfy as follows. 1) Chemical Injection Procedure Chemical

Operation Mode

Mane

Conc.(%)

Injection Point

Method

Con. Water Boiler Initial Hydrazine

15

Pump Manual

Supply Outlet

Filling & Clean-up

Ammonia

0.2

Closed Cooling Water System

Purpose Oxygen

Revolution: Constant

Removal

Stroke: Constant

Manual pH control

2

Fresh

Auto.

Water Storage

Oxygen Removal

tank Hydrazine

2

Revolution: Constant Stroke: Constant Revolution : Proportion

Deaerator Hydrazine

Control Method

to feedwater flow Stroke: Feed-back control by deaerator outlet hydrazine

Closed Cooling Water System

Manual

Oxygen

Revolution: Constant

Removal

Stroke: Constant

Normal

Revolution: Proportion to condensate flow Ammonia

0.2

Condensate Pump Outlet

Auto.

pH

Stroke: Feed-back

Control

control by deaerator outlet specific conductivity

Phosphate

0.5

Boiler Drum

Manual

Scale Control

Manual

Deaerator Hydrazine

15

Shut Down

Fresh Water Storage

Manual

Oxygen Removel

Manual

Tank Ammonia B.

0.2

Condensate Pump Outlet

Manual

pH Control

Manual

The chemical tank shall have capacity of 2 days storage.

6.15-2 KHABAT TPP UNITS 1&2 - VOLUME I

6.15.1.3 Performance requirement The feed water entering the boiler shall be treated pH 9.3(±0.1) and dissolved oxygen shall be treated less than 7 ppb. The cooling water shall be treated pH 7.2 ~ 8.0 6.15.1.4 Design and construction features A.

General 1) The chemical feed system shall be designed so as to insure continuous, safe, and economical operation providing the maximum of reliability and without vibration or noise. 2) Duplication of components shall be maximized to the greatest extent possible such that similar components shall be interchangeable. 3) The equipment and all assembly joints or junctions shall include alignment or centering fits as required to ensure accurate reassembly or alignment of all parts. 4) The chemical feed system equipment shall be shop assembled, properly aligned and shop tested.

B.

Tanks 1) Two(2) hydrazine tank, one(1) ammonia tank and One(1) phosphate tank shall be provided by the bidder for each unit. 2) One(1) sulfuric acid tank, one(1) sodium hypochlorite storage tank, one(1) sodium hypochlorite tank and one(1) inhibitor tank shall be provided by the bidder for cooling water system. 3) All tanks shall be of welded construction of the size and arrangement as specified. The supports and skid arrangement shall be designed under the applicable code for the loads encountered during operation when filled to overflow capacity. 4) Tank shells and heads for hydrazine, phosphate and ammonia shall be not less than 3.2 mm in thickness. 5) Tank legs and skids shall be of carbon steel or equal.

6.15-3 KHABAT TPP UNITS 1&2 - VOLUME I

6) The bottom discharge of hydrazine, ammonia and phosphate tanks shall be equipped with a vortex breaker. 7) The tanks shall be constructed in accordance with API 650. C.

Metering Cylinders 1) Two(2) hydrazine and one (1) ammonia metering cylinder shall be provided by the bidder for each unit. 2) Demountable thirty(30) liter graduated metering cylinders shall be provided and fabricated as specified below. 3) Graduations should be permanently marked, in one(1) increments, with five(5) liter markings numbered.

D.

Pumps and Accessories 1) Dispensing Pumps a) The bidder shall provide one(1) hydrazine and One(1) ammonia dispensing pumps for each unit. b) Dispensing pump shall be of the air-operated, reciprocating bung type of drum pumps. c) Dispensing

pump shall be suitable for the transfer of a 35 %

solution of hydrazine shall be operated by air of 5.0 ~ 8.8 kg/㎠.g d) The lower assembly material of chemical dispensing pump shall be for type 316 stainless steel or equal. The pump shall have a stainless steel flexible hose in low-pressure. The length of hose supplied shall be suitable for the equipment arrangement and access provided by KNOC. 2) Chemical Feed Pumps a) Two(2) 100% capacity hydrazine feed pumps and two(2) 100% capacity ammonia feed pumps and two(2) 100% capacity phosphate feed pumps for each unit shall be provided by the bidder. b) Three(3) 50% capacity sulfuric acid pumps, two(2) 100% sodium hypochlorite unloading & transfer pumps, three(3) 50% capacity 6.15-4 KHABAT TPP UNITS 1&2 - VOLUME I

sodium hypochlorite pumps and three(3) 50% capacity inhibitor feed pumps for cooling water system shall be provided by the bidder. c) Pumps shall be the single-acting, positive-displacement diaphragm type and shall be furnished complete with drive motors, reduction gears, stroke and revolution-control devices, and guards, all mounted on a common base plate. d) Pumps shall be provided with an electro servo unit to permit changing the stroke with a remote signal. e) The wet parts for chemical service shall be Type 316 stainless steel or equal. Pump heads and check valves shall be replaceable and interchangeable with those within the same pressure-capacity service group, and shall be accurately machined and finished to a smooth surface with necessary drain connections provided. f) Pump frames shall be of cast iron and of rugged construction so as to support the pump chamber. All guides and seals shall be machined integral with the frame. g) Suction and discharge valves shall be replaceable and have replaceable seats, preferably without disturbing piping connections. Valves and seats shall be ASTM A 494(Hastily C) or equal. Pump connections shall be flanged to permit liquid end disassembly without disturbing piping. h) All materials such as gaskets, seals, 0-rings, etc., in contact with the pumped liquid shall be inert and free of organic materials, additives, or plasticizers. Teflon or similar fluorocarbons may be acceptable, provided the design retains the seal and does not permit material to be lost in the pumped liquid. Pump design shall ensure that no foreign material such as oil, grease, or other lubricant is in contact with the solution pumped or can come into such contact as a result of seal failure. i) Speed

reducer,

stroke

and

revolution

mechanism,

and

displacement control shall be totally oil-enclosed with means to

6.15-5 KHABAT TPP UNITS 1&2 - VOLUME I

ensure that no loss of lubricant into the pumping chamber can occur. j) Motor bearings shall be grease lubricated through suitable fittings. k) The control system shall be capable of smooth and continuous adjustment of pump feed rate through a range of 0 to 100 percent of pump capacity in response to controller output signal. l) Pump location shall provide for convenient maintenance and accessibility. m) Skid arrangement shall provide for charging any metering cylinder from a reagent drum with full view of gauge glasses on the metering cylinder. n) The bidder shall provide a relief valve of Type 316 stainless steel or equal with each proportioning pump package, and the valve shall be suitably sized to relieve at full capacity at a maximum pressure not to exceed 10 percent above the design pressure of the pump. Internal relief in a hydraulic displacement system is acceptable in lieu of external relief in the pump discharge line. o) External relief, if used, shall be piped back to the supply tank with means to observe proper reseating by a view port permitting observation of the pipe outlet. 3) Agitators and Strainers a) Each tanks specified herein shall be provided with a mixing agitator. b) All Parts in contact with the liquid, including shafts, tube, chuck and propellers shall be of type 316 stainless steel. c) The bidder shall provide a Y-type strainer of 316 stainless steel between the mixing tank and feed pump inlet. The size of inlet screen shall be at least 18 mesh, with openings not to exceed 1 mm.

6.15-6 KHABAT TPP UNITS 1&2 - VOLUME I

6.15.1.5 Instrumentation and controls A.

The Bidder shall design and supply all instrumentation and control system so as to insure accurate, safe and reliable operation under conditions of service.

B.

Instrumentation and controls shall be designed in accordance with the section 8 of this technical specification.

C.

All automatic and manual control action shall be possible through LCD monitor and PCS’s LCD monitor in main control room. And all engineering work shall be possible through the LCD monitor.

D.

The Bidder shall configure LCD graphic of the chemical feed system to the plant PCS.

E.

PLC based control cubicles and complete field instrumentation for the automatically controls and monitoring shall be provided.

F.

Minimum one(1) operator interface station with dual LCD monitor(21” min.) and printer shall be provided.

G. All hardware and software to establish the digital data communication link between the plant PCS and PLC. 6.15.2

Sampling system

6.15.2.1 General The plant shall be equipped with a system for the continuous extraction and monitoring of selected samples from the boiler steam and water circuit. The system shall be complete in all respects including sample cooling systems, analyzers, measurement devices and pipework. The selection of sample locations and analyzers shall ensure adequate observation and control of condensate, feed-water, boiler water and steam chemistry limits. The measurements from the analyzers shall be recorded on the power station PCS. A manual sampling facility shall be provided for each sample. A.

The system shall be designed with complete sample conditioning devices analyzers, transmitters, interlock, etc. The sample points and sample measuring items of each sample point are shown on the water analysis system design data and the attached drawing, water analysis system flow diagram.

B.

The water analysis system shall be designed to operate accurately and safely under the operating conditions described or implied in this 6.15-7 KHABAT TPP UNITS 1&2 - VOLUME I

specification, without undue heating, vibration, wear, corrosion or other operating troubles. C.

All piping/tubing and system components wetted by the sample stream shall be type 316 stainless steel.

D.

Each sample inlet connection shall be provided with an isolation valve suitable for the specified maximum pressure and temperature conditions for each sample.

E.

The flow stream to each measuring cell or analyzer shall include a flowmeter and a throttle valve for manual flow adjustment.

F.

The fabrication and design of the equipment to be furnished by the Bidder and the arrangement of equipment within the assemblies shall be such as to afford maximum accessibility to all parts.

G. All parts subject to high pressure or temperatures or other severe duty shall be type 316 stainless steel. H.

Parts subject to wear, corrosion or other deteriorating, or requiring adjustment, inspection or repair, shall be made accessible and capable of convenient removal when required.

I.

Rack and panel channel bases shall be provided by the Bidder.

J.

The equipment shall be completely assembled, piped and wired at the factory, ready for installation when received at the site. It shall be suitably braced to prevent distortion and damage during shipping and handling.

K.

Where a measurement signal is used for more than one device, the transmitter or other components shall be fully equipped to provide all signal requirements.

L.

The design shall permit removal from service of any indicating without upsetting the control system or requiring its readjustment.

M. The Bidder shall advise KNOC the approximate size, arrangement, weight, channel base arrangement, and access requirements of the enclosure. N.

To ensure sample freshness, each analyzer sample shall flow continuously. Bumpless transfer shall be incorporated so that the flow to the analyzer is undisturbed by grab sampling or maintenance of analyzers. 6.15-8 KHABAT TPP UNITS 1&2 - VOLUME I

6.15.2.2 Analyzers A.

Analyzers

and

associated

instruments

shall

be

designed

with

microprocessor based. The outputs shall be compatible with receiver and alarm device inputs. B.

Each analyzer shall have a self-contained digital readout meter. Each analyzer shall provide a high or low alarm status. The alarm points shall be set and indicated from the monitor's readout meter.

C.

Each analyzer shall have one(1) analog output circuits with independent zero and span adjustments. However, if a signal is required for chemical feed control system, the Bidder shall additionally one(1) analog output.

D.

Analyzer shall be suitable for flush panel mounting.

E.

Each analyzer shall be suitable to analyze the measuring range of samples as specified in attachments "water analysis system design data".

F.

The Bidder shall provide analyzers warranty service by use of local agent. This means that any problems with the analyzers can be handled locally and any malfunction resolved immediately. However, the formal warranty shall still be from the Bidder to KNOC.

G. Each analyzer shall have an independent power supply. When an analyzer is removed, there should be no power interruption to the other analyzers or devices. H.

The analyzer required reagents shall be provided with one(1) year supply of reagents.

I.

Specification and Cation Conductivity Measurement 1) Indicating analyzers for each point shall be provided for monitoring the signal output from the conductivity cell(constant: k=0.xx) assemblies. Range of measurement shall be as specified in attachments "water analysis system design data". The accuracy of measurement shall be within ±1.0% of reading. 2) The conductivity measurement shall consist of cell assemblies, indicating transmitter, cables and necessary accessories. Indicating

6.15-9 KHABAT TPP UNITS 1&2 - VOLUME I

transmitter shall be the function of password protection to secure data and access to critical setting and configuration. 3) Cation conductivity shall be measured by conductivity cell after cation columns. The Bidder's method of detecting cation column exhaustion shall be subject to approval by KNOC. Resin column, which is made transparent material, can be removed and attached easily. When the resin is exhausted, the resin column shall be refillable with regenerated resin or new resin. Being saturated with cation, the resin color shall be different from original color. 4) Conductivity

analyzer

shall

have

automatic

temperature

compensation with each kind of fluid. J.

pH Measurement 1) pH analyzer for each point shall be provided for measurement of the signal output from the pH electrode assemblies. The accuracy shall be within ±1.0% of reading. 2) pH analyzer shall include pH electrode assemblies (reference and pH electrodes), indicating transmitter, cables and necessary accessories. 3) pH analyzer shall have automatic temperature compensation, and shall have the indication of grass break and line disconnection, and shall have automatic calibration with auto-buffer recognition and sensor status.

K.

Silica Measurement 1) The silica analyzer system shall include all control valves, filters, constant head vessels, solenoid valves, manifold, sample cells, air operated valves, reagent containers and accessories required for proper operation. Unit shall be provided with one(1) year supply of reagents. The accuracy of measurement shall be with in ±5.0% of reading. 2) Zero calibration shall be performed automatically and be fully programmable auto-zeroing(blanking) capability. The measured value shall

be

compensated

implementation.

Span

for

contamination

calibration

shall

by be

analysis also

cycle

performed

6.15-10 KHABAT TPP UNITS 1&2 - VOLUME I

automatically. The Bidder shall subject automatic calibration method. Sample analysis methods shall be fully programmable reagent addition sequence with pre- and post-measurement wash capabilities. Measuring technology shall be single beam dual wavelength fiberoptic probe in the transfection mode. 3) The analyzer shall have the fully auto cleaning device for the cleaning the probe, and have programmable automatic calibration, zero point and gain, and automatic check of sample flow and reagent addition. 4)

At restart after the shutdown, the measurement cycle shall start only when the sample and the unit are at their optimum condition in order to improve the accuracy of the measured values.

5) The silica analyzer shall be capable of analyzing three(3) different sampling points, and independent output signal per each channel shall be available. Additionally while one(1) stream is analyzing, the analyzer outputs signals from the remained two(2) channels shall be maintained for continuous KNOC's PCS monitoring. L.

Dissolved Oxygen Measurement 1) Dissolved oxygen analyzer shall be provided for measurement of the signal output from the oxygen cell assembly.

The accuracy of

measurement shall be within ±5.0% of reading. 2) Dissolved oxygen analyzer shall consist of oxygen cell(316 stainless steel flow cell), indicating transmitter and necessary accessories for proper

operation.

Measurement

shall

be

made

through

electrochemical detection, using an "galvanic sensor" has a silver cathode in close contact to a pre-mounted PTFE membrane, and a lead anode that produces a fixed potential to complete the circuit. 3) Dissolved oxygen analyzer shall be equipped with calibration facility and the Bidder shall propose the calibration method. 4) The analyzer shall have the function of automatic temperature, and ambient pressure compensation, and automatic range switching, and the function of flow monitoring with alarm for flow of sample stream. 5) The Bidder shall provide the analyzer with low operational cost. 6.15-11 KHABAT TPP UNITS 1&2 - VOLUME I

M.

Hydrazine Measurement 1) Hydrazine analyzer shall be provided for measurement of the signal output from the hydrazine cell assembly. The accuracy of measurement shall be within ±5.0% of reading. 2) Hydrazine analyzer shall consist of hydrazine cell, solid state electrode, indicating transmitter and necessary accessories for proper operation. Passive diffusion reagent Addition system to condition the sample for optimal performance. Two point calibration shall be used by adding two known standards to the sample using a syringe pump. 3) Automatic calibration shall be achieved by introducing a standard known hydrazine concentration to the analyzer. The hydrazine analyzer shall automatically introduce the calibration solution, carry out any adjustments and then turn the analyzer to the sample mode. 4) Hydrazine analyzer shall have self-cleaning system with automatic temperature compensation. 5) The Bidder shall provide an analyzer that has low operational cost.

N.

Sodium Measurement 1) Sodium analyzer shall be provided for measurement of the signal output from the sodium cell assembly. The accuracy of measurement shall be within ±5.0% of reading. 2) Sodium analyzer shall be consisted of sodium cell, reagent container, indicating transmitter and necessary accessories for proper operation. Unit shall be provided with one(1) year supply of reagents. 3) The analyzer shall have the function of calibration by introducing double known standard the ppb range. 4) Sodium analyzer shall have the function of auto range change ( 0～1/ 1～10 ppb) and automatic temperature compensation automatic sample and pH conditioning with no pumps and have detection limit for sodium ion concentrations 0.01ppb.

6.15-12 KHABAT TPP UNITS 1&2 - VOLUME I

5) Sodium analyzer shall have flow cell with air stirring and sample air transport. Also, Sodium analyzer shall have the function of Self diagnostics. 6.15.2.3 Sample conditioning rack, analyzer panel, and control panel A.

The water analysis system shall consist of three sections as sample conditioning rack, analyzer panel and control cabinet taking into account improved functions and easy maintenance.

B.

The sample conditioning systems shall maintain samples within the following tolerances of the desired values using cooling water at 35 deg.C maximum and approximately 5.9 kg/cm2g operating, 10 kg/cm2g maximum.

C.

Sample flow to each cell or analyzer ± 2 percent.

D.

Sample temperature to each cell or analyzer 25 ± 1 deg.C.

E.

Under all sampling conditions, cells or analyzers not requiring minimum sample flow rate shall be designed with a flow rate of approximately 50～100 cc/min. If the analytical equipment requires some range of flow rate, the analyzer minimum flow shall be the design basis.

F.

Plant cooling water about 35 deg.C maximum and approximately 5.9 kg/cm2.g operating, 10 kg/cm2g maximum will be supplied to sample conditioning rack where required. The required coolant flow of the cooler in cubic meters per hour shall be stated by the Bidder.

G. Sample condition indicators shall be provided as the following. 1) A thermometer, flow meter and pressure gage in each sample line downstream of the secondary cooling system. 2) A flow meter in the sample line to each measuring cell and analyzer. The flow meter range shall be suitably coordinated with the flow requirements of the cell or analyzer. H.

Rack and panels shall be completely fabricated by the Bidder, including equipment mounting with properly designed supports and complete factory installed internal piping, tubing and electrical wiring for all devices.

6.15-13 KHABAT TPP UNITS 1&2 - VOLUME I

Internal piping, tubing, wiring and connections shall be securely fastened, compactly arranged and readily accessible. I.

Rack and panel shall be furnished with vibration dampeners, for isolation of the panel from vibration transmitted through the supporting floor. Type of the dampeners shall be subject to KNOC approval.

J.

The Bidder shall provide a water baffle between the sample conditioning rack, analyzer panel and control panel to prevent damage to analytical and transmitting instruments in the event of a high pressure tubing rupture.

K.

All required pressure, temperature and flow indicators, and the handle of isolation valves shall be mounted to permit viewing or manipulation from the front of the panel.

L.

Sample Conditioning Rack 1) The sample conditioning rack shall be totally enclosed with rear doors. The rack shall consist of sample lines. The size of sampling conditioning rack shall be enough to maintenance and repair. 2) A typical line shall be consist of the following items, but not be limited to; - Interface connection - Manual isolation valve - Primary cooler with cooling water throttling valve - Automatic controlled sample inlet and blowdown valve - Pressure reducing valve - Sample filter - Pressure relief valve downstream of the pressure reducing valve - Secondary cooling system - Pressure and temperature indicators - Automatic pressure control device (where required) - Grab sample valve - Routing to the sink 3) A manual isolation valve(immediately downstream the interface point) shall allow the operator to isolate the line for maintenance and repair. Double isolation valves shall be provided at high pressure sample lines as shown on attached reference drawing. 6.15-14 KHABAT TPP UNITS 1&2 - VOLUME I

4) Sample temperature control Sample temperature shall be reduced using 'primary' full counterflow sample coolers to achieve close approach temperature of the primary cooling water. Secondary "trim" coolers shall be used and cooled by a closed chilled water system, to achieve a controlled temperature of 25+1 deg.C. All coolers shall be furnished as an integral part of the conditioning rack. The temperature control system shall be furnished to maintain automatically the temperature of all samples (including manual samples) at 25+1 deg.C. Sample temperature shall be controlled by controlling the temperature of the cooling water supply to final temperature control sample "trim" coolers with chiller units. The cooling water shall be circulated between the sample coolers and chiller unit in a closed loop, with temperature automatically controlled by controlling refrigerant flow to the compressor in the chiller unit. The temperature control system shall include all necessary accessories; including the sample coolers, full-capacity circulation pump for the cooling water, full-capacity hermetically sealed compressor, and all necessary piping, valves and controls. A control valve to regulate the refrigerant cooling water supply to the chiller unit shall be furnished.

The chiller unit for each unit service shall be

mounted outside the panel in an adjacent area. The Bidder shall establish the chiller loads and include 50% over capacity, submit the calculation sheet after award. Where required, primary sample coolers shall be installed upstream of the temperature control coolers, to provide the initial sample cooling,

bringing the temperature within a range at which it can be

satisfactorily controlled with the trim cooler. All coolers shall be of the shell and tube type design, with counter current flow of sample and cooling water. All coolers shall be arranged side by side on a rack and shall be connected to an inlet and an outlet cooling water header, without disturbing the sample connections and other cooler for rapid removal and replacement of tube. The primary sample coolers shall be equipped with a inlet globe valve and outlet check valve, and secondary sample cooler shall be 6.15-15 KHABAT TPP UNITS 1&2 - VOLUME I

equipped with a inlet and outlet globe valve for throttling the supply of cooling water. The sample coolers shall have removable shells. All coolers shall have 316 stainless steel tubing. All shells shall be 304 stainless steel. Temperature indicators shall be provided to measure and indicate each trim sample temperature. Temperature measurements shall be taken downstream of each trim cooling device. 5) Two air pneumatic shutoff valves shall be provided for each line. The first valve shall be for sample inlet and the second valve shall be for blowdown. These valves shall be controlled both manually and automatically from the control panel. 6) Automatic pressure reducing devices shall be provided in order to automatically control the required pressure and flow to account for the sample line pressure variation during plant load cycling such as boiler feed pump outlet, economizer inlet and main steam. 7) Primary filters shall be provided and installed upstream of pressure reducing valves, and shall be placed with easy access in the sample conditioning rack. These filters shall be capable of protecting the devices of the filter downstream from contamination. 8) Each analyzer incoming sample except that for grab sample shall be filtered before analyzer.

Pore size shall be between 10 and 300

microns. 9) Pressure control valves with pressure controllers or pressure reducing valves shall be provided to maintain sample pressure specified by the analyzer manufacturer. 10) Each sampling line except hotwell sample line shall be provided with a pressure relief valve downstream of the pressure reducing valve, to protect the associated measuring cells and/or analyzers from overpressure in accordance with pressure limitations imposed by the manufacturer. 11) The conditioning rack shall be a free standing rack, into which all conditioning equipment is mounted. The sample shall be connected to the rack at the top rear side. From this point, the sample shall 6.15-16 KHABAT TPP UNITS 1&2 - VOLUME I

flow through tubing and various control instruments to be conditioned its pressure, temperature, and flow rate. 12) Grab sample facility shall be designed to exhaust sampling water through the common sink and equiped with manual valve individually. 13) The sample conditioning rack shall have a 304 stainless steel waste header extending the length of the rack for collection of all wastes. 14) The sample drain headers shall extend the entire length of the rack and shall be provided with connections for all installed analyzers. 15) The rack shall have a 316 stainless steel used sample header which shall extend the length of the sample rack and have a sufficient number of openings on the top of the header to accommodate all used samples to be reclaimed together for disposal. 16) The Bidder shall provide the differential pressure switch between coolant supply and return line. The switch shall be used for the monitoring of loss of primary coolant. M. Analyzer Panel 1) The analyzer panel shall be designed to be located in close proximity to the sample conditioning rack. The analyzer panel shall be totally enclosed with rear doors. 2) It shall be a free standing panel into which analyzers are mounted. 3) If stand alone type analyzer will be provided, they shall be installed next to the sample conditioning rack. 4) The drain lines from the analyzers shall be directed such that whenever the sample inlet valve closes, cells /probes shall be kept wet until the flow restores. N.

Control Panel and Programmable Logic Controller 1) The control cabinet shall be NEMA 12 enclosure type for protection against dust and water. 2) The system shall have alarms for the following condition as a minimum.

6.15-17 KHABAT TPP UNITS 1&2 - VOLUME I

- Each analysis result abnormal - Condensate hotwell sample pump discharge press. low - Condensate hotwell sample pump trip - Chilled water circulating pump trip - Chilled water temperature high - Control system trouble & power failure - Logic discrepancy - Others (after award) 3) The sampling 4～20mA signals shall be transmitted to chemical feed control system from water analysis control system by hardwire 6.15.2.4

Sample pump A.

The Bidder shall supply one pump per skid, four skids per unit.

B.

Sample pump skid shall include the suction, discharge and return valves, check valve, discharge pressure gages and switches, and differential pressure gages and switches.

C.

The pumps shall be the horizontal, centrifugal canned type with all specified and required accessories for operable units. 1) The pumps shall be designed and manufactured to avoid pump cavitation .

D.

The Bidder shall state the maximum limits of vibration and the method of measurement that will be used to determine correct operation of the pump and coupling before shipment.

6.15-18 KHABAT TPP UNITS 1&2 - VOLUME I

6.16

Auxiliary Boiler

6.16.1

General A.

The auxiliary boiler shall be natural circulation and shall be composed of a drum type, including all pressure parts, refractory, insulation, casing, supporting steel base, usual accessories, trim and soot blowers.

B.

The furnace shall be fired by air and light oil incorporating air inlet damper, forced draft fan with motor, discharge ductwork, inniter system, burner assembly, flue gas outlet breeching, outlet damper, duct and stacks.

6.16.2

Design and construction The boiler shall be designed throughout so as to ensure continuous, safe and economical operating providing max. of reliability and without undue heating, vibration and noise. The boiler, auxiliaries and accessories shall be designed in accordance with the applicable parts of the listed codes and standards. The boiler proper shall be shop assembled as complete as possible and shipped as a single section so that only the forced draft fan with electric motor drive, sir ducts, gas duct and breechings, piping, and miscellaneous trim and control devices will require attachment during installation. Auxiliaries Doiler and accessories shall be designed for the seismic factor and winding loading in this specification..

6.16.2.1 Furnace and casing The furnace shall be adequately sized to prevent overheating in any portion of the boiler when operating continuously throughout any load and condition. The furnace walls, floor, and roof shall be cooled with water tubes, however, a portion of the front wall at the burners may be protected from overheating by an adequate amount of refractory material. The distance from the centerline of the burners to the wall, roof, and internal tubes shall be sufficient to prevent any flame impingement on the tubes throughtout any load and condition. The boiler casing shall be reinforced for pressurized operation and shall be designed to prevent gas leakage. The furnace, fans, flues, ducts, piping, and appurtenances provided by the Bidder shall be thermally insulated so that the outside surface temperature wiil not exceed the ambient air temperature by

6.16-1 KHABAT TPP UNITS 1&2 - VOLUME I

more than twenty(30) degree C when operating with ambient air velocity of 1 meter per sec. The flue gas outlet transition section shall be flanged with an expansion joint for connection to the ductwork or stack. Necessary observation ports and access doors shall be provided as required for operation, inspection and maintenance. 6.16.2.2 Pressure parts Pressure parts for the boiler shall be designed and fabricated from materials with analysis and thickness that meet the requirements of the ASME Boiler and Pressure Vessel Code, Section I. The longitudinal and circumferential welds of the drum and header shall be fully radiographed and stress relieved in accordance with the applicable code and standard, and magnetic particle test shall be examined on the welds after stress relieved. Nozzle shall be forged steel and welded to the drums and headers. The steam drum shall be equipped with multistage internals for steam drying and with provisions for feedwater distribution. Tubes shall enter steam drum radially and below the normal water level. Bends shall be such that the tubes can be cleaned internally with a commercially available mechanical tube cleaner. Tube shall be expanded at drum connections without over-rolling. 6.16.2.3 Trim Boiler trim shall be include all ASME Boiler and Pressure Vessel Codes, Section I items and at least the components listed in the following subparagraphs : A.

Drum and superheater outlet safety valves, including gages and drip pan discharge elbows and exhaust stack.

B.

Electric motor-operated main steam outlet stop valve and check valve, and piping up to main steam steal line terminal point, which may be attached in the field if necessary.

C.

The stop valves of feed water shall be furnished with an electric motor operated sized to hold the valve tightly closed during hydrostatic testing of the feedwater piping system.

D.

The feedwater regulating valves shall be provided with two isolating block valves, a bypass globe valve and all piping. The main steam backpressure control valve shall be provided with all necessary modulating 6.16-2 KHABAT TPP UNITS 1&2 - VOLUME I

type pneumatic controls to ensure that boiler outlet pressure does not fall below a predetermined point. A 25mm bypass valve shall be included with the electric motor-operated main steam outlet stop valve for warmup purpose. E.

Light oil control and trip valves shall include piping from the trip valve to the burners.

F.

Water column with gage glass and level transmitter for high-low level alarm and low-low level fuel trip switches shall be provided and shall be piped to the boiler drum with the isolating valves.

G. Drum level indicator located at eye level at grade shall be provided including a constant head chamber, compatible secondary electronic indicator, and all required shutoff valves and manifolds. H.

Drum steam pressure gage shall be provided with 150mm dial, range (050kg/cm2g), minimum scale range (0.1kg/cm2g), accuracy (± 1.0%), piped with valves for observation at grade.

I.

Self-contained, controlled, steam sootblower system shall be provided by the Bidder.

J.

Continuous bloedown valve located at grade operating level.

K.

Dual lower drum bloeoff valves and piping shall be provided up to terminal point.

L.

Acid cleaning connections shall be provided as required for cleaning the pressure parts and to facilitate flushing and drainage.

M. All drain and vent pipings with valves shall be provided as required. N.

Nozzles with double valves shall be provided for all vents, drains, instrumentation and controls, chemical feed, and sampling connections.

O. Heating steam to the lower drum heating coils will be obtained fron the auxiliary steam system. The steam coils should be large enough to maintain adequate boiler pressure. All piping, valves, steam traps, etc. should also be sized on the above basis. P.

Deaerator pegging steam control valve(s) shall be supplied to control deaerator pressure over the opearting range. The pegging steam shall be derived from the auxiliary boiler steam header. Deaerator makeup shall be controlled by a deaerator makeup control valve supplied by the Bidder. Deaerator storagr tank level shall be controlled by a level control valve suplied by the Bidder.

6.16-3 KHABAT TPP UNITS 1&2 - VOLUME I

6.16.2.4 Forced draft fan The forced draft fan shall have a max. speed of 1,500 rpm and shall be direct motor driven. The fan shall have test block margins of site condition for temperature, 30% for static pressure and 20% (by weight) for capacity. Vane-type inlet dampers shall be furnished with the fan, together with a discharge duct and supports to the boiler windbox. 6.16.2.5 Burners and windbox The burner(s) shall be of a size and quantity to meet the boiler performance requirements. The boiler shall supply all steam necessary for the operation of its burner(s). The connecting piping shall be complete with all valves, traps and strainers. The burner(s) shall be compatible with the control system. The windbox shall be manufactured of steel plate at least 6mm thick and shall be designed to provide uniform air entrance into the burner registers. The windbox shall be seal welded to the boiler front plate. The light oil burner(s) shall be of the air-atomizing type for start-up and steam atomizing after sufficient steam pressure is generated. The switchover shall be done manually at the burner front in cold start-up and automatically in hot start-up. An oil gun shall be designed to fit into a burner socket and shall be clamped securely in place but manually retractable for cleaning. The burner shall incorporate a device to permit the oil passages of the gun to be purged with steam or air after use so that the gun may be removed without dripping oil. All burner-front accessories, such as flexible hoses, supervisory cocks with limit switches, gun engagement switches, fuel and atomizing media gages, atomizing media pressure control valves, and drain traps, shall be provided in accordance with the required codes. 6.16.2.6 Sootblower The unit shall be provided with a motor driven soot blowing system. Sootblower elements shall be suitable for continuous extra high temperature exposure to the products of combustion. Each element shall include its shut-off valve including steam trap with block and bypass valves for complete cycle operation and the following appurtenant items : A.

Integral motor starters with NEMA 12 enclosures for rotary sootblowers and long retractable sootblowers.

6.16-4 KHABAT TPP UNITS 1&2 - VOLUME I

6.16.2.7 Stack The stack shall be self supporting type. The stack shall be of welded steel construction and limited to ensure satisfactory operation throughout the full expected life of the station. All structural steel and plate material shall be ASTM specification A36 or equivalent. All welding shall produce full penetration, gas-tight joints and be in strict compliance with AWS code D1.1 structural welding code. A stack shall be equipped with drains and an inspection manhole. Stack shall be located at grade. The Bidder provide breeching, including a sealed flexible joint and breeching supports, between the casing and the stack. All surfaces of the breeching and all surfaces of the stack to a height of 2.0m above grade or to the top of the breeching, whichever is higher, shall be insulated by the Bidder. Lighting for stack shall be provided, if required. The Bidder shall furnish necessary instrumentation for measuring the contents of oxygen and combustible in the flue gas, which shall be recorded, indicated at the Bidder’s control system. 6.16.2.8 Blowing system One continuous blowdown system shall be supplied for the steam drum. The maximum blowdown rate shall be 3% of the feedwater flowrate at MCR. The blowdown system shall include, but not be limited to, the following. A.

One manual-operated isolation valve, normally locked in the open position.

B.

All blowdown piping to the blowdown tank.

C.

All necessary hangers and supports.

D.

Blowdown valves and piping shall be suitable for passage of acid wash and shall be of design.

E.

Blowdown tank shall be designed, fabricated and inspected in accordance with the ASME Boiler and Pressure Vessel Code, Section VIII, Division I.

F.

Blowdown tank shall be arranged for venting to atmosphere.

6.16.2.9 Combustion and feedwater controls A.

Automatic modulating combustion and feedwater controls of the microprocessor based control system shall be furnished. The control system shall be designed fo automatic and manual operation from the 6.16-5 KHABAT TPP UNITS 1&2 - VOLUME I

operator interface station with bumpless, transfer from one to the other. The electronic and pneumatic controls shall be designed to prevent resetwindup. It shall not be necessary to place any of the control stations in manual mode during periods of normal firing condition, but shall be necessary to operate in manual mode partially during period of low firing or hot standby(boiler shut-down) to prevent reset windup. All instruments and controls for operating the boiler, auxiliary pumps and other associated items in the auxiliary steam generating system shall be located near the auxiliary boiler. It shall be a freestanding item entirely separate from the boiler. B.

Master steam pressure control system shall be provided to maintain steam pressure by proper regulation of fuel and air flows. The control system shall be operate the boiler with a minimum of excess air maintaining steam pressure within ±3 percent of set pressure.

C.

The combustion control system shall include fuel and air flow controls, fuel-to-air ratio adjustments, and fuel and air cross limit controls to ensure a safe-to-air ratio over the entire operating range. The system shall also include the fuel regulator, air flow damper actuator, transmitters, and square root extractors, to form a complete, safe, and dependable control system. Afuel supply pressure regulator shall be provided to maintain constant pressure ahead of the Bidder’s fuel control valve. The fuel flow transmitter shall be designed to assure dependable metareing over the required range of flows and shall be complete with the necessary primary flow element. Aminimum firing rate limit shall be provided to prevent operation of the burner at rates below the minimum required for stable burner performance.

D.

The minimum firing rate limit shall consist of a minimum burner pressure limit. The fuel control valve shall be selected to operate within the maximum and minimum usable Cv listed by the manufacturer. If sufficient range ability cannot be attained with one valve, two fuel conatol valves of different sizes shall be provided in parallel and arranged for sequential operation with overlap.

E.

The Bidder shall provide a three-element, feedwater control system with transmitter and all other necessary devices to form a complete and dependable control system. The feedwater and steam flow transmitters shall be supplied complete with required primary flow elements. 6.16-6 KHABAT TPP UNITS 1&2 - VOLUME I

F.

The deaerator control system shall consist of three major elements ; • Deaerator pressure control • Deaerator condensate make-up control • Deaerator level control The source for pressurizing the deaerator shall be auxiliary steam. Control shall be provided to modulate the pressure control valve(s) over the entire operating range. Split range control shall be used if required. Feedwater demand shall be used as a feed forward index for deaerator level. Suitable interlocks shall be provided to prevent high water level damage to the deaerator during rapid bad changes or boiler trip conditions. Deaerator level control shall be modulated by the deaerator level control valve.

6.16.2.10 Burner safety controls In addition to the safety features included in the combustion control system, the Bidder shall provide an automatic programmable logic controller(PLC) type’s burner ignition, and operational safeguard system in accordance with NFPA standards. The safeguard system shall consist basically of the controls and interlocks required to produce a safe firing and tripping sequence and a series of devices and interlocks to trip the boiler during any of a number of specified unsafe operating conditions. Station operating personnel shall start and/or determine that the necessary auxiliaries are in service before starting the boiler with a push button on the local control panel. Permissive conditions shall be determined by Bidder. 6.16.2.11 Pumps The auxiliary boiler feedwater pumps, condensate make-up pumps shall be horizontal centrifugal pumps with electric motor drivers and light oil feed pumps shall be screw pumps provided with electric motor drivers and baseplates. A.

Auxiliary boiler feedwater pumps The Bidder shall furnished two(2) 100 percent capacity as an integral part feed water pumps of the auxiliary boiler package. The pumps shall include at least 4 percent surge and 4 percent wear allowance. The suction of each pump shall be provided with an isolation valve, strainer and pressure gauge. The pump discharge with isolation and check valve and pressure gauge shall be provided. Minimum flow and 6.16-7 KHABAT TPP UNITS 1&2 - VOLUME I

recirculation lines with control devices and isolation valves piped to the deaerator storage tank shall be provided. Each pump and its driver shall be mounted and line up on a grid fabricated steel, drip-rim, common base plate of adequate size. Pumps shall be mounted below the deaerator and shall operate within their NPSH requirements for all conditions of operation. Each base plate shall be large enough to preclude equipment overhang. Pump material and construction shall be suitable for the specified service. Materials or parts where close running clearances will be encountered shall be selected for their resistance to galling. Shaft sleeves are required and shall be of suitable heat treated or hard faced material, ground and polished and so arranged that that will not turn on the shaft. The sleeves shall have an adequate seal to prevent leakage of air or water between the shaft and the sleeve. The general design and arrangement of all working pumps parts shall provide ready access for inspection, renewable and repair of parts and lubrication. All passages of the pumps shall be designed to permit complete drainage with the pumps in the normal operating position. The pumps shall be designed to be free of crevices and to prevent accumulations of particulate matter. Connections shall be provided for vents, drains and pressure gauges. Attachments for lifting and handling shall be provided. Pump casing shall be designed to withstand the hydro test pressure as well as pump shutoff head at rated speed. The impellers and shafts completely assembled shall be statically and dynamically balanced before incorporation into the pump. They shall be designed with critical speeds substantially away from operating speed. Oil lubricated ball bearing shall be furnished to provided smooth operation and absorb any unbalanced forces during all service conditions. Pump seals shall be of the mechanical seal type. Pumps shall have provisions for collecting seal leakage so it may be routed to sumps. Seal design on all pumps shall preclude introduction of bearing oil in the feedwater. Forged steel, flexible shaft coupling shall be furnished for each pump6.16-8 KHABAT TPP UNITS 1&2 - VOLUME I

motor connection. Coupled pumps shall be provided with coupling guards. Keys of keyholes shall not extend beyond the coupling guard. All necessary controls and instrumentation such as selector switches, pressure switches to activate the standby pump, etc., to meet the pump design conditions shall be provided. B.

Condensate make-up pumps The Bidder shall furnished two(2) 100 percent capacity condensate make-up pump as an integral part of the auxiliary boiler package. The pumps shall operate within their NPSH requirements for all conditions of operation.

Minimum flow and recirculation lines with orifices,

isolation valves and check valves piped to the condensate storage tank shall be provided. Pump seals shall be of the gland seal type. C.

Light oil feed pumps The Bidder shall supply furnished two(2) 100 percent capacity light oil feed pumps as an integral part of the auxiliary boiler package. The baseplates shall be of fabricated steel or cast iron with drain rim and drain connections. The surface of the baseplates shall extend under both the pump and the drive motor, and shall be fitted with all necessary mounting pads, anchor bolts and grout holes. Suction and discharge connections may be flanged as required for the specified service. Flanges of cast steel shall be raised face, face and drilled in accordance with ANSI ASME B16.5. Bearings may be of the sleeve or anti-friction type in accordance with the manufacturer’s standard design. Shafts shall be accurately machined from hardened carbon steel and of adequate size and strength to maintain all clearances and withstand safety all stresses resulting from full voltage starting and normal operation. Pumps shall be furnished with mechanical seals. Drip chambers shall be so constructed to ensure effective collection of all drips. Pumps shall be direct coupled to the drive motor by a flexible coupling of suitable size to transmit the require torque continuously and the satisfactorily and to handle any misalignment that may occur under normal conditions. Pump material and construction shall be suitable for the specified service. Materials or parts where close running clearances will 6.16-9 KHABAT TPP UNITS 1&2 - VOLUME I

encountered shall be selected for their resistance to galling. All necessary controls and instrumentation such as selector switches, pressure switches to activate the standby pump, etc., to meet the pump design conditions shall be provided. 6.16.2.12 Deaerator and storage tank The deaerator shall be of spray and tray type. The deaerator shall be designed, fabricated, examined, and constructed in accordance with the ASME Code, Section VIII, Devision I. The deaerator shall be designed quietness of operation and minimum vibration at all rates up to and including its maximum capacity, during rapid load changes, and with entering feedwater temperature. The deaerator and its component parts shall be designed so that safe working stresses are not exceeded during any mode of operation. Design and fabrication of structural steel shall be in accordance with the applicable Codes and Standards. Deaerator storage capacity shall be at least 5 minutes without influent flow at rated output. Over the entire load range, the free carbon dioxide content shall be reduced to zero, and the deaerated water shall be heated to the saturation temperature corresponding to the steam pressure maintained in the shell. Distribution pipes and other welded internal heater trays, impingement plates and nonwelded internal trim shall be made of ASTM A240 type 304 stainless steel. All internals trim shall be made of ASTM A240 type 304 stainless steel and shall be fastened in place so that they cannot shake loose. The storage tank shall be horizontal and an integral part of the deaerating section. Adequate access shall be provided for inspection and maintenance of the deaerator internals. Pressure vessels shall be of all welded construction. The storage tank shall be provided with a drain connection, located flush with the bottom of the tank. The deaerator shall be provided with an internal stainless steel vent condenser, including vent deflector-hood, vent orifice or a separate vent valve. Downcomers shall be equipped with deflector hoods to protect the tray from upsurges of condensate. Steam inlet impingement baffles shall be designed to withstand an occasional water slug. Nozzle shall be extend beyond the insulation 6.16-10 KHABAT TPP UNITS 1&2 - VOLUME I

thickness. The auxiliary boiler feedwater connection shall extend 75mm up from the bottom of the storage tank. Pipe manifolds shall be furnished for all inlets and outlets requiring multiple connections to the deaerator, including the manifolds for the level instruments. 6.16.2.13 Chemical feed tanks and pumps A complete system shall be provided for mixing, storing and metering phosphate, hydrazine and ammonia solutions into the auxiliary boiler drum and feedwater for the prevention of corrosion and scaling. The phosphate tank and metering assembly shall consist of one tank with cover and two metering pumps. The phosphate tank shall be provided with a motor driven portable mixer, mixing basket and gauge glasses. The hydrazine and ammonium hydroxide tank and metering assemblies shall consist of one tank with cover and two metering pumps. The tanks shall be provided with motor driven portable mixers and gauge glasses. 6.16.2.14 Instrumentation and control A. The Bidder shall furnish a complete package of instrumentation and controls necessary to meet the requirements of this specification, and that shall offer a high degree of reliability and safety to both personnel and apparatus. B. Instrumentation and controls shall be designed in accordance with the section 8 of this technical specification. C. PLC based control cubicles and complete field instrumentation for the automatically controls and monitoring shall be provided. D. Minimum one(1) operator interface station with dual LCD monitors(21” min.) and printer shall be provided. E. All instruments and controls shall be easily accessible for maintenance and adjustment. Cubicles and equipment therein shall be suitable for operation in the ambient condition at their locations. Internal fluorescent illumination with switch, fan, space heater and power receptacles shall be mounted in each cubicle. F. The control system shall be designed to enable the operator to supervise and operate the system by using LCD/keyboard in local and OWS in CCR. 6.16-11 KHABAT TPP UNITS 1&2 - VOLUME I

G. The control system shall be provided with the data communication interface devices with PCS for the supervisory control and monitoring in the central control room.

6.16-12 KHABAT TPP UNITS 1&2 - VOLUME I

6.17

Diesel Generators

6.17.1

General The specification for four(4) set of black start & emergency diesel generator system for Irag Kurd Project complete with accessories are descriptive of the requirements but do not attempt to enumerate all details of accessories and appurtenances. Such details are to be provided by the Bidder after award.

6.17.2

System description

6.17.2.1 Each diesel generator shall be a direct injection, compression ignition, turbocharged and charge air cooled industrial engine of standard design and construction in accordance with the requirements of ISO 8528. 6.17.2.2 The engine flywheel shall be suitable for the required starting duty. 6.17.2.3 Turbochargers shall be exhaust gas driven. 6.17.2.4 Engine governors shall be in accordance with ISO 8528 Performance Class G1. Each diesel generator shall be complete with a local control panel which shall be interfaced to the electrical control system. 6.17.2.5 The fuel shall be derived from the main fuel oil system. 6.17.2.6 One cooling radiator shall be provided for the engine taking into account the engine duty. 6.17.2.7One heat exchanger shall be provided for cooling the engine jacket water. The jacket water system shall be thermostatically controlled, with an engine driven circulating pump. 6.17.2.8 The lubricating oil system shall be self contained independent pressurized serving all the engine requirements. 6.17.2.9Engines started using compressed air shall have one receiver per engine, and the system shall be sized for six starts. 6.17.2.10

It shall be possible to exercise each diesel generator on load for test purposes. When exercising all engine protection, alarms and trips shall be operational. During exercising the load on the essential supplies/common switchboard shall be transferred to the diesel generator.

6.17.2.11

Each generator shall be of the brushless type with Class 155 (F) insulation with temperature rises and total temperatures limited to Class 130 (B) limits. 6.17-1 KHABAT TPP UNITS 1&2 - VOLUME I

6.17.3

Operation condition

6.17.3.1 The power station shall be equipped with diesel engines generating plant with the purpose to perform both black-start of a unit and to feed emergency loads during an emergency shutdown. 6.17.3.2 It shall be composed by four diesel generators. Their size shall be selected in order to allow the following action : -

Three diesel generating units must be able to perform the black start of a plant unit and feed emergency common loads.

-

Two diesel generating units must be able to feed emergency loads of two plant unit and emergency common loads.

-

Each diesel generating unit must be able to feed emergency load of one plant unit and emergency common loads.

6.17.3.3 Each diesel generating set shall be equipped with its own step-up transformer, circuit breakers, protection, measuring and control panel. 6.17.3.4 The characteristics of the generator will be as follows : - Design load(preliminary)

[1250] kVA

- Design voltage

400 V or 6 kV

- Design frequency

50 Hz

- Design power factor

0.85

6.17.3.5 Start-up,

shut-down

and

paralleling

operations

shall

be

performed

automatically by means of a local PLC providing the diesel engine control. 6.17.3.6 Alarms and instrumemtation will be connected to terminals for remote monitoring. 6.17.4

Mechanical design requirements

6.17.4.1 The diesel engine shall be of the multi-cylinder, in-line or V-type, water cooled, cold starting type, fuel diesel, four stroke cycle, stationary type and of the ISO and IEC 60034-22 standard design for emergency source of power required for power plant service. 6.17.4.2 The power rating of the engine shall be stated by the Bidder for each rated output of the unit. The site continuous rating shall be based on unlimited engine operating hour and not less than 2,000

engine operating hour

between maintenance overhauls.

6.17-2 KHABAT TPP UNITS 1&2 - VOLUME I

6.17.4.3 The engine shall be manufacturer's current design for stationary service. The engine shall be directly connected to the generator. The rated speed of the engine shall not exceed that of the manufacturer's engines of the same configuration already in operation for a period of 3 years either base load or emergency electrical power generation. Tandem or twin units driving a common generator are not acceptable. 6.17.4.4 The basic engine accessories shall include : a) Engine piping, including inlet and outlet connections as required for jacket water, lubricating oil, fuel, starting air and exhaust, including all counter flanges. b) Lubricating oil sump including level dip stick indicator for level observation c) Electric load, speed-sensing and woodward type or equivalent governors including control box, resistor box, and potentiometer. The governor shall have capability for both independent and parallel operation. Load sharing is not required. The governor supplied shall comply with ISO 3046. Frequency drop for independent operation shall not exceed 5％. d) Overspeed trip device at 115 percent of the rated speed. e) Flywheel turning device. f)

Turbochargers exhaust gas driven type.

g) Relief valve for cylinder and/or crankcase. 6.17.4.5

The air intake system shall include : a) Dry type intake filter. b) Finned tube or plated fin air cooler.

6.17.4.6

The exhaust gas/air system shall include : a) Silencer, reactive type. b) Expansion joint, stainless steel bellows with carbon steel flanges.

6.17.4.7

The fuel oil system shall include: a) Heavy duty filters with fine mesh, duplex, replaceable element type, inlet and outlet differential pressure indicator gauge, differential pressure switch for annunciation. b) The fuel storage capability of day tank designed for 4 hours continuous operation with high and low level switches for annunciation and level gauge, suitable supporting structure for placing on foundations.

6.17-3 KHABAT TPP UNITS 1&2 - VOLUME I

c) Control provisions(dry contacts) for starting and stopping the fuel oil transfer pump by high and low level of fuel oil day tank. d) Solenoid valve for fuel inlet 6.17.4.8

The lubricating oil system shall include : a) Cooler, radiator driven AC motor. b) Duplex full-flow lube oil filter metal edge type, or basket type with fine mesh, inlet and outlet differential pressure indicator gauge and differential pressure switch for annunciation. c) Warm lube oil circulating and prelubrication pump, motor driven, with mechanical seal, baseplate, and flexible coupling with guard. d) Lube oil temperature indicators on inlet and outlet of lube oil cooler. e) Main lube oil pump, integral with engine. f)

Priming lube oil pump including one(1) stand-by pump.

g) Lube oil preheater. h) Potable electric lebe oil pump for filling. 6.17.4.9

Cooling system shall include : a) Engine-driven jacket water circulating pump. b) Air-cooled radiator with shroud and mounting devices. c) AC Motor driven radiator fan. d) Expansion tank with level indicator and level switch for low level alarm, air vent and float valve. e) Jacket water heater with thermostatic control to maintain minimum jacket water temperature when engine is not in operation. f)

All instruments, controls, etc. necessary to maintain the required minimum and maximum water temperatures for each component.

6.17.4.10 Starting equipment shall include : Suitable starting equipment shall be supplied. The equipment shall be of the compressed air and rated for three start attempts in succession followed by one successful start. a) Compressed air system shall include that one(1) air receiver tank sized to start engine a minimum of four(4) times without recharge, with pressure gauge, safety valve, and automatic drain, which shall be designed in accordance with ASME Section Ⅷ. One(1) air compressor multi-staged, air cooled type, having capacity to 6.17-4 KHABAT TPP UNITS 1&2 - VOLUME I

charge air receiver from minimum pressure to maximum pressure within thirty(30) minutes. Start and stop of air compressor shall be controlled automatically by pressure switch fitted at air receiver. b) In case of the initial starting for black start & emergency diesel generator sets under black out, the Bidder shall provide small capacity of generator set with cell motor starting device using battery remotely for supply electric power of lube oil priming pump and air compressor. c) Air compressor including one(1) stand-by compressor d) Small diesel engine generator(90kVA Class) including battery, battery charger, minimum one(1) fuel oil tanks, etc. 6.17.4.11 Other mechanical requirements; a) Each auxiliary system supplied by the Bidder shall be complete with sufficient pressure, temperature, level, flow, and differential pressure instruments for control and monitoring of the system. b) Exhaust thermocouples shall be in accordance with JIS. c) Each pump, except those mounted inside of equipment shall be provided with local pressure indicators in the suction and discharge. d) Each cooler, except those mounted inside of equipment shall be provided with local temperature indicator at the inlet and outlet. e) Pneumatic instruments and controls shall not be used. f)

The Bidder shall provide process temperature connections 25mm(1inch) NPT and pressure connections 20mm(3/4inch) NPT for connection of monitoring instruments.

g) A complete set of foundation bolts, nuts, plates and washer for the diesel generator unit where required, shall be supplied by Bidder to anchor the engine generator to the foundations. h) One set of special tools, required for regular operation, maintenance, and repair of the diesel generator unit shall be supplied for the station. i) The Bidder shall be responsible for sizing and providing anchor bolts and nuts. 6.17.5

Electrical and Control System Design Requirements

6.17.5.1 The diesel generator unit shall be capable of picking up and sustaining the guaranteed loads continuously with operating limit Values complying with ISO 8528-5 Class G2.

6.17-5 KHABAT TPP UNITS 1&2 - VOLUME I

6.17.5.2 The diesel generator set shall be equipped with the local control board which consist of the following panels; - Engine control panel - Generator control panel - Synchronization panel 6.17.5.3 The Bidder shall guarantee the diesel generator unit to be capable of attaining rated frequency and voltage within 15 sec. after receiving the starting signal. 6.17.5.4 Starting loading and operation shall be automatic upon receipt of a starting signal. The diesel engine normally will be shut down manually. For test purpose, local and remote manual starting and stopping capability shall be furnished. 6.17.5.5 The diesel generator loading shall be accomplished automatically after being started, whether for operation or test purpose. This function will be carried out by the KNOC furnished load-sequencing system. The loading shall commence as soon as the generator-rated frequency and voltage are reached. 6.17.5.6 The generating unit shall be provided with protection equipment which shall protect the alternator/generator set from damage due to fault conditions. All relays or similar equipment for overspeed, oil pressure, cooling water level and high cooling water temperature, directly associated with the prime mover shall be mounted on the generating set engine and associated with a suitable trip relay. Protection equipment shall be provided and arranged to trip the associated circuit breaker, suppress the excitation and shut down the prime mover if faults should occur. 6.17.5.7 The Bidder shall provide provision for the following remote control features on ECS in the CCR: a)

Manual start and stop selection

b)

Auto/Manual synchronizing selection(Auto-Off-Man)

c)

Voltage selection for synchronizing

d)

Governor Control (Raise-Lower)

e)

Voltage Control (Raise-Lower)

f)

Synchronizing CB closing switch

6.17-6 KHABAT TPP UNITS 1&2 - VOLUME I

6.17.5.8 Auto-manual selector switch Equipment and necessary panels and wiring shall be supplied by the Bidder to provide the following local control features :

6.17.5.9

a)

Emergency stop push button

b)

Manual start and stop control switch

c)

Auto/Manual synchronizing selector switch

d)

Voltage selector switch for synchronizing

e)

Frequency control switch

f)

Voltage control switch

g)

Auto-manual selector switch

h)

Local-remote selector switch

i)

Generator breaker close-trip control switch

j)

D/G master on-off switch

The control panel shall include, but not be limited to the following instrumentation to monitor the emergency diesel generators during operation. a)

Frequency meter

b)

Excitation voltmeter & ammeter with transfer switch

c)

Generator output ammeter with transfer switch

d)

Generator output voltmeter with transfer switch

e)

Generator output wattmeter

f)

Power factor meter

g)

Watt hour meter

h)

Engine speed

i)

Running hour meter (RH)

j)

Temperature indicator, digital type, with alarm contact

k)

Pressure indicator, digital type, with alarm contact

l)

Level indicator, digital type, with alarm contact

m)

Automatic voltage regulator (AVR)

Digital type

6.17.5.10 The instrument panel shall include, but not be limited to the following instrumentation to monitor the emergency diesel generators during operation. a)

Exhaust gas temperature

b)

Jacket water temperature

c)

Lubricating oil temperature 6.17-7 KHABAT TPP UNITS 1&2 - VOLUME I

d)

Lubricating oil pressure

e)

Compressed air pressure

f)

Fuel oil pressure

g)

F.O day tank level

h)

Water expansion tank level

6.17.5.11 The generator control panel shall include a master "Station in control" onoff selector switch that will disconnect all remote control and automatic start features. 6.17.5.12 The Bidder shall provide sufficient mechanical and electric instrumentation to survey the variables required for successful operation and to generator abnormal and trip signals required for alarm for the following systems. a)

Starting air system

b)

Lubrication oil system

c)

Fuel oil system

d)

Cooling water system

6.17.5.13 The following conditions shall be alarmed on a Bidder furnished visual annunciator, and an audible alarm buzzer as a minimum. The sequence of operation of all alarms shall be ISA-S18.1, sequence M. a)

Lubricating oil pressure low

b)

Jacket water temperature high

c)

Fuel oil day tank level low/high

d)

Compressed air pressure low

e)

Water expansion tank level low

f)

Speed or frequency high/low

g)

Voltage high/low

h)

Engine running no load

i)

Alarm system failed

j)

Engine start switch not on REMOTE

k)

Oil mist high

l)

Start failure

m)

Control power failed

n)

L.O filter pressure differential high

o)

F.O filter pressure differential high

p)

Generator bearing temperature high

q)

Generator overcurrent trip 6.17-8 KHABAT TPP UNITS 1&2 - VOLUME I

r)

D/G trouble(electrical or mechanical failure)

6.17.5.14 The protective devices that function to shutdown the diesel generator shall comprise the following : a)

Start failure

b)

Engine overspeed high-high

c)

Jacket coolant temperature high-high

d)

Lube oil pressure low-low

e)

Generator bearing temperature high-high

f)

Emergency stop

6.17.5.15 The diesel generator shall also be designed for automatic operation. Equipment shall be supplied for automatic loading. This equipment shall include, but not be limited to : a)

Speed governor

b)

Automatic voltage regulator

c)

Overspeed protection

d)

Overload alarms

6.17.5.16 The Bidder shall provide devices to signal that the diesel generator has reached rated voltage and frequency and is ready to accept load. The output of these devices shall be used to initiate closure of diesel generator circuit breaker and load sequencing. 6.17.5.17 The Bidder shall provide the synchronizing equipment at the local control panel. This equipment shall include, but not be limited to; a)

Synchroscope

b)

Dual indicated voltmeter

c)

Dual indicated frequency meter

d)

Synchronizing switch

6.17.5.18 The diesel generator unit shall utilize two(2) separate control and auxiliary power supplies for redundancy. The Bidder shall provide a automatic transfer scheme for the above two separate power supplies. 6.17.6 6.17.6.1

Generator The generator shall be designed for single-operation and for parallel running.

6.17-9 KHABAT TPP UNITS 1&2 - VOLUME I

6.17.6.2

The diesel generating set shall be complete with a direct driven generator together with automatic voltage control equipment (AVR). The AVR shall be of well established design selected in conjunction with the other features of the diesel generating set offered, to ensure trouble free operation.

6.17.6.3

Three phases sensing of the AVR shall be used to minimize the effect of the waveform distortion caused by load. The generator shall be fitted with a fully linked damper winding to keep the sub-transient reactance to a minimum.

6.17.6.4

The generator frames shall preferably be of fabricated construction and incorporate an exciter. The generators shall be air cooled, insulation shall be to at least Class F with temperature rise to the next lowest class of insulation.

6.17.6.5

A solid coupling shall connect the generator rotor to the diesel engine crankshaft.

6.17.6.6

Generator rotor shafts shall be machined all over to accept the cooling fan and the rotating field assemblies for the generator and exciter, all of which shall be readily detachable for maintenance purposes. The whole rotor assembly shall be statically balanced on completion.

6.17.6.7

Deviation Factor: 10 percent maximum, open circuit, line to line terminal voltage.

6.17.6.8

Adjustable Frequency range: 48 to 52 Hz for synchronizing.

6.17.6.9

Overspeed: To withstand an overspeed of 20 percent 2 minutes without mechanical injury.

6.17.6.10

Maximum Momentary Overloads: To carry 30 seconds overload of 50 percent of normal rated current.

6.17.6.11

The generator shall be provided with space heaters which shall be singlephase with operating 230 Volts AC.

6.17.6.12

Terminal connections, including those for neutral earthing, space heaters shall be made in terminal boxes to be provided by the Bidder.

6.17.6.13

The diesel generator frame shall be provided with two earthing copperfaced pads located on the corners of the generator frame. The pads shall be furnished with solderless connectors for 120mm2 copper earth cables. 6.17-10 KHABAT TPP UNITS 1&2 - VOLUME I

6.17.6.14

The diesel generator neutral earthing cubicle including resister shall be provided. The rating of resister shall be as follows;

6.17.7 6.17.7.1

Exciter and voltage regulator The generator shall be provided with a brushless exciter with fast response voltage regulator, including necessary power, current and potential transformers.

6.17.7.2

Automatic voltage regulation shall be within ±2½ percent at rated kVA, power factor and frequency.

6.17.7.3

The regulator shall provide for manual operation, independent of the automatic control, and have a manually adjustable voltage set point.

6.17.7.4 6.17.8

The Bidder shall provide a rectifier fault detector and monitor. Piping and valves If the connecting type of piping, the Bidder shall design, supply the isometric drawing shown on interconnecting piping considering the arrangement of equipment for the Bidder, and also submit necessary counter flange, gasket, packing and bolts/nuts/washers for counter piping.

6.17.9 6.17.9.1

Drives When equipment is V-belt driven, the drive shall be in accordance with manufacturer’s standard.

6.17-11 KHABAT TPP UNITS 1&2 - VOLUME I

6.18

Service Gas System The service (N2) gas supply system including the gas storage facility shall be provided for unit preservation against oxidation during long periods of plant shut down. The system shall be installed in common use for two (2) units. The N2 gas supply system and the scope of supply shall be generally as shown on the Bid drawing. A.

N2 gas shall be supplied to following portions during long period of plant shut down. 1) Boiler 2) High and low pressure feed water heaters 3) Deaerator 4) Other portions, if required

B.

The N2 gas supply system shall include, but not be limited to the following: 1) N2 gas, bottles and bottle racks 2) Pressure reducing and control equipment 3) All necessary piping, valves, connections and accessories for each unit

The volume of N2 gas storage shall be sufficient to provide at least one (1) times of filling in empty one (1) unit after blowout of boiler water. The N2 gas bottles shall be provided in some groups to enable to switch supplying line from each group. The N2 gas bottles shall be of standard type available locally with appropriate fill pressure. The storage area shall be arranged to comply with the appropriate standards and safety regulations with provisions for easy removal of gas bottles.

6.18-1 KHABAT TPP UNITS 1&2 - VOLUME I

6.19

Fire Protection and Detection

6.19.1

General requirements All plant and buildings shall be designed and arranged to minimize the possibility of fire hazards originating from them or spreading to them from a fire in the vicinity. Plant and cables shall be segregated to reduce fire risk, damage and multiple shutdowns. Electrical equipment located in hazardous areas shall be explosion proof, flame proof, intrinsically safe or otherwise designed to be suitable for the location zone. The Bidder shall provide all calculations for all of the fire protection systems; conduct the design, procurement, equipment and system installation and subsequent testing. All shall comply with the applicable NFPA and related Code requirements, applicable national and local Codes and Standards and local Fire Department (FD) regulations and shall be subject to approval by the KNOC. All equipment and valves etc shall be FM and UL approved and listed.

6.19.2

Scope of supply The scope of the fire protection and detection system shall include but not be limited to the following: A.

fire fighting water supply system, comprising fire water storage (dedicated reserve of raw water tank), main electrical motor driven and standby diesel engine driven pumps, jockey pumps, and Fire water mains;

B.

automatic water spray deluge protection for all oil filled transformers and cable floors, steam turbine lub oil system and surrounding floor area (manual protection for steam turbine bearings);

C.

automatic water sprinkler system for steam turbine cable tunnels, and for stores and workshop;

D.

manual-initiated water sprinkler system for burner areas of boilers;

E.

fire detection for burner areas of boiler;

F.

fire detection for air heaters;

G. manual initiation of water sprinkler system for air heaters; H.

automatic foam/water spray deluge protection for fuel oil pump house;

I.

remote/local manually initiated foam protection for the fuel oil tanks and the bund area and spray cooling water system for fuel oil tanks;

6.19-1 KHABAT TPP UNITS 1&2 - VOLUME I

J.

standpipe and hose reel/hose rack cabinet system in the buildings and plant areas;

K.

yard hydrants and yard hose cabinets;

L.

gas extinguishing fire protection system for switchgear rooms, panels, instrument room and control rooms;

M. fire protection system for fuel gas scrubber and boosting station; N.

portable extinguishers in all the buildings;

O. comprehensive site fire detection system with master alarm panel in Control Room and repeater panel in gatehouse. 6.19.3

Fire water supply

6.19.3.1 Fire water storage Water for fire fighting purposes will be treated raw water. An indicative analysis of raw water is provided in Volume 2, Schedule A. A dedicated reserve of water for fire fighting shall be stored in a combined raw/fire water tank - refer to Section 6 for details. 6.19.3.2 Fire water pumps One 100% duty electric motor driven pump and one 100% duty diesel engine driven pump shall be supplied, each pump capable of supplying water to all sprayers, sprinklers, hydrants or hose reels associated with the largest single fire risk and comply with the requirements of NFPA 20. The pumps shall be of the horizontal axis centrifugal type with flooded suction. Details of the pump characteristics shall be submitted for approval. The design of the diesel engine, in particular its lubricating system, shall be such that periods of long standing will not affect the starting up of the diesel engine. The fuel supply tank shall have a capacity such that the diesel engine can be run at full load for at least [eight] hours. The outlet from the tank shall be at a height of not less than 600 mm above the inlet to the fuel injection pump on the engine. A trickle charger system shall be provided suitable for keeping the starting battery fully charged. In the event of fire water demand within the site the duty electric pump shall start on sensing low pressure in the main. The diesel pump shall start if the pressure remains low after a 5 second delay, or falls due to high demand. Each pump discharge shall be fitted with a full flow recirculation line to the 6.19-2 KHABAT TPP UNITS 1&2 - VOLUME I

storage tank to facilitate pump testing. Isolating valves normally locked closed shall be fitted to these recirculation lines. Pressure relief devices shall be provided to protect the pumps under low flow conditions. One 100% duty jockey pumps shall be provided to maintain the fire main under pressure and to cater for minor usage/leakage. The status of each pump shall be indicated on the master fire alarm panel. The fire pumps shall be located within a building to give adequate protection from the environmental conditions. 6.19.3.3 Fire main The pressurized fire main shall be designed on a ring main basis and sized to cater for the maximum water demand in accordance with NFPA 24. Valves (normally locked open) shall be fitted at appropriate points in the main to allow isolation of discrete sections of the site. All thrust blocks (if required), valve pits, vent and drain connections and corrosion protection measures are to be provided. The capacity and layout of the main, and the position of hydrant outlets shall be submitted for approval after award. 6.19.4

Fire fighting systems

6.19.4.1 Automatic water spray deluge system Automatic water spray deluge systems shall be provided for the protection of oil filled transformers, cable floors and for the steam turbine lubricating oil piping, all in accordance with NFPA15. Deluge system for the transformers shall be operated by a pneumatic detection systems and for cable floors shall be operated electrically. The pneumatic detection system shall derive instrument air from the station air distribution system. The alarm system shall be as described in Section 8. Local manual push button release of deluge valves shall also be provided. Steam turbine generator bearings shall be protected by a manually initiated spray water deluge system. The bearings shall be provided with shields to prevent discharge of water onto hot turbine parts and control valves shall include contacts to transmit system activated signal to the CCR. 6.19.4.2 Automatic wet pipe sprinkler alarm system A wet pipe sprinkler and alarm system shall be provided for the steam turbine building, and workshop and stores buildings. The sprinkler systems shall 6.19-3 KHABAT TPP UNITS 1&2 - VOLUME I

operate on the ‘Quartzoid’ bulb principle and shall detect an outbreak of fire and distribute water automatically over a predetermined area. The installation shall be in accordance with NFPA 13 and local FD regulations for sprinkler installations. Alarm valves shall be provided with a retarding chamber. Operation of each individual sprinkler zone shall initiate an alarm after a time delay on the fire alarm system specified in Section 8. The alarm shall be initiated by a suitable flow switch type alarm valve. 6.19.4.3 Automatic foam/water spray deluge systems The design of these systems shall be in accordance with NFPA 11 or 11A as appropriate and FD regulations and water shall be taken from the underground hydrant ring main. A.

Balanced pressure proportioning system. The fuel oil pump house shall be provided with balanced pressure proportioning system with aqueous film forming foam (AFFF), capable of a 3% mixture in service water, shall be stored in the foam concentrate storage tank. The capacity of the tank(s) shall be twice the size of the calculated foam charge. Two positive displacement foam concentrate pumps (duty and standby) with automatic regulating valves shall draw foam and inject into the water supply via proportioners. The thermal detectors located in the fuel oil pump house shall initiate operation of the deluge valve through the fire alarm panel.

Operation of

the deluge valve shall start the foam concentrate pump and open the foam concentrate motor operated isolating valve. Local manual push button station shall also be provided. B.

Diaphragm pressure proportioning system. The diesel engine fire pump including its fuel oil day tank shall be protected by foam/water which shall be provided from a diaphragm type foam concentrate proportioning tank via an in line injector. The water supply for automatic foam/water system for the fuel transfer pump house shall be fed from the fire main. An automatic control panel located in the boiler control room and a manual push-button station with complete alarm indication/annunciation to the master fire panel shall be supplied. The size of the foam tank shall be suitably sized (1 m3 minimum). The foam concentrate shall be AFFF capable of a 3% mixture in service water. 6.19-4 KHABAT TPP UNITS 1&2 - VOLUME I

The thermal detectors located in each protected area shall initiate through the firm alarm panel, the operation of the deluge valve and solenoid valve which shall open a piston operated ball valve to pressurize the bladder and eject foam through the proportioner.

Local push button stations

shall also be provided. 6.19.4.4 Remote/manual foam system and water spray system The fuel oil storage tanks and bund area shall be protected with a remote manual foam system, comprising foam injection system, bund pourer system, and foam monitor system (located on the fuel oil tank bund wall), and a remote/manual spray water cooling system, sized to cool a full tank. All systems shall comply with the requirements of NFPA 11 or 11A as appropriate and 16. The foam systems shall be supplied from the foam station comprising foam concentrate tanks, foam concentrate pumps, motor operated valve and proportioning equipment. The fire water supply shall be obtained from the underground ring main. The oil tank foam injection, bund pourer, foam monitor and cooling water spray systems shall be controlled remotely from the foam station. Operation of the deluge valve shall automatically start the foam concentrate pump and open the foam concentrate isolating valve. Local manual release push button station shall also be provided. 6.19.4.5 Fuel oil tank foam injection system The foam concentrate shall be fluoroprotein foam capable of a 3% mixture in desalinated water. One foam station shall be provided for the injection of foam into each group of fuel oil tanks. The foam station shall comprise one concentrate storage tank, two positive displacement concentrate delivery pumps (duty and standby), one balance pressure proportioner and all associated pipe work, motor operated valves and deluge valves. The design and capacity of foam pumps and chambers shall be based on foam concentrate injection rate calculated in accordance with the codes. The foam concentrate storage tank shall be sized to hold two times the calculated foam charge to protect the fuel oil tank. Each foam chamber mounted on the fuel oil tank shall have a rupture disc assembly provided on the foam discharge outlet, to ensure that the foam 6.19-5 KHABAT TPP UNITS 1&2 - VOLUME I

system is not contaminated by oil should an overflow occur. 6.19.4.6 Fuel oil tank farm bund area foam pourers The oil tank bund area shall be provided with foam pourers, equally spaced along the bund walls of each oil tank bund area which shall be capable of covering with foam/water the entire bund area (including the oil tank) and shall be supplied with foam water from the main pipe work ring located outside the bund. The details of the system shall be as described for the Tank Foam Injection system. 6.19.4.7 Foam monitors system Motor operated oscillating type foam monitors complete with pipe work and valves shall be provided and placed on the bund walls. At least three monitors shall cover the tank and its bund area. Monitors shall be capable of operating at the fire system pressure and reaching the top of oil tank from any direction. Monitors shall have horizontal and vertical movement in any combination thereof to give a complete arc of operation over the bund area with locking facilities to allow manual operation from any position. Monitors shall be of stainless steel construction and be provided with motor operated valves. Access platforms and ladders shall be provided as necessary to facilitate operation and maintenance of all monitors, valves and equipment. One foam station shall provide the bund pourers and foam monitors located on the tank bund wall. Each system shall be fitted with motorized isolating valve. The foam concentrate storage tanks for foam pourers and monitors shall be sized to hold two times the calculated foam charge to protect one oil tank. 6.19.4.8 Spray water cooling system for the fuel oil tanks The fuel oil storage tanks shall be protected by a remote/manual controlled spray water cooling system. The system shall be supplied with water from the underground site hydrant water supply system. The design and construction of the cooling system shall comply with the requirements of NFPA 15 of VdS 2109. Run off spray water shall not be taken into account in the design of the cooling system.

6.19-6 KHABAT TPP UNITS 1&2 - VOLUME I

The system provided for the tank shall be divided equally into four hydraulically balanced quadrant systems, the operation of any one quadrant or combination of quadrants being individually controlled automatically and also from local manual release push button stations. Each tank quadrant shall be provided with headers individually piped to a motorized control valve position suitably located outside the bund wall. A number of frangible bulb temperature detectors shall be provided on the external periphery of the tank shell adjacent to the tank roof to activate the cooling water spray system and to raise alarm on the main fire alarm panel located in the control room. Each control valve shall be provided with all fixtures necessary for test, and operation, and shall include manual override facility for emergency manual operation. Pressure switches shall be provided for each deluge valve to provide ‘system activated’ signal to the fire alarm panel located in the Control Room. 6.19.4.9 Standpipe and hose cradle/reel cabinet system Each building shall be provided with a standpipe system complying with NFPA 14 and designed to give Class [III] service. The Bidder shall provide fire hose reels and hose cradles in each building. Fire hose reel cabinets shall be equipped with a 30 metre length of 25 mm diameter double braded rubber, non collapsible hose mounted on reel drum which shall be of the swinging arm type. The hose reel connected to the water supply shall be supplied with DN25 isolating ball valve and DN25 pressure reducing valve and adjustable spray/jet nozzle. Hose cradles shall consist of a 30 metre length of 40 mm lined, collapsible, synthetic hose mounted on a hose rack which shall be of the swinging arm type. Both hose reels and hose cradles shall be equipped with quick coupling type of gun metal with adjustable jet/spray nozzles. A single 65 mm

automatic

pressure regulating

valve

with

female

instantaneous coupling connection shall be provided in each hose reel/hose rack cabinet, connected separately to the water supply inside the cabinet and available for the connection of Fire Brigade hoses even when the hose reel/hose rack is in use. The hose reel/hose rack cabinet shall be made from galvanized steel with double glass door clearly labelled “FIRE” in Arabic and English and painted red with white lettering to an approved procedure. Each hose reel/hose rack 6.19-7 KHABAT TPP UNITS 1&2 - VOLUME I

cabinet shall also be supplied with one (1) unit of 9-10 kg dry power fire extinguisher for class ABC fires. 6.19.4.10 Site fire hydrant system 6.19.4.10.1 Fire hydrants The arrangement of the site fire hydrant system shall comply with the requirements of NFPA 24 and shall generally comprise a buried sectionalized ring main, distribution pipe work complete with post indicator valves, isolating valves wash-out valves and valve pits. The distribution network shall provide supply of water to each standpipe system, automatic spray foam and water deluge system, fire hydrants positioned around the power station site and the main oil tank area fire protection systems. All fire hydrants shall be installed at a spacing not greater than 60 m and shall comply with FD requirements. Fire hydrants shall be constructed from cast iron (150 mm) with two DN65 globe valve couplings, cap, chain and a 100 mm connection for fire engine pump suction. Each fire hydrant shall be provided with an auxiliary valve with curb box. Curb box assembly shall be cast in concrete at grade and depth of cover shall be adjusted to the proper depth of pipe. The valve shall be key operated with an operating key provided at each outdoor hydrant cabinet. Each fire hydrant and post indicator valve position shall be protected from damage by four vertical guard rails painted with red and white bands. Where direct buried these shall be protected by suitable sleeving and backfilled with selected material approved by the KNOC. Post indicator valves shall be butterfly type and provided at all branch lines and for sectionalizing portions of the water network and shall meet UL design requirements. The stem length of the post indicator valves shall match the site gradient and hydrant main invert. 6.19.4.10.2 Outdoor hose storage cabinets and equipment The Bidder shall provide one outdoor hose storage cabinet at each hydrant location, comprising weatherproof steel cabinet complete with a break glass lock mechanism. Each cabinet, mounted on a concrete foundation shall contain, as a minimum: A.

One (1)

hydrant turnkey and bar

B.

One (1)

65 mm hose standpipe with instantaneous outlet connections

C.

Three (3)-25 m lengths of 65 mm light synthetic fibre imperviously jacketed hose with light alloy instantaneous couplings 6.19-8 KHABAT TPP UNITS 1&2 - VOLUME I

D.

One (1)

Jet/spray - on/off nozzle

E.

One (1)

65 mm hose branch pipe 22 mm bore nozzle

F.

One (1)

Fire axe and crowbar

6.19.4.10.3 Fire hose The fire hose shall be light and flexible besides being resistant to abrasion and damage due to contact with chemicals or oil.

The hose shall comply with

the relevant internationally recognized codes and standards. The bursting pressure of the hose shall not be less than twice its working pressure. Hose is to be 65 mm gauge and supplied in 25 m lengths with male and female

instantaneous

couplings

compatible

with

local

requirements/regulations. 6.19.4.10.4 Jet/spray - on/off branch pipe nozzle These nozzles shall emit a powerful straight jet, atomized spray or a wide spreading cone of solid water and shall include fog and shut off features. The type of spray shall be adjusted by twist control. Nozzles are to be manufactured in light alloy and fitted with a stainless steel valve cone and designed for maximum velocity at the minimum restriction to flow. The inlet shall be a male instantaneous coupling. 6.19.4.10.5 Standard water branch pipe Branch pipes shall comply with the relevant internationally recognized codes and standards. The inlet shall be a male instantaneous coupling. The outlet shall be 5/8” diameter to give a high power straight jet of water. 6.19.4.10.6 Fuel gas treatment (AGI) system The AGI for the gas system shall be protected by the yard hydrants which shall be located near this area at spacings as specified. The area shall also be provided with a fire detection system as described in section 8. 6.19.4.10.7 Portable extinguishers The following types of portable fire extinguisher equipment complying with NFPA 10 shall be provided and installed at agreed locations including wall mounting, in the plant and building areas. A.

9-10 kg capacity dry power extinguishers for use against oil fires associated with electrical equipment. The powder shall be expelled from the extinguisher by compressed CO2 gas and controlled by a pistol grip nozzle attached to the discharge hose. 6.19-9 KHABAT TPP UNITS 1&2 - VOLUME I

B.

9-10 kg and 6 kg capacity CO2 extinguishers for use against fires associated with electrical equipment. The extinguishers shall be provided with fixed discharge horn and trigger valve control and trolley where required.

C.

9-10 litre/capacity CO2 gas pressure operated water extinguishers for use against ordinary small fires. The discharge nozzle shall be supplied with flexible hose and the control shall be such that intermittent control is possible.

D.

9-10 litres capacity foam extinguishers for use against small oil fires. The extinguishers shall be pressurized with CO2 gas.

The number and types of extinguisher per building are to be advised in the Tender and shall be in accordance with the recommendations given in NFPA 10 and shall be to the KNOC approval. 6.19.4.11 Fire detection and alarm system The fire alarms system shall be complete in all respects and shall include the main and local fire alarm/control panels, the fire detection system, the alarm contacts for local and remote signaling, all cabling between the fire detectors and alarm contacts and the local and main fire alarm/control panels. Refer to Section 8 for details regarding the fire and gas detection and fire alarm systems.

6.19-10 KHABAT TPP UNITS 1&2 - VOLUME I

6.20

Cranes and Lifting Equipment

6.20.1 Conditions of service 6.20.1.1 Description of service A. The Bidder shall furnish lifting device with associated support, rails, runways and lifting eyes required for the adequate maintenance weighting in excess of 25kg any equipment. B. The overhead traveling cranes are indoor installations. The turbine over head crane will be used to service the generator rotor and other equipment and components within the turbine building for construction, and maintenance. C. The adegunit type cranes at the raw water intake (one for the bar screen area and one to serve the traveling band screens) are installations and for construction and maintenance, respectively. D. The overhead traveling cranes will be preferably operated in longitudinal direction of the subject building. Each crane shall be capable of handling the heaviest part and the part with a certain overall length installed in the subject building, i.e. the stators of the alternators E. In the case of the steam turbine building the traveling crane lifting height shall be designed for lifting the turbine rotor of the lower part of the turbine casing, as also for lifting the LP heater tube nests out of their shell or shells above tops of the tube nests, up to the steam turbine building floor F. Wherever required, local hoists (monorails) shall be installed for proper handling and maintenance of equipment. According to specific needs, the hoists can be permanently installed or can be removable. They can be electrically or manually operated. G. The B.F.P underhung crane will be used to service the B.F.P and auxiliaries components in the B.F.P area for construction and maintenance. H. All cranes will be used during plant construction for lifts up to the crane rated load. 6.20.1.2 Design conditions A. General The cranes, hoists and lifting devices shall be used primarily for unloading, installation and future maintenance of the mechanical and electrical equipment. The Bidder is not bound to adopt the crane design outlined in 6.20-1 KHABAT TPP UNITS 1&2 - VOLUME I

the drawings, but he shall observe all governing dimensions shown there. Regarding the outer appearance, the crane shall be pleasant from an aesthetic point of view, and the mechanical and electrical equipment shall be fully protected from the influence of dust and high salty air humidity at the Site. The crane drive and trolley arrangement shall be designed to require a minimum of space while optimizing the accessible working area. Furthermore, the design shall provide easy accessibility of all important parts which require regular maintenance and inspection. The maximum full load starting speed shall be 10% (ten per cent) of the maximum operating speed for the crane hoists, the gantry drive and trolley drive. Electrical driven cranes hoists and lifting equipment shall have a nominal and a creep speed. The crane shall operate within the following tolerances : With the hook carrying 125% (one hundred and twenty-five percent) of the nominal load and with the hoist brakes properly set and operating under normal conditions, the vertical motion at the rated inching speed shall be controllable within 3 mm. The crane will be installed indoor or outdoor, and building temperature and relative humidity are indicated in General Design Condition. B. Additional Seismic Requirement Seismic requirements shall be in accordance with Seismic Zone. All cranes shall be designed to withstand seismic conditions, including the horizontal and vertical seismic forces combined with the gravity load. Positive means shall be provided on the crane to prevent bridge, trolley, or any other part from falling on structures or equipment below the crane in the event of an earthquake. The holding brakes or restraining lugs, using normal design stress, shall be designed to prevent the trolley and bridge from falling during an earthquake. 6.20.2 Design and construction features 6.20.2.1 General The crane to be furnished under this Section of the specification shall be of rigid frame design. All equipment and components shall be in conformance with codes and standards. 6.20.2.2 Material standards The material to be used for manufacturing the lifting equipment steel structures 6.20-2 KHABAT TPP UNITS 1&2 - VOLUME I

shall conform to the equivalent ASTM standards. However, the Bidder shall restrict the structural steel to St. 37-2 and St. 52-3 or ASTM A 36; the latter may be regarded as equivalent to St. 42. 6.20.2.3 General design particulars A. Nameplates stating the nominal load capacity in kg or tons shall be attached to both sides of the lifting equipment structure and to both sides of the rope block. The printing shall be clearly legible from the floor. Flexible couplings shall be installed to relieve the bearings and shafts from any stresses due to misalignment and to facilitate the removal of motors, wheels and gears. The motor couplings also shall be of the flexible type. All couplings, drive wheels and gears shall be press fit and keyed to the shaft. All wheels shall have a hardened tread with a minimum Brinell hardness number of 320, and shall be made of carbon steel or low-alloy steel forgings. They shall have double flanges, shall be machined to a uniform diameter concentric with the hub bore. All bearings preferably shall be anti-friction bearings designed to permit easy shaft disassembly and easy replacement. The minimum average lifetime under design load conditions shall be 5000 hours. All bearings except those for the hooks and rope sheaves shall be lubricated by central lubrication systems. An independent system for the trolley and one for two independent systems for the bridge will be acceptable. All gears shall be designed and executed as bevel gears. For all high-speed gears and pinions, oil bath lubrication shall be provided. Low-speed gears may be lubricated with soft grease. Suitable oil and grease catching drip pans shall be installed and be readily accessible for draining and cleaning. B. Trolley The trolley frame shall be made of welded structural steel and shall have a rigid construction to ensure a uniform distribution of the loads to all wheels without undue deflection. After manufacture, the trolley frame shall be stress-relieved. Flexible bumpers shall be provided at the ends of the trolley frame; they shall be designed to absorb the impact forces arising when the trolley, running at maximum speed with the nominal load suspended from it, is stopped with the motor switched off. Removable track sweeps shall be furnished, and the trolley frame shall be fitted with safety grips to prevent the 6.20-3 KHABAT TPP UNITS 1&2 - VOLUME I

trolley from leaving the rails and to limit the maximum sag of the trolley to 20 (twenty) millimeters in the event of any one wheel assembly breaking. The trolley shall be driven by an electric motor mounted on the trolley frame and connected through gearing and an axle to one wheel on each track. C. Ropes The wire ropes for the hoists shall be of twist-free construction preferably with a fiber-core; the wires should consist of hardened and tempered plow steel. They shall be long lay-ropes with heavy-duty permanent lubrication. The stresses in the ropes shall be assumed at the maximum point and shall include the overall efficiency of the hoist in the parts of the line from the drums as well as the weight of the load, hook, and rope sheaves. The ropes shall be attached to the drum in a simple and safe manner so that for their adjustment and replacement, only a minimum number of parts need to be removed. D. Drums The drums shall have machined grooves to the right and left to receive the ropes. The center of the drums shall not be grooved. The drum bullgear shall be press or shrink fit to it and secured by dowels or keys or similarly fastened to the drum shaft if the drum is driven through the shaft. The drum shall be dimensioned adequately to leave at least three complete windings of the lifting rope in the grooves on each side with the hook in lowest position for the specified lifting distance, and it shall not be necessary for the rope to be wound in a double layer when the hook is in its highest position. E. Sheaves and Blocks The rope sheaves shall be cast steel or steel weldments with machined grooves which have suitable diameter tolerances and are sufficiently smooth to minimize wear on the ropes. The sheave pins shall be made of annealed carbon steel or steel alloy and shall have an ample sheave bearing surface. All moving sheaves shall be fitted with roller bearings, each suitable for force-feel fabrication; they shall be accurately balanced for smooth running. The load blocks shall be built so that they will entirely surround the lifting ropes and will prevent the rope from coming out of the sheave for all operating conditions. The rope-guard shall be of grease-tight cast steel or welded construction and shall fit close to the rope sheave circumference. 6.20-4 KHABAT TPP UNITS 1&2 - VOLUME I

F. Hooks The load hooks shall be made at forged steel subject to the KNOC approval; the yield point shall be approximately two thirds of the ultimate strength. The hooks shall be load tested to 150 % of the rated load and x-rayed of magnafluxed after testing to ensure that there is no hidden damage to the hooks. The hooks shall be finish-ground by hand and shall rotate freely on anti-friction bearings. The bearings shall be totally enclosed, dust-tight and properly sealed to avoid the egress of grease. The main hoist shall be equipped with a double hook in accordance with DIN 15402. G. Brakes The main hoist and the auxiliary hoist shall be equipped with brakes. Holding the load shall be effected by means of an automatic springset, electrically or elctro-hydraulically released double shoe-type brake. The brake capacity shall be not less than 200 % of the torque caused by the maximum nominal load of the crane. The brake must prevent the load from descending until the hoist motor is energized for operation in the lowering sense. The load control brake preferably shall be an electrical brake, working on the basis of frequency transformer control. An electrical brake of the eddy-current type or a combination of electrical and mechanical brakes also will be accepted. Friction load braking will not be accepted. Bridge and trolley drives shall be equipped with a spring-set, electrically (solenoid or electro-hydraulic) released shoe or disc brake, whose capacity shall be at least 1.5 times the full operating torque of the drive. The brake shall be applied when the motor control switch or the main power switch is in the "off" position and/or when the current fails on any one phase. The braking action shall be gradual and the brake shall become fully effective after a certain time lag. Remote Wireless Pendant Control with hard wired pendent as back up. Auto crane movement audible alarm signaling crane movement/operation.

6.20.2.4 Instrumentation control equipment and electrical equipment The crane control system shall be the full magnetic type, complete with main circuit-breakers, master switches, controls, resistors, time or current relays, reversing contactors, overload relays, auxiliary relays, accelerating contactors, limit switches and all other accessories required for speed and operating control as specified. 6.20-5 KHABAT TPP UNITS 1&2 - VOLUME I

The coils and contacts of the magnetic control must be enclosed in metal cabinets. The Manufacturers shall supply detailed information about the materials used in these components, such as contact life, closing and opening time of the contacts, etc. The main contacts shall be able to operate without excessive wear, overheating, sticking or any other malfunctioning. The electrical control devices shall be installed in panels and steel cubicles mounted on the crane girder. All controls shall be conveniently grouped in a panel to enable the operator to operate the crane from a point where he can best watch all crane movements, by means of a pendant switch control panel respectively by means of wireless control. All master switches, hand-operated switches, circuit breakers, contactors and relays shall be distinctly and durably marked. The control switches shall be reversible. All control switches shall be accommodated in adequately ventilated sheet steel housings. Each of the housing shall have a small heater to prevent condensation. The heating system shall be controlled by a thermostat which will disconnect the current in the event of an undue temperature rise. The resistors shall be air-cooled, and corrosion and fire-resistant. They shall be dimensioned adequately to withstand all stresses from the crane movements. A. Limit Switches The crane shall be equipped with the following enclosed limit switches of the closed-circuit type : 1) Block-actuated switches to limit upward travel of the load blocks; 2) Two switches to limit travel of bridge and trolley in both directions; first switch to reduce the speed to creep speed 0.5 m before the end position is reached, second switch to stop at the end position, 3) Lower hoist limit switch, gear or chain-driven from drum (on auxiliary hoists acceptable for upper and lower hook position). 4) Limit switches shall be arranged to reset by reversing the associated controller. Only the motion being limited shall be affected by tripping the limit switch. B. Motors The motors to be provided shall be induction motors with adequate rating to cope with the load involved. Motors of relatively low-speed shall be given preference. The motors shall comply with Section 7. 1) Current Feed Cables for Trolley 6.20-6 KHABAT TPP UNITS 1&2 - VOLUME I

The current feed cables for the trolley shall be arranged so that they are readily accessible for replacement. A sufficient number of cables shall be furnished and installed so that each motor is electrically-controlled independent of all other motors and controls. Additional cables shall be provided for grounding the trolley to the ridge frame and for one socket which shall be suitably located on the trolley for maintenance purposes. 2) Cables, Cable Conduits and Terminals Cables shall be laid in rigid, galvanized steel conduits with screwed connections and draw-in boxes which shall be suitably built into the crane structure. All cables shall run to terminal strips for making the outer connections. The cables must not be spliced. All cables shall be clearly identified by suitable tags or durable markings to facilitate installation and maintenance. Separate cable conduit systems shall be provided for the power, light and control circuits. The entire cable conduit arrangement shall be grounded. The configuration of all lines, terminal strips and cables shall be subject of approval. 3) Power Supply Line for the Crane Power shall be fed to the crane by 4 (3-phase plus grounding) rigid copper conductors of the protected type located on the upstream wall of the

powerhouse.

These

conductors,

complete

with

insulating

wall-mounting brackets and collectors mounted on the crane, shall be included in the supply. 6.20.3

Control points

6.20.3.1 The cabin shall be fitted with a emergency-stop foot switch. 6.20.3.2 All cranes shall be operated from a pendant. The pendant shall be supported in such a manner as to be readily handled by a single operator. It shall control the bridge, trolley, and hoist power at either end of the bridge with the trolley at the other end. The pendant shall be provided with a traverse motor controlled from the pendant and a key to control the master switch located on the crane. The pendant control pushbuttons shall be oil-tight heavy-duty and return to off position when released. 6.20.4

Electrical overhead travelling cranes

6.20.4.1 A pendant operated overhead travelling crane shall be provided in the [Workshop, the steam turbine building], and in other plant buildings if required for maintenance of the plant. 6.20-7 KHABAT TPP UNITS 1&2 - VOLUME I

6.20.4.2 The crane shall be designed and constructed in accordance with the requirements of the relevant internationally recognized codes and standard’s and shall be complete in all respects for safe and efficient operation. 6.20.4.3 The bridge or gantry, trolley and hoist movements shall be controlled by suitable reversible controllers. The bridge trolley and hoist control schemes shall permit variable speeds in both directions of travel. Limit switches shall be provided at end limits of bridge, trolley and hoist travel. 6.20.5

Mobile cranes Mobile crane shall be diesel powered and minimum 40ton.

6.20.6

Runway beams and lifting facilities

6.20.6.1 All heavy parts of the plant supplied under the Contract shall be provided with arrangements for lifting, slinging and handling during erection and overhaul. All parts normally lifted during periods of maintenance and weighing one tonne or over shall be appropriately marked with their weight. 6.20.6.2 Runway beams shall be provided to facilitate handling of the various parts of the plant which require to be removed for cleaning and overhaul. The beams shall be supplied with trolleys for the attachment of blocks and lifting tackle and a range of suitable blocks and tackle shall be supplied. The runway beams shall comply with the requirements of the relevant internationally recognized codes and standard shall be tested after erection. The Bidder shall be responsible for the provision of the appropriate test certificates which must be in accordance with Appendix C of the relevant internationally recognized codes and standard. All necessary lifting beams and slings shall be provided 6.20.7

Testing

6.20.7.1 All cranes and lifting equipment shall be proof load tested, mechanically, electrically and operationally. The Test results shall be recorded on certificates, copies of which shall be submitted to the KNOC. 6.20.7.2 The safe working load shall be clearly marked on all cranes and lifting equipment. 6.20.7.3 Load test The hooks shall be load tested to 150% of the rated load and x-rayed of magna fluxed after testing to ensure that there is no hidden damage to the hooks. 6.20-8 KHABAT TPP UNITS 1&2 - VOLUME I

6.20.8

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

6.20-9 KHABAT TPP UNITS 1&2 - VOLUME I

6.21

Laboratory Equipment These equipment are to be used for analysis and test of water, fuel and environment.

6.21.1

Design features A. Laboratory equipment and appurtenance furnished under this specification shall be designed to meet the requirements of this specification. B. The Bidder shall furnish laboratory equipment in accordance with the specification. C. Scale shall be designed to read directly in engineering units, legends, charts, scales, and nameplates shall be in the English language. D. All equipment requiring compressed air shall accept the following : instrument dry compressed air at 5～8.8 kg/cm2g. E. Unless otherwise stated in the specifications of this specification, the Bidder shall furnish the list of manufacturer's standard and optional accessories to support each item and equipment. F. Training and Technology Transfer. The Bidder shall provide training and technology transfer to the KNOC for operation and maintenance. G. The water analysis for examination of water and waste water shall have the equipment, accessories and chemicals necessary to perform, at least the following analysis. 1) Alkalinity 2) Oxygen (DO, BOD) 3) COD 4) Ammonia (NH3) 5) Calcium (Ca) 6) Hardness 7) Chlorine (Cl2) 6.21-1 KHABAT TPP UNITS 1&2 - VOLUME I

8) Chloride (Cl) 9) Conductivity, high and low concentrations 10) Copper (Cu) 11) Hydrazine (N2H4) 12) Iron (Fe) 13) Phosphate (PO4) 14) pH 15) Silica (SiO2) 16) Sodium (Na) 17) Total Solids 18) Turbidity 19) Others Magnesium (Mg) 20) Sulfate (SO4) 21) Aluminum (Al) 22) Acidity 23) Nitrite (NO2) 24) Nitrate (NO3) 25) Others H. The fuel analysis for examination of fuel and lube oil shall have the equipment, accessories and chemicals necessary to perform, at least the following analysis. 1) Low Heating Value (LHV) / High Heating Value (HHV) 2) Specific Gravity 3) Viscosity 4) Flash point 5) Acidity 6.21-2 KHABAT TPP UNITS 1&2 - VOLUME I

6) Water and Sediment in Oil 7) Others a) Materials b) Composition and physical properties of all materials shall be best suited to their purposes in accordance with the Bidder's usual practices for this type of equipment, unless otherwise specified. 6.21.2

Attachment A. Laboratory Equipment List – Refer to the C2 mechanical Schedules C2.20 1) Optional accessories specified below shall be supplied with its test equipment as scope of supply. 2) Standard accessories shall be supplied with test equipment at no extra cost. 3) Battery chargers shall be supplied with rechargeable batteries specified below at no extra cost. 4) Operation & service manual shall be supplied. 5) The installation and operation & test-run should be carried out by the Bidder at end-user's site. B. The specification in the following list is the minimum requirement, so the Bidder shall provide detailed specification and supply the latest model as of the date of purchase without any extra cost. C. The Bidder shall provide one(1) lot of laboratory equipment for two(2) Units.

6.21-3 KHABAT TPP UNITS 1&2 - VOLUME I

6.22

Workshop, Stores and Equipment

6.22.1

General A complete workshop shall be provided to enable general maintenance work, of the whole plant, to be carried out. The workshop shall be provided with an overhead travelling crane, pendant operated, of suitable capacity for the largest maintenance load. This workshop is not intended for major boiler overhaul work. A stores building shall be provided to provide suitable storage conditions for plant spare parts, consumables etc The Bidder shall furnish the services and equipment including all necessary features, components, accessories and appurtenances for the safe, efficient and reliable erection, operation and maintenance whether mentioned in this specification or not. A store building shall be provided to provide suitable storage conditions for plant spare parts, consumables etc.

A. MECHANICAL WORKSHOP MACHINE TOOLS & EQUIPMENT Item No 1 2 3

Item Description

Qty

Large Lathe (580mm dia ,swing over bed x 2000mm between centers with gap bed ) Medium Lathe (450mm dia ,swing over bed x 1500mm between centers with gap bed ) Radial drill machine (distance from center main axis to column; Min. under 300mm, Max. over 1300mm)

1 1 1

4

Flore drill machine swing 540 mm over

1

5

Universal Milling machine (table size 1100mm x 270mm)

1

6

Shaping machine table size 710 x 320mm

1

7

Metal cutting sow machine Cap. Φ450mm, 450mm x 310mm

1

B. Furnish all relevant documentation and drawings.

6.22-1 KHABAT TPP UNITS 1&2 - VOLUME I

6.22.2

Workshop compressed air system It is intended that the station instrument and general service air systems be piped into the workshop building. The Bidder may however propose a separate system for the workshop if the location of the workshop poses any difficulties in routing of the station compressed air supplies into the building.

6.22.3

Stores equipment The stores shall be fully fitted out for operational use. The Bidder may offer his own proposals but these shall include but not be limited to: A.

Steel racking for storage of materials and components.

B.

Steel racking and plastic bin system for storage of smaller parts.

C.

Propane powered stacking fork lift truck with capacity to reach highest storage racking.

D.

Outdoor Storage, Storeman’s Office, Substantial Shelving, (cannot be manufactured from re-bar or from scrap)

6.22-2 KHABAT TPP UNITS 1&2 - VOLUME I

6.23

General Plant Requirements The following requirements shall apply to all plant and equipment to be supplied under this Contract, unless specified otherwise in sections relating to specific items of equipment. For general requirements regarding inspection and testing, refer to Volume 2, Schedule G of this Specification.

6.23.1

Plant referencing

6.23.1.1 Plant referencing system The Bidder shall apply a plant coding/referencing system e.g. KKS (Kraftwerk Kennzeichen System) or other similarly internationally recognized numbering system for referencing of power equipment and systems. The Bidder and his subcontractors shall use the plant referencing system for numbering of equipment, piping, valves, cable, instrumentation and spares. Reference numbers listed on identification nameplates or tags shall be as per the approved plant referencing system. 6.23.1.2 Plant numbering/nomenclature guidelines In addition to the plant referencing system, plant and equipment items shall be identified by a nomenclature system; the following guidelines shall be used by all parties in determining the plant numbering/nomenclature: A.

the reference should be logical and simple

B.

each name should be unique

C.

there should be a differentiation between unit and non-unit names

D.

the names should be as short as possible

E.

the name should start with the major and proceed to the minor (in the case of feed heaters numbering shall be consecutive from the lowest pressure to the highest) the same name should consistently appear on all drawings, schedules and labels.

References shall follow a logical sequence based on layout or history and in any particular installation, a set of similar duty drives where any number of units may run, shall be suffixed 1, 2, 3 4 etc. whereas alternative drives for the same duty, where only one unit may run (i.e. duty/standby), shall be suffixed A, B, C etc.

6.23-1 KHABAT TPP UNITS 1&2 - VOLUME I

The Bidder shall also prepare a comprehensive Plant or Equipment Identification Schedule(s) using the plant reference system, which shall be updated and issued to KNOC every 6 months for the duration of the Contract. The Schedules shall include the Purchaser’s numbering system and the respective flow sheet or Diagram Identification Numbers. After final painting, all main plant items shall be identified by the reference characters. Such references to be affixed in a prominent position on the plant body with characters not less than 100 mm high or as otherwise specified. Characters shall be bold capital letters and/or Arabic numerals. The abbreviation ‘No.’ shall not be used 6.23.2

Nameplates and labels Instruction plates, nameplates and labels shall be provided for all items of the plant giving particulars of duty, size, serial number and full information for identification and operation. Nameplates shall be 3 mm thick laminated white, black, white traffolyte with lettering of a minimum height of 4 mm. Warning labels and emergency equipment shall have red lettering in place of the black. Warning and safety notices shall be in the English and Arabic languages. Labels shall be of sufficient size to carry a full description of the plant item and a unique item identification alpha-numeric. Abbreviations in the plant description shall only be used with prior approval of the KNOC. Valve labels shall be circular and fitted in the centre of the valve handwheel. All other labels shall be square or rectangular and shall be fitted by 3 mm stainless steel self-tapping screws or stainless steel banding as appropriate for the location. Labels shall be fitted such that they are not readily lost or broken during routine operation and maintenance. Any labels damaged or defaced during installation or plant start-up shall be replaced by the bidder prior to plant acceptance by the KNOC.

6.23.2.1 Pipe service identification A color banding scheme shall be used to identify pipe work. The identification requirements and colors employed shall be in accordance with the requirements of the relevant internationally recognized codes and standards. Color bands shall be painted on each side of all valves and equipment on the piping systems. The use of adhesive-backed color bands is not permitted. Valve labels shall be circular and fitted under the hand wheel captive nut. For 6.23-2 KHABAT TPP UNITS 1&2 - VOLUME I

check valves and small valves the Bidder may provide rectangular labels fitted to the valve or secured close by the valve. The inscription or “name” on each valve label shall summarize the duty of the valve, and the number shown on each valve label shall be the number in the unified plant valve numbering scheme. Where the direction of flow through a valve or other device is an important requirement for correct functioning, the body of the valve or device shall be legibly marked with a cast on or a properly secured arrow, showing the direction of flow. Pipe work shall be provided with plentiful large painted arrows and/or other secure and durable arrow markings to allow the flows of fluids around the plant to be readily understood. 6.23.3

Plant vibration Rotating Plant shall be designed and constructed to operate throughout its operating range without vibration insofar as the nature of the works will permit. In the case of rotating plant, vibration shall be reduced to the minimum, which can be achieved by good design, careful balancing and correct installation and alignment, as follows: A.

Rotating elements shall be balanced in accordance with the relevant grade of ISO 1940-1 as applicable.

B.

The vibration levels for the machinery covered by this Specification shall comply with the appropriate parts of ISO 10816 and ISO 7919 standards.

C.

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

Refer to the relevant specification sections for vibration requirements for specific equipment, and to Section 8, Control and Instrumentation for details of vibration measurements. 6.23.4

Sunshades Outdoor plant shall be rated and constructed so that its performance, operation, reliability, maintenance, or life shall meet the specified design and operating conditions. Where personnel have to be in attendance frequently or maintenance has to be regularly carried out, permanent minimum weather protection or sunshades shall be provided. Facilities such as lighting, lifting beams and rainwater drainage shall be 6.23-3 KHABAT TPP UNITS 1&2 - VOLUME I

provided wherever necessary to the approval of KNOC as an integral part of the sunshade structure. 6.23.5

Special tools and tackle for maintenance The Bidder shall supply a complete set of any special tools and other equipment necessary for the dismantling, re-erection and adjustment of the plant. This shall include any special lift jigs, frames and stands necessary to remove and support the major items of plant. The tools provided shall be in new condition, adequately labelled as to their use and contained in stout and suitable padlocked boxes. The KNOC’s instructions as to who shall be the recipient of the tools shall be sought before delivery is made. Any special slings required shall be provided and clearly marked by embossed labels to show safe working loads. Test certificates shall be provided where applicable.

6.23.6

Locks and keys for mechanical plant Locks and keys for mechanical plant shall be of an approved dead latch type, or padlocks as appropriate. Three keys shall be supplied for each lock. Keys shall be unique to each lock. Where a set of locks is provided under any particular section of the Plant, a group master key shall be supplied in addition. All locks and padlocks shall be of brass and where they are fitted to switchboards or similar cubicles shall have the visible parts chromium plated. Where a group of locks is supplied under any part of the Contract, a rack or cabinet of approved design shall be supplied for the accommodation of all padlocks and/or keys while not in use. The padlocks and keys shall be engraved with an agreed identifying code or inscription and this shall be repeated on the racks or cabinets on engraved labels.

6.23.7

General mechanical requirements

6.23.7.1 General The Bidder shall be responsible for the detailed design and engineering of the plant and systems. The requirements specified herein shall form the minimum basis for the design and scope of work and working practices, manufacturing, testing and erection. 6.23-4 KHABAT TPP UNITS 1&2 - VOLUME I

Selection of materials, components, methods of construction and erection shall be made with due consideration to the requirements and capabilities of the equipment served, as well as the reaction and thermal, chemical, or other effects of the medium being handled by each system or component. Corrosion allowance for piping shall be 1.5 mm unless otherwise specified. The equipment, materials and services provided by the Bidder shall be consistent with the need to develop a safe, dependable, and adequate installation. The Bidder shall ensure that no individual element or system will set a limit on the station capability, or will disturb its architectural appearance when completed. 6.23.7.2

Pumps

6.23.7.2.1

General requirements

All pumps supplied within the Contract shall be designed, manufactured and tested in accordance with the requirements of the relevant Standards and Codes. Unless specified otherwise, centrifugal pumps shall be designed, manufactured and tested in accordance with the relevant internationally recognized codes and standards or equivalent internationally recognized standards. The pumps shall operate satisfactorily when delivering varying quantities from minimum up to the design maximum flow and shall be constructed to ensure continuity of service, ease of inspection, cleaning and repairs, together with satisfactory operation under all climatic conditions prevailing at site. Where duplicate pumps for the same service are provided they shall operate satisfactorily in parallel with each other. All pumps shall be designed far maximum continuous operation conditions even at system frequencies between +4% of rated frequency. All pumps shall have a design margin of 10% on flow and 20% on head. The characteristic curve of a centrifugal pump shall be stable under all conditions, i.e. the head shall increase with decrease in delivery until maximum head is reached at zero flow. Details of head and flow/performance characteristic curves shall be submitted for design review. The Net Positive Suction Head (NPSH) required at any capacity up to and including runout shall be at least 20% or 1 m less than the available NPSH, whichever creates the greater margin. The pumps shall be free from vibration at all load conditions and shall be designed to allow satisfactory and safe operation during all possible operating conditions, including cold and warm start-up and run out flow. 6.23-5 KHABAT TPP UNITS 1&2 - VOLUME I

The pumps shall be designed in such a way that no leakage shall result from a change in fluid temperature. In general mechanical sealing systems shall be used throughout. Material shall be specifically chosen to resist cavitation, erosion and corrosion, seizure or other destructive influences to which a pump may be subjected in service. If the pump impellers and the impeller shaft are of different material, any portion of the impeller shaft which could be in contact with the fluid must be covered by a sleeve of the same material as used in the impeller construction. The general arrangements of the pumps, motors, supports, piping etc. shall allow handling for maintenance with the least possible dismantling and joint breaking. All structures and foundations etc shall be designed, supplied, installed and tested under this Contract. This shall include steel wedges, levelling screws, support plates, foundation plates and anchor bolts, etc. All leakages shall be collected and directed to suitable drain connections and discharge system. Flexible coupling with guards shall withstand all service conditions and shall be arranged for easy disconnection and reassembly. Suitable connections for instruments, drain and vents shall be provided. 6.23.7.2.2

Types of pumps

Horizontal spindle pumps of the centrifugal type shall have fully balanced impellers and at least two bearings. The driving motors shall be mounted on an extension of the pump base plates. Base plates shall be provided with drip tray facilities and provision shall be made for drainage. All pumps shall be capable of reverse rotation up to 125% of rated speed due to back flow of fluid without causing damage to the pump, alternatively a reliable method of preventing reverse rotation shall be provided. For certain services, the pump may be installed in a tank of suitable material which forms a well from which the pumps takes its suction. Such tanks will normally be cast in concrete, with the discharge flange above the floor level. Only the mounting and discharge flange bolts will require removal to pull the pump. Portable sump pumps shall be of the heavy duty submersible self priming type, each complete with 10 meters of flexible hose, sealed-off electric motor and flexible power cable 20 meters long. The power cable/pump motor connection shall be completely waterproof when connected. All portable sump pumps 6.23-6 KHABAT TPP UNITS 1&2 - VOLUME I

shall be suitable for pumping dirty water which may be contaminated with fuel oil. All positive displacement pumps shall be of the horizontal screw or gear type. All positive displacement pumps shall be complete with electric motor driver, common baseplate, gear type flexible coupling and base mounted coupling guard, arranged for easy disconnection and reassembly and designed to withstand all service conditions. The pump/motor combination shall be nonoverloading at 125% of the normal system operating pressure at the maximum pumping viscosity value. Spacer type couplings shall be used if required to allow pump disassembly without moving the motor. All pumps shall be direct drive. Pumps of the rotary screw type shall have two (2) or three (3) rotors in accordance with manufacturer’s standard. Externally lubricated indexing gears and bearings shall be provided. 6.23.7.2.3

General construction requirements

Air release valves shall be fitted where necessary at suitable points on the pump casing. Each pump shall be fitted with isolating valves and pressure gauges to suction and discharge, and a non-return valve on the discharge line. The following requirements are applicable to all pumps unless specifically noted otherwise in the particular system subsection. A.

Casing

B.

Cast iron/cast steel/stainless steel casting for casing materials shall be used to suit the duty.

Connections between pump parts shall be doweled where necessary to assure proper alignment and fitted with gaskets of standard thickness and material selected for durability and compatibility with the pumped fluid. The pump casings shall be horizontally split to allow easy maintenance, and suitable means shall be provided for withdrawing the removable top half casing and impellers without disturbing any of the connecting pipes or valves. A.

Seals Shaft seals shall be of highest quality design and material. Ample room shall be provided for seal maintenance and/or replacement. Unless specified otherwise, mechanical seals shall be used exclusively. Precautions shall be taken to prevent seal leakage entering the bearing housings. 6.23-7 KHABAT TPP UNITS 1&2 - VOLUME I

B.

Bearings Antifriction type bearings shall be provided as required by the particular pumps specification. They shall be amply sized to carry all loads applied and shall be designed for 100,000 hour rated life under design conditions. Where bearings are of the ball or roller type the inner race shall be fitted directly to the shaft and shall be located at a raised machined shoulder of the shaft. Where the pumps are operated intermittently, special care shall be taken to prevent brinelling of the races while the pumps are not in operation. Intermediate shaft bearings for the suspended vertical type of pumps shall be securely connected to the main pump supporting tube. The weight of the pump impellers and shaft in addition to fluid axial forces shall not be taken by the motor bearings but by a separate thrust bearing for which ample access shall be provided for examination and maintenance. All bearings shall be oil tight against the atmosphere. Provision shall be made at each end of the bearing to prevent oil or grease being thrown off outside the bearing housing or creeping along the shaft. Bearings requiring cooling water shall be provided with all the necessary pipe work, valves and strainers for this purpose. All pumps shall have adequate thrust bearing provision.

C.

Shafts Impellers shall be mounted on shafts, keyed against rotation, and accurately positioned by collars or other suitable means. Shaft material shall be stainless steel 316 L unless specified otherwise.

D.

Impellers Impellers shall be accurately machined, statically and dynamically balanced to provide vibration-free operation. All surfaces shall be finished to a smooth contour. Impellers shall be of stainless steel 316 L unless otherwise specified.

E.

Couplings Each coupling half shall be keyed and properly fitted to it’s shaft. It shall be capable of absorbing variations in alignment and axial movements without affecting performance. It shall be adequately sealed to prevent entrance of sand or other foreign material. All couplings and any intermediate or dummy shafting shall be efficiently guarded. 6.23-8 KHABAT TPP UNITS 1&2 - VOLUME I

F.

Wear rings Renewable casing and impeller wear rings shall be furnished on all pumps and shall be of materials compatible with pump casing and impeller.

G. Workshop tests All pumps shall be workshop-tested in accordance with the relevant approved standard, as noted above. Pump performance curves, based on actual tests unless prototype tests are accepted, shall be submitted for each pump in the quantity and manner set forth elsewhere herein. 6.23.7.3 Tanks and pressure vessels Unless otherwise specified, tanks and pressure vessels shall be of welded construction, manufactured from carbon steel plate of accepted quality and thickness, and designed, constructed and tested in accordance with the appropriate API, AWWA and ASME standards as applicable. The tank supports - if any - shall be of such a height as to permit cleaning and painting of the floor plate of the tanks from the tank bottom. Tanks and vessels which are to be lagged shall be provided with external lugs for attaching reinforcement wire where necessary. Prior to the application of internal protection the tanks and vessels shall be thoroughly cleaned, dried by hot air or other approved means and shall then be

sandblasted

and

treated

internally

by

processes

as

specified.

Arrangements shall be made for the blanking off or removal of all valves or pipe connections during sand blasting to prevent the ingress of sand or other matter. The protective process shall be applied also to any ferrous fittings mounted inside the tanks. All tanks and pressure vessels shall be painted externally, in accordance with the specified provisions. All equipment shall be earthed and cathodically protected where appropriate. Corrosion allowance for pressure vessels and tanks shall be 3.0 mm unless otherwise specified. Tanks where appropriate shall be electrically isolated from cathodically protected pipe by insulating flanges or dielectric unions. 6.23.7.4

Bolts and nuts All bolts and nuts etc. shall conform to the stipulated standards. Bolts or studs which are subjected to high pressure and temperature shall be high tensile alloy steel with nuts of a suitable, approved material, and shall comply with ANSI requirements for power piping. 6.23-9 KHABAT TPP UNITS 1&2 - VOLUME I

All bolts or studs manufactured from alloy steels or steel shall be suitably machined at the shank and under the bolt head. Washers shall be provided under nuts, and also under bolt heads if required. 6.23.7.5

Thermal insulation

6.23.7.5.1

General requirements

Unless otherwise stated all pipework, ductwork, casings, flues and equipment that transmits or receives heat, or will form condensate shall be insulated with asbestos free materials. Heat insulation of all plant and pipe work having temperature of 65°C or more shall be provided to reduce the heat loss to atmosphere to a minimum, reduce the cooling load on the air-conditioning system, and to afford operational safety to the personnel. Where applicable the heat insulation shall be made of prefabricated formed lagging. Otherwise, insulation mats stitched on a mesh of galvanized wire shall be used. The insulation material shall consist of noncombustible and chemically inert material. The aim is to achieve an optimum reduction in heat loss by providing insulation of the appropriate type and thickness. Personnel protection insulation and protective covering shall he provided on piping and equipment where heat loss is inconsequential and where the surface temperature may exceed 60°C. All piping, valves and equipment which contain chilled water shall be covered with approved anti-sweat insulation, comprising a vapour resistant barrier jacket. Furthermore, the thickness shall be chosen in such a way that a heat loss of 230 watts/m2 is not exceeded. That calculation of thickness and thermal conductivity shall be subject to approval by the KNOC. All insulation shall be installed with proper allowance for expansion and insulation exposed to the weather shall be installed with proper flashing so as to keep the insulation dry at all times. The Bidder shall exercise extreme care in storing and applying insulation to make sure that it remains dry until water proofed. Insulation materials shall be stored in an enclosed area and shall always be stored in original containers until ready for application. Insulation that has become damp shall not be applied. Before applying the insulation, all piping vessels and equipment shall be 6.23-10 KHABAT TPP UNITS 1&2 - VOLUME I

tested for leaks and repaired, if necessary. Metal surfaces to be insulated shall be free from rust, grease, dirt, frost and moisture. Insulation shall not be applied to any vessel or equipment until all tests have been made, leaks repaired and tests accepted. Piping shall be covered with pre-formed half-cylindrical or curved segments of insulation materials. Insulation shall be applied with the circumferential joints staggered for single layers and with both the circumferential and longitudinal joints staggered for double layers. Each layer shall be securely wired. All joints of each layer and any voids or irregular surfaces shall be filled with insulating cement so that the surface will be cylindrical and smooth before the next layer or jacketing is applied. This principle shall be applied to every application. Covering on vertical runs of pipe shall be supported in such a manner as to prevent displacement due to slipping or contraction. This shall be accomplished without welding to pipes. Flange covers shall be made of sectional pipe covering or block insulation. These flange covers shall be made removable and to the thickness of the pipeline covering. Sufficient space next to flange shall be allowed for bolt removal. All valves and fittings shall be covered with insulating material of the same kind and thickness as that specified for the pipeline in which they are installed or by plastic insulating cements. The surface shall be coated with a vapour barrier cement or mastic and covered as appropriate. The final outer layer shall be aluminium cladding so as to be completely weatherproof. In the case of reducing fittings the largest pipe size shall determine the thickness of the material to be used. Insulation shall be removable. On equipment with regular surfaces such as tanks and vessels, calcium silicate blocks shall be applied. Layers shall be secured on the shells with stainless steel bands on 225 mm maximum centers machine stretched, and clamped in place under tension.

Where multilayer application is required, all

joints are to be staggered over joints of preceding layer. Heads of vessels are to be insulated with flat block insulation and secured with bands on 300 mm maximum centers attached to a double layer of circumferential bands or to rings welded to the vessels. Where removable head covers are required for exchanger head removal, the covers shall be field fabricated to allow access to these areas without disturbing adjacent insulation. Equipment insulation is to be covered with aluminium jacketing as specified for piping. Longitudinal 6.23-11 KHABAT TPP UNITS 1&2 - VOLUME I

and circumferential seams shall be lapped a minimum of 75 mm.

Insulation

shall be cut away from markings such as nameplates, clips, code inspection plates, etc, sealed and flashed against the entrance of water. Insulation and metal covers for manholes and blind flanges where required shall be twopiece removable covers. Skirts and supporting legs on equipment shall not be insulated. Longitudinal expansion of vessels shall be provided for by installing expansion joints. Nameplates on insulated equipment shall be removed and reinstalled by the Bidder on outside of covered surface in a secure manner satisfactory to the KNOC. Code stampings on pressure vessels shall be insulated with a removable section of insulation and lagging for easy accessibility for inspection. The Bidder shall furnish and install all insulation clips. All instrument connections on pipes, ducts, vessels or equipment shall be insulated. The insulation shall be shaped at these connections by tapering it to and around the connection with insulating and finishing cement. All access doors, removable panels, manhole covers and other parts on equipment requiring insulation, which must be opened or removed, shall be insulated. The method of insulating removable parts shall be such as to eliminate damage to the insulation on the removable part and on the adjacent surfaces. Edges and corners shall be protected by light structural angles or metal strips, and wire mesh shall be employed where necessary to hold the insulation securely and permanently in place. 6.23.7.5.2

Materials for heat insulation

The material used shall withstand the specified temperatures without deterioration shrinkage, change in form or pulverization. A.

Heat insulation Heat insulation materials shall be calcium-silicate in the form of flat or curved blocks for equipment and in the form of half-cylindrical or curved segments for piping. The materials shall meet the requirements of ASTMC533, Type I or equivalent. The use of preformed insulation materials shall be maximized when fabricating covers on valves, fittings, flanges, vessels, etc. The Bidder shall ensure a satisfactory fit on all piping and tube sizes to accommodate thermal expansion.

B.

Finishing cement If required finishing cement shall consist of asbestos free mineral fibre and suitable fillers premixed with a hydraulic setting binder. It shall be 6.23-12 KHABAT TPP UNITS 1&2 - VOLUME I

compatible with adjacent insulating materials and conform to ASTM-C449 or equivalent. When mixed with water, it shall form an easily workable plastic mix suitable for trowel application. After drying, it shall present a hard, smooth and durable surface free of cracks. C.

Wire-mesh and binding wire Wire mesh shall have hexagonal openings of 10-20 mm nominal size. It shall be woven of No 20 wire gauge from stainless steel wire. Binding wire shall be of stainless steel and not smaller than No 16 SWG.

D.

Aluminium for jacketing Aluminium sheets shall be of alloy type, resistant to seawater corrosion, medium hard. Embossed material with vapor barrier shall be used for cladding over thermal insulation with a minimum thickness of 1.2 mm.

E.

Mineral wool Mineral wool shall be used for loose insulation where use of prefabricated blocks is not possible. The mineral wool shall be stitched on one side to wire mesh by means of stainless steel wire. The material shall comply to the following specification: The mineral wool shall not contain any sulphur, or other corrosion causing materials i.e. it should be resistant to acid, hot water and steam. The mats shall have good resistance to shocks. The fiber of the mineral wool shall not be destroyed under the influence of long-term mechanical vibrations.

6.23.7.5.3

Frost protection (if applicable)

The plant shall be adequately protected against frost damage. Particular attention should be given to pipe work, pump casings, etc, and any part of the plant and equipment likely to stand for periods charged with static water. Water used in closed circuits shall be treated with an approved antifreeze compound. All water pipe work, pumps, valves, etc situated out of doors shall be protected against frost damage by thermostatically controlled electric trace heating and approved

weatherproof

insulation.

The

trace

heating

shall

energize

automatically when the ambient air temperature drops to 3°C and shall maintain the system at a temperature no lower than 3°C. The trace heating supply shall be energized at 110 V 50 Hz, centre point earthed, utilizing on approved proprietary system. The trace heating system shall be installed in sections such that failure of one section does not affect other sections of the heating system. Local panels 6.23-13 KHABAT TPP UNITS 1&2 - VOLUME I

shall indicate when each section of heating is energized and failure of any section such that the faulty section can be readily identified. An alarm shall be raised when a fault occurs and transmitted to the PCS system in the central control room. Insulation shall be suitable for outside installation and completely impervious to all weather and atmospheric conditions on the works. Lagging materials containing asbestos shall not be used. The lagging shall be sectional and easily removed for maintenance purposes. Joints shall be sealed together with an approved waterproof adhesive tape. 6.23.7.5.4

Finishes

Protective covering shall be applied to all heat, personnel protection, and antifreeze insulation. The materials for anti-sweat insulation shall be highly effective in preventing sweating and capable of satisfactorily withstanding moisture, and shall therefore not require additional protective covering. Metallic cladding and weather proofing shall be applied to all insulated surfaces where practicable. Longitudinal and circumferential joints for lagging shall be lapped to a minimum of 75 mm. Longitudinal laps shall be generally located on the horizontal centerline of horizontal runs of pipe.

The outer

part of the lap for all horizontal joints and circumferential joints in vertical runs of piping shall be turned downward in order to shed all water from the joint. Jackets shall be secured with stainless steel sheet metal piping screws on l00 mm centers on longitudinal joints. Elbows, bends and fittings shall be provided with cladding made from individual segments. The covering shall be furnished with neatly cut-off openings with separate sheets collars for the pipe hangers and other pipe connections/tappings. On bends, fittings valves and on equipment where a minimum overlap of aluminium is not possible, special workmanship such as beaded and crimped edges, shall be employed to produce a weatherproof covering. 6.23.7.5.5

Insulation for the boiler

Adequate cleats shall be provided together with wire netting reinforcement to ensure a satisfactory fixing of the insulation to all flues and ducts and other similar equipment. The boiler, superheater and economizer enclosure, and all gas ducts shall be insulated where possible by a preformed slab material. The casing finish shall be in galvanized mild steel or other stainless material sheeting and completely 6.23-14 KHABAT TPP UNITS 1&2 - VOLUME I

weathertight. Access doors in the ducts shall be insulated to a similar degree as the unit casings and flues which they serve. Insulation of doors shall be removable and replaceable to enable access to be gained without damage to the surrounding insulation. The insulation shall preferably be calcium silicate, mineral wool or other equivalent material and shall contain no asbestos such that cutting and forming operations will not present a health hazard. Refer to the General Mechanical Section for overall insulation requirements. 6.23.7.5.6

Insulation for the turbine

The insulation of the turbine shall contain no asbestos-derived materials. Cylinder insulation is to be by mineral wool with galvanized netting. The netting shall be covered by an impervious service. On areas to which access is required, such as valves, mattresses made of insulating material and enclosed in aluminium sheets may be used. All other hot areas, including hot drains piping shall be lagged and cleaded with metal cleading. All instrument root and drain valves to be external to the cleading. A soundproofed enclosure shall be supplied for the steam turbine if noise levels at any point 1 m distance from the set will exceed 85 dB(A). The enclosure shall have hinged access doors to enable routine inspections with adequate lighting system as required for routine inspection, completely wired with plugs and disconnects to allow for enclosure removal. Refer to General Mechanical Section for overall insulation requirements. 6.23.8

Steelwork All supporting steel structures shall be provided for plant, ducting, pipework and galleries, including pipe support brackets. All necessary platforms, toe-plates, ladders, stanchions, handrails, chains and all associated fittings shall be supplied to provide a safe and efficient installation. All mild steel items shall be protected by hot dip galvanizing after fabrication with a minimum thickness of 85 microns, unless otherwise specified. No cutting, drilling, bending, riveting, threading or similar operation will be permitted after galvanizing, and due care shall be exercised in transporting, handling and fixing galvanized metalwork to prevent damage to the zinc coating. Under no circumstances shall damage to the zinc coating be repaired with rust inhibiting paint. 6.23-15 KHABAT TPP UNITS 1&2 - VOLUME I

6.23.8.1

Platforms Platforms shall be constructed using galvanized open steel flooring to the relevant internationally recognized codes and shall cater for the relevant loadings for maintenance. The minimum acceptable size being 30 mm deep, 3 mm thick bars at 42 mm bar spacing. The flooring shall be bolted to the framework using approved bolted clips. The platform framework shall be galvanized. Platforms shall be provided and toe plates fitted to all platform edges. All platform panels shall be individually secured and be of suitable size and weight for ease of handling. Plated flooring shall be chequer plate having a minimum base thickness of 8 mm with a non-slip tread pattern, secured to the supporting steelwork with countersunk screws, which shall be cadmium plated. For manoeuvring smallwheeled items eg switchboard trucks, plain floor sheeting 8 mm minimum thickness shall be provided over specified areas. Open mesh platforms shall be open type, galvanized mild steel flooring suitable for a loading of 15 kN/m2 supported by heavy duty curbing giving a landing of 35 mm. Hinged grating with facilities for securing in the open position shall be provided as necessary.

6.23.8.2

Ladders and stairways Access ladders shall be provided as required. Step type ladders shall have flat section, non-slip, open type treads not less than 450 mm wide between stringers, with handrails fitted to each side extended to meet the platform handrails at the upper end. Vertical fixed ladders for emergency use shall be in accordance with the relevant internationally recognized codes and standards with equally spaced rungs between 230 and 260 mm apart with a width between stringers not exceeding 400 mm. Safety hoops shall be provided where necessary. Stairways shall be not less than 760 mm wide between stringers, and have an inclination to the horizontal not exceeding 40°. The stairways shall be constructed of galvanized mild steel stringers with galvanized open steel treads, reinforced at the leading edges, supported by substantial structural members. Galvanized handrails and standards shall be provided on each side of the stairway. 6.23-16 KHABAT TPP UNITS 1&2 - VOLUME I

6.23.8.3

Stanchions, handrails and chains Handrailing shall be 25 mm bore, with welded joints carried on solid forged steel handrail standards all galvanized with the upper rail not less than 1.1 m above the platform level. Ball type tubular standards are to support the handrails at not more than 1.5 m centers and arranged so that there is a standard not more than 300 mm away from any bend and 150 mm from any handrail joint. Handrails are to be secured to prevent movement within the standards. Stanchions and handrails shall be attached to the platform/walkway frame and not to any non-structural floor or toe-plates. Wherever possible, runs of handrail shall be continuous and sharp vertical changes of direction shall be avoided. Handrails shall terminate in swept ends either to the wall or return to the knee rail by means of a U bend which shall not extend greater than 350 mm beyond the centre line of the last standard. Entry points to ladders and platforms where necessary shall be protected by a double row of safety chains of mild steel 3 swg × 3 links per 100 mm complete with ‘S’ hook attachments.

6.23.8.4

Toe-plates All platform and walkway frames shall have toe-plates attached to the sides where handrails are fitted. Only around cut-outs provided in floor plates shall the toe-plate be secured the floor plate by welding. Toe-plates shall be at least 100 mm high and 5 mm thick and the gap between toe and floor plates shall not exceed 15 mm.

6.23.9

Safety guards for plant and apparatus Guards to ensure safety of personnel shall be provided to the approval of the KNOC and shall be generally in accordance with the relevant internationally recognized codes and standards.

6.23-17 KHABAT TPP UNITS 1&2 - VOLUME I

6.24

Painting and Protection Against Corrosion All material and equipment shall be effectively protected against corrosion during transit and while being stored at site. All materials and equipment shall be protected by the application of anti-corrosion agents in a mineral-oil base. This specification defines the requirements for painting, surface preparation, as well as the application of protective coatings for structural steel, equipment, piping, tanks, etc. for the entire plant.

6.24.1

General The Bidder shall, at all times, have access to the works in order to inspect surface preparation or application of work in progress in the workshop as well as on Site. Should any work or product be found to be defective or not in compliance with the specification, correction or replacement shall be made by the Bidder at his costs. The Bidder shall bear the full responsibility for the application of coatings, applied by him on surfaces, primed or painted by others. All coatings proposed for the internal protection of potable water tanks shall be certified by an approved independent institute. Covers should be used where required to protect building structures, equipment, insulation and lagging. When surfaces have been stained or otherwise damaged by the painting and/ or surface preparation work, the

Bidder is responsible to thoroughly clean and/ or repair these surfaces. Scaffolding shall be erected, maintained and dismantled without damage to equipment, piping, machinery or structures. Parts which cannot be coated and which are very sensitive to atmospheric exposure must be efficiently packed for storage. The inside of equipment and machinery shall be cleaned thoroughly at works, and before transportation all holes and access openings shall be efficiently sealed in order to prevent infiltration of dirt and humidity. Treated and machined parts not to be painted shall receive a provisional corrosion protection.

6.24-1 KHABAT TPP UNITS 1&2 - VOLUME I

Unless otherwise specifically indicated, surfaces, such as stainless steel, brass, copper or any other nonferrous items, finished hardware, aluminium windows, etc. shall not be painted. •

Exception : Gas turbines/generators and its auxiliaries shall be painted in accordance with the Bidder’s’ Standard.

•

Structural bolts shall be galvanised, sheradised or cadmium-plated and painted as specified under painting systems for carbon steel surfaces.

The method of application shall be to the approval of the KNOC and shall be taken to ensure mechanical and electrical compatibility with the factory applied coating and the cathodic protection system. The Bidder shall provide a full paint and coatings schedule to demonstrate the adequacy of the provision. The Bidder shall submit to the KNOC six (6) sample chips (100 × 150 mm size) of each colour and finish on the type of surface specified. Colours shall be indicated on the paint and coatings schedule. 6.24.2

Protective coatings and paint systems Type and number of protective coatings for any item which requires corrosion protection on this project shall be in accordance with the attached coating specification. The intention of the coating specification is to protect all parts which require corrosion protection with a prime coat which should be applied at Bidder's works. Only touch-up of bolts, welds and damaged areas will be required for field priming of these items. For parts which are not likely to be damaged during transportation, the KNOC may give the approval to apply the full number of coats for these parts in the shop.

6.24.3

Conditions for painting In general, coatings shall not be applied when the temperature of the steel is below +10 ℃. Surface temperature must be at least 3℃ above the dew point to ensure that condensation does not occur on the surface. In order to prevent condensation on the steel surface, the relative humidity must be checked continuously. The measurement of these conditions is under the Bidder’s responsibility. 6.24-2 KHABAT TPP UNITS 1&2 - VOLUME I

Coating materials should not be applied if the steel temperature is above +38 ℃. No coating should be executed during sand storms and rain. If more stringent, the manufacturers' recommendations shall supersede the above. Special exception for applications at higher or lower temperatures are possible if approved by the Coating Bidder and the KNOC at Site. 6.24.4

Safety precautions All necessary precautions shall be taken by the Bidder to protect personnel and property from hazards due to falls, injuries, toxic fumes, fires, explosion or other harm. All painting and corrosion protection work, including the inside of buildings and vessels, shall be performed under strict safety conditions. The Bidder is responsible for adequate ventilation, protection from open flames, sparks and excessive heat, by taking into consideration the high temperatures prevailing especially during summer. The areas where this work is performed shall be clearly marked with warning signboards. the Bidder is responsible to ensure that all work to be done and all equipment used is in accordance with the local authority regulations. The Bidder also has to follow the safety regulations of the relevant local or plant safety department.

6.24.5 Surface preparation All surfaces to be protected shall be coated in accordance with the requirements of ISO 12944: 1998. Preparation grade for surfaces shall be a minimum of Sa 2½. 6.24.6 Galvanizing Where employed, galvanizing of surfaces shall be in accordance with the requirements of ASTM A123/A123M-01a or equivalent. Bolt fixings shall be galvanized in accordance with the requirements of ASTM A153/A153M-01a. Preparation grade for surfaces shall be Sa 2½. Where the galvanized surface is rendered discontinuous for any reason, the un-galvanized surface shall be thoroughly cleaned to bright metal and painted to the requirements of ASTM A123/A123M-01a or equivalent.

6.24-3 KHABAT TPP UNITS 1&2 - VOLUME I

6.24.7 Painting All exterior surfaces, including buried and aboveground pipe work, shall be of high durability (>15 years) and appropriate to a C5-I (very high industry) or C5-M (very high marine) environment as appropriate. Interior surfaces shall be of be of high durability (>15 years) and appropriate to a C4 environment. High temperature and intumescent coatings shall be in accordance with manufacturers’ guidelines.

6.24-4 KHABAT TPP UNITS 1&2 - VOLUME I

6.25

Packing and Marking On Packages All apparatus shall be carefully packed for export shipment and storage at Site in such a manner that it is protected against all climatic conditions. All tubes and pipes shall be protected from external damage and to prevent ingress of dirt during transport and storage. The Bidder shall submit details for approval of the proposed methods of protecting the individual pipe ends before any pipes are dispatched to Site. Wood plugs shall not be used for sealing the ends of tubes. When tubes are to be stored on Site they shall be placed on supports so that they are not in contact with the ground. All bright parts liable to rust shall receive a coat of anti-rusting composition and shall be suitably protected. Special precautions shall be taken to protect journals where they rest on wooden or other supports likely to contain moisture. At such points wrappings shall be used impregnated with antirusting composition and of sufficient strength to resist chafing when subjected to the pressure and movement likely to occur in transit.

Motors and

equipment with ball or roller bearings shall be protected with resilient packing to prevent damage due to vibration. The packing cases and packing materials are included in the Contract and shall be the property of the KNOC. 6.25.1

Receipt and storage at site All items, packing cases, containers and packages received at Site shall be recorded against the shipping schedule and immediately inspected for signs of damage. All items are unpacked and inspected upon receipt including those with packing that is damaged. All signs of damage shall be investigated and the extent and nature of the damage recorded. The contents of each packing case, container or package shall be checked against the contents list and any discrepancies noted. Each item shall be carefully unpacked and checked for mechanical damage and/or damage to the corrosion protection. All such damage shall be recorded. No item will be accepted for storage on Site until all mechanical and/or corrosion protection damage has been notified and rectified to the KNOC’s satisfaction. It is emphasized in this respect that for damage which may affect the life or function of the component the Bidder must submit a full report to KNOC describing the consequences of the damage and the proposed rectification procedures. 6.25-1 KHABAT TPP UNITS 1&2 - VOLUME I

All plant and equipment to be stored out of doors shall be placed on timber or the equivalent so that it is out of contact with the ground and provided with adequate protection against weather. KNOC may, if he considers it necessary, instruct the Bidder to carry out a repair or special cleaning process on any item on which the protection has been ineffective and/or which has been subjected to adverse storage conditions. All items stored at Site shall be inspected on a regular basis and adequate records of inspection and corrosion protection rectification carried out shall be kept. All such records and the items in store will be subject to periodic audit and inspection by KNOC who may require additional work to be carried out to either restore the condition of the item or to ensure that deterioration does not occur. The cost of all recording, inspection and rectification shall be borne by the Bidder who is also responsible for any necessary insurance claims against shipper and/or other parties in respect of the damage to or loss of any item or component. On withdrawal from store, each item or component shall be prepared for erection by removal of temporary shipping and site storage protection. Immediately prior to erection, inspection shall be carried out to ensure that all such protection has been properly and completely removed as necessary unless the protection is to be used for additional protection during erection. All such ‘left on’ protectives must be removed prior to commissioning the plant unless with the specific approval of KNOC they will be removed during testing and/or commissioning without detriment to the plant or associated plant and equipment. All desiccants and vapor phase inhibitors must be removed prior to erection

even

though

semi-completed

systems

and/or

vessels

may

subsequently require reprotection by similar means to prevent deterioration during erection. The Bidder shall be held responsible for, and make good, all damage occurring due to improper preparation of goods for shipment or storage. 6.25.2

Erection mark All members comprising multipart assemblies, eg steel framework, piping installations, etc. shall be marked with distinguishing numbers and/or letters corresponding to those of the approved drawings or material lists. These erection marks, if impressed before painting or galvanizing, shall be clearly readable afterwards. Color banding to an approved code shall be employed to 6.25-2 KHABAT TPP UNITS 1&2 - VOLUME I

identify members of similar shape or type but of differing strengths or grades.

6.25-3 KHABAT TPP UNITS 1&2 - VOLUME I

6.26

Flue Gas Desulfurization System

6.26.1

System description The FGD system shall be designed throughout so as to insure continuous, safe and economical operation providing the maximum of reliability and without undue noise, vibration, unstability, unbalance, scaling, plugging, overheating, abrasion and corrosion. The FGD system shall be designed and guaranteed up to 115% gas volume (FGD design condition) compared to gas volume of BMCR that include the increase of excess air, air preheater leakage and etc. From the SOx's point of view, the FGD system shall be designed and guaranteed up to max. Shut down of one unit shall not affect the operation of the other unit. The FGD system shall be designed to keep the balance of gas flow through absorber and flue gas system under all operation conditions. The Bidder shall submit the CFD(computational Fluid Dynamics) result descriptions including gas flow velocity and pressure distributions under all operation conditions.

6.26.2

System design criteria

6.26.2.1 The FGD system shall be designed and guaranteed to perform all performance guarantees with the boiler burning residual oil, heavy fuel oil, light fuel oil and natural gas. But, the flue gas system requirements given in design guide shall be designed and guaranteed to perform with the measured max. gas flow rate. After award, at the time of FGD system design start, the Bidder shall measure and recheck the flue gas conditions on Bidder's own responsibility and design the FGD system to meet all performance guarantees required in this specification under any flue gas conditions. 6.26.2.2 One(l) absorber shall be furnished per unit. 6.26.2.3 The FGD system shall be designed to provide reliable service over the life of the plant. 6.26.2.4 The Bidder shall also meet any additional design considerations imposed at the various boiler load conditions. 6.26.2.5 The FGD system shall operate automatically over the load range. 6.26.2.6 The specific location of equipment and arrangement of the facilities is flexible within the general area shown and shall be located by the Bidder to minimize 6.26-1 KHABAT TPP UNITS 1&2 - VOLUME I

the unstability and unbalance of gas flow, and pressure losses, optimize operational costs and procedures, and allow maintenance access to all equipment. 6.26.2.7 The limestone slurry preparation system and gypsum dewatering system shall be designed as a common facility for Two(2) units. 6.26.2.8 The FGD waste water treatment system shall be capable of treating all FGD waste water discharged from the FGD system of Two(2) units. 6.26.3

Design and construction features

6.26.3.1 Absorber system A.

General description The process adopted for the FGD system supplied by the Bidder shall be the wet limestone-gypsum process with in-situ forced oxidation. In the absorption reaction process, the sulfur dioxide captured from the flue gas by the chemical reaction with calcium carbonate in the slurry shall be converted to calcium sulfite. The clean gas shall pass through the mist eliminators to remove entrained mist droplets and solids from the gas stream. Air is sparged into the slurry collected in the absorber reaction tank i.e. the absorber lower section, for in-situ oxidation of the calcium sulfite to calcium sulfate. For complete oxidation and good mixing, a sufficient number of agitators shall be provided to maintain solids suspension and good mixing within the reaction tanks. The gypsum slurry shall be bleed to the gypsum dewatering system. All mist eliminator washing water shall be used as make-up water to the absorber.

B.

Number of components and redundancy The Bidder shall provide main equipment including the following not be limited to:

6.26-2 KHABAT TPP UNITS 1&2 - VOLUME I

Number for one(1) unit

Number for two(2) units

One(1) lot

Two(2) lots

N + 1 sets (one set stand-by)

Two(2) * (N + 1) sets

N sets

Two(2) * N sets

One(1) lot

Tow(2) lots

E. M/E washing water tank

-

One(1) lot

F. M/E washing water pump

-

Items A. Absorber with internal B. Absorber recirculation pump C. Reaction tank agitators and drivers D. Mist eliminator including water washing subsystem

G. Gypsum bleed pump

Two(2) sets (one set stand-by)

H. Oxidation air blowers

-

Three(3) sets (One set stand-by) Four(4) sets (Two sets stand-by) Three(3) sets (One set stand-by)

One(1) lot

Tow(2) lots

Two(2) sets (One set stand-by) Two(2) sets (One set stand-by)

Four(4) sets (Two sets stand-by) Four(4) sets (Two sets stand-by)

L. Emergency storage tank with agitator

-

One(1) lot

M. Emergency storage pump

-

Two(2) sets (One set stand-by)

1 lot

2 lots

I. Absorber slurry sump agitator J. Absorber slurry sump pump K. Absorber density pump

N. Other equipment required for complete absorber & aux. system

C.

Absorbers 1) The type of the absorber shall be designed by the Bidder. Each absorber shall include all necessary internal components, supports and linings, in-situ forced oxidation facilities, integral reaction tank and agitators, and maintenance access doors. The type and number of SO2 removal stages shall be determined by the Bidder. The Bidder must submit the detail data for the approval. The Bidder shall provide a design for the absorber which has been demonstrated to operate successfully in similar electric power utility service. 2) The optimum design parameters in the absorber, such as pH level, L/G ratio, limestone stoichiometric ratio, gas velocity, oxidation ratio, 6.26-3 KHABAT TPP UNITS 1&2 - VOLUME I

pressure drop, gypsum super-saturation, slurry reaction tank retention time, suspended solids content, etc. shall be determined by the Bidder based on the design conditions in this specification, and shall be described in the Bidder's document. The design parameters shall be of a proven design. The design concept shall have been used in previously designed and currently successfully operating installations at the same or similar design conditions. The basis for the selection of these design parameters shall be submitted for the review. 3) The absorber shall be constructed to form a leakproof envelope. Welded joints shall be used wherever possible. Flanged and bolted joints shall be used only where necessary for maintenance. Any penetrations of the shell required for slurry spray headers, piping connections, or accessories, shall be sealed and made leakproof. 4) The absorber shall be designed for the maximum positive or negative pressure loads, whichever is more severe considering upset conditions caused by damper operation. The absorber shall be provided with over pressurization protection to prevent an inadvertent over pressurization. Over pressurization protection shall be provided by piping loop water seal or the KNOC approved equivalent. Make-up water to loop seal shall be provided automatically from the washing water system and shall re-establish the seal in the event of over pressurization. The loop shall be sized to relieve the maximum flow from all pressurizing sources while maintaining vessel pressure at level where no damage to the vessel or linings could occur, but in no case shall that pressure be above the vessel design pressure. The water seal shall be freezing protected. The absorber tower shall also be designed for piping forces and moments, wind and seismic loads, and all other loads imposed on the absorber. Bracing and reinforcement shall be adequate to prevent excessive deflection and vibration. Internal supports and mist eliminator section shall be designed to withstand the maximum flooded weight of the supported section or the weight of the supported section with scale build-up and deposits that may be experienced in the plant. 5) The absorber shall be designed to achieve the uniformity of gas flow distributions on the absorber inside under all operation conditions. If 6.26-4 KHABAT TPP UNITS 1&2 - VOLUME I

the serious variation of gas flow occurs on the absorber inside, the Bidder shall provide the means to overcome the problem. 6) The Bidder shall perform computational fluid dynamics(CFD) model study of GGH, absorber, ductwork and stack(if required) combination to assure that appropriate gas velocities and uniform distribution is achieved in the full- scale installation of FGD systems furnished under this specification. The CFD model study shall be performed, completed, reviewed and approved by the KNOC within three(3) months after contract so that the test results can be fully incorporated into the final GGH/absorber/duct design. The CFD modeling shall demonstrate that the scrubbed flue gas at the inlet face of the first stage mist eliminator shall have the following gas velocity/distribution characteristics : a) 85% of all individual gas velocity reading shall be within ±15% of the average gas velocity. b) All individual gas velocity reading shall be within ±25% of the average gas velocity. c) In addition, the scrubbed flue gas leaving the second stage mist eliminator shall have appropriate uniform distribution for proper operation of GGH. The Bidder shall submit to the KNOC for approval a copy of the proposed model study, methodology and standards at least four(4) week prior beginning the model study. 7) The absorber and internal shall be constructed of ASTM A240(6% Mo. Or equivalent). The CCT (Critical Crevice Temperature) range value shall be average value of the super austenitic stainless steel(6.0% Mo) value or more. The CCT value shall be tested in accordance with the ASTM G48, method B or D. The guaranteed CCT Value shall be submitted for approval. High wear areas shall be protected against erosion. Wet-dry zones of the absorber inlet shall be ASTM B 265(Grade 2) solid, ASTM B575(14.0% Mo.) solid or equivalent up to the expansion joint immediately upstream of the absorber tower. Tower exterior shall withstand the corrosive salt laden atmosphere of the project site. 8) All equipment exposed to hot flue gas shall be designed by the Bidder to withstand upset gas temperature excursions. Also, materials 6.26-5 KHABAT TPP UNITS 1&2 - VOLUME I

located in the wet gas path shall be protected from the temperature excursion by operation of the emergency quenching system. Outlet gas temperature from the emergency quenching system under the conditions of maximum temperature excursion shall be low enough to preclude damage to components located in the gas path. There shall be no damage whatever to any equipment as a result of these excursions. 9) The Bidder shall design and select the proper distance between the upper spray level and the bottom of the absorber mist eliminator. The absorber gas inlet shall be located sufficiently high enough to prevent splashing from the absorber reaction tank. The gas inlet shall be downward sloping to facilitate draining of all fluids. A means of preventing sprayed slurry from entering the gas inlet side shall be provided. 10) The absorber shall be designed to include side-hinged, bolted manholes/access doors to permit entry. A larger access door shall be provided for the reaction tank to permit entry of cleanout equipment and/or maintenance tools and personnel. 11) The Bidder shall provide viewpoints to permit on-line viewing of mist eliminator surfaces and other section needed for inspection of absorber internal. Each viewpoint shall be at least 500 mm diameter, be constructed of suitable material and have a manual washing system of the internal viewing surface. 12) The absorber reaction tank volume shall be adequately sized to provide sufficient retention time for limestone dissolution, oxidation of calcium sulfite to calcium sulfate(gypsum), desupersaturation of recycled scrubber liquid to minimize vessel scaling, and promote gypsum crystal growth. The tank shall be sized to provide a minimum retention time which conforms to the Bidder's standard, proven design based on actual operation experience of full-scale commercial FGD system installations. The absorber reaction tank shall be constructed such as ASTM A240(6.0% Mo.) soild or equivalent. 13) The Bidder shall provide a detailed justification for the selection of the absorber reaction tank retention time sizing and materials of construction. 6.26-6 KHABAT TPP UNITS 1&2 - VOLUME I

The location and number of agitators for each absorber reaction tank shall be determined to minimize solids deposition on the tank bottom and to prevent pump cavitation. The reaction tank bottom shall be designed to prevent accumulation of any slurry and for ease of cleanout. Motor driven knife gate drain valve at the absorber reaction tank bottom shall be provided to permit complete draining of the absorber reaction tank to absorber slurry sump. In addition, the absorber reaction tank shall be provided with a sloped floor to facilitate cleaning of residual solids and/or liquids as well as washing water. The absorber reaction tank shall be provided with an overflow pipe properly sealed and heat-traced if required. The overflow pipe shall be designed for ease of cleanout. The slurry overflowed from reaction tank shall be collected in the absorber slurry sump. 14) For in-situ forced oxidation, oxidation air shall be introduced to the absorber reaction tank. The oxidation air supply system shall be equipped with the oxidation air humidification facilities. The oxidation air supply pipeline shall be solid super austenitic stainless steel(6.0% Mo) or equivalent from the humidifier to inside of the absorber and A53 Gr.B or eq. for rest parts of the line. A part of oxidation air line shall be insulated for personnel protection. The oxidation air supply facilities shall be designed to avoid being plugged by settlement of slurry, and to facilitate cleanout. The oxidation air flowrate shall ensure that adequate mixing velocities are maintained within the absorber reaction tank to prevent dead spots and permit even distribution of air flow. 15) Each absorber shall be equipped with one(1) absorber automatic vent valve required for maintenance, clarification, and etc. The vent valve shall be designed for complete and rapid ventilation of absorber. D.

Absorber recirculation system 1) The absorber recirculation system shall consist of pumps, pipe work, spray headers and nozzles to provide intimate contact between the slurry and the flue gas to be cleaned. This system shall be designed to have a sufficient and necessary liquid to gas (L/G) ratio to reliably achieve the required performance without scaling of absorber internal 6.26-7 KHABAT TPP UNITS 1&2 - VOLUME I

surfaces. The Bidder shall design for the appropriate number of absorber recirculation pumps. Each absorber recirculation pump shall serve only one(1) spray level. No manifolding of recirculation pumps shall be permitted unless it is part of the Bidder's proven commercial design with operating FGD system. The absorber recirculation pumps shall be installed in the absorber recirculation pump room of absorber building. 2) The absorber recirculation pumps shall be equipped with auto isolation valve on each suction and discharge line. The Bidder shall provide the facilities(auto isolation valve) to prevent the leakage of flue gas or slurry to the discharge line during pump maintenance in the discharge line at an accessible location. The slurry recirculation line shall be equipped with auto-flushing system, and the Bidder shall determine the flushing procedure of absorber recirculation pump not to break the mechanical seal. 3) The Bidder shall design the arrangement of spray levels and nozzles such that the absorber cross-section is uniformly covered. The spray pattern shall have extensive overlap to ensure full coverage of the gas path, thus avoiding channeling. The Bidder shall clearly demonstrate exactly how this uniform slurry spray pattern is achieved. The Bidder shall submit the absorber spray droplet distribution. Internal spray header piping shall be corrosion and erosion resistant material on the internal and external surface such as alloy or FRP suitable for the intended service. External spray header piping shall be rubber lined carbon steel, duplex stainless steel, or equiv. Nozzle arrangement shall be designed to minimize and preferably avoid direct slurry impingement on internal surfaces, or absorber walls. 4) The absorber spray nozzles shall be designed to prevent scaling, plugging and thermal shock, and to ensure long term operation. Spray nozzles shall be constructed of ceramic material such as silicon carbide or stellite. 5) Spray nozzles shall be connected to the spray nozzle header by flanged connection or special quick disconnect clamps for easy installation and removal. Flanged sections shall be abrasion and

6.26-8 KHABAT TPP UNITS 1&2 - VOLUME I

corrosion resistant material suitable for intended service. Flange bolts shall be ASTM A240(6% Mo.) solid or equivalent. 6) The absorber recirculation pumps shall be of an appropriate design suitable for handling abrasive slurry and well proven in full-scale commercial operating wet limestone-gypsum FGD plants. Impeller tip speed shall be less than 25 m/sec. The absorber recirculation pumps shall be provided with lifting devices for installation and maintenance. 7) The operation of absorber recirculation pumps shall be interlocked with the reaction tank level and absorber start-up permission. Whenever a pump is stopped, it shall be automatically drained and flushed with make-up water. The time interval for flushing and draining shall be adjustable by the operator. 8) Regardless of how many absorber recirculation pumps are provided, at least one absorber recirculation pump shall be a standby for effective operation and maintenance under any operating conditions. The stand-by pump shall be automatically put into service when any operating pump fails in the automatic mode. All performance requirements and guarantees of FGD system must be met at least one pump/spray header in stand-by and regardless of stand-by spray header position. 9) The recirculation flow rate to the discharge of each absorber recirculation pump shall be monitored and recorded by utilizing electrical current flow to the pump motors. 10) The bearings of the absorber recirculation pump shall be provided with temperature measuring instruments with temp. transmitter which shall be alarmed and logged in control system. 11) The absorber recirculation pumps shall be started or stopped corresponding to the effective required L/G ratio to remove SOx in the untreated flue gas so that the desulfurization process can be economical. The Bidder shall provide the detailed explanation of each reaction conditions and performance curve of the absorber recirculation pump at the reaction conditions. E.

Mist eliminators 1) The absorber shall be equipped with multi-stage, multi-pass, chevron type mist eliminators. The mist eliminators shall be located 6.26-9 KHABAT TPP UNITS 1&2 - VOLUME I

downstream of the last absorber recycling slurry header section. All mist eliminators shall be washed with make-up water and shall be designed for minimum carryover, pressure drop and plugging. The mist eliminator shall be of the continuous vane arrangement. For first stage, hooks or pockets shall not be used. The total carryover mist content(including acidic mist) from final mist eliminator shall not exceed 100 mg/N㎥ dry gas. The particulate loading downstream of the mist eliminator section shall not exceed the particulate loading into the FGD System. Performance test of entrained mist shall be performed using recommended method by mist eliminator manufacturer. The Bidder shall submit the relation between mist size distribution inlet of mist eliminator and mist removal efficiency. 2) The mist eliminators shall be constructed in individual cells with integral supports holding the slats or blades together such that the cell can be removed intact. The individual cells shall be sized so that no more than two maintenance personnel can handle them manually for removal from the absorber vessel even if they are fully scaled or plugged. Each cell shall be capable of passing through the access doors for the mist eliminator section. The individual cells shall also be capable of being removed without replacing the adjacent cells. 3) The mist eliminators shall be constructed of materials capable of withstanding the chemical and thermal environment of the absorber module. They shall be capable of withstanding high pressure water lancing typically employed in manual cleanings. Alloy, FRP or polypropylene is considered acceptable. 4) The mist eliminators and support structure shall be capable of supporting the weight of maintenance personnel and equipment in addition to any scaling or plug of the mist eliminators without deformation. The mist eliminator and spray nozzle support structure shall be constructed of solid super austenitic stainless steel(6.0% Mo) or equivalent which is the same material of absorber. 5) The actual average gas velocity through each mist eliminator part with vertical gas flow shall not exceed 4m/sec at design condition(115% BMCR Condition). The actual average gas velocity

6.26-10 KHABAT TPP UNITS 1&2 - VOLUME I

through each mist eliminator with horizontal gas flow shall not exceed 7m/sec at design condition(115% BMCR Condition). 6) For the absorber, the distance between two mist eliminators shall be no less than 1.5m. The cross-section of the tower or duct after the last mist eliminator shall not reduce in cross-section for at least 2.0 m. 7) The mist eliminator washing nozzles shall be connected to separate washing water supply headers for different areas of the mist eliminator. An automatic isolation valve shall be located on each header just outside the absorber module to allow independent operation of each header. The pressure of the washing water shall be monitored and adjusted in the supply line just before the header connection. The washing headers shall be designed such that the pressure of each nozzle shall be operated within ±10 percent of the average washing water pressure. Washing headers and nozzles should be of alloy, FRP or PP. Sufficient nozzles shall be supplied to provide at least 50 percent spray overlap coverage. 8) The mist eliminators shall be automatically washed on-line. The controlling system for the automatic mist eliminator washing sequence, duration, and frequency shall be capable of being easily reprogrammed. Washing procedure shall be not to occur the mist carry-over. Also, provision shall be made allowing the operator to manually initiate or interrupt the sequence. 9) The front and back side of each stage mist eliminator shall be provided with washing header and nozzles. The backside washing header of the second stage mist eliminators will be used at low or no load conditions. 10) The mist eliminator shall be capable of operating for at least 12 months without an increase pressure drop of more than 20% above the pressure drop measured during clean operation. The Bidder shall provide pressure taps and transmitters at the absorber inlet, just upstream of the first stage mist eliminators, and after the last stage mist eliminators. Pressure taps shall be provided with a method for cleaning without removal of the transmitters and associated equipment. The Bidder shall provide a differential pressure transmitter each mist eliminator.

6.26-11 KHABAT TPP UNITS 1&2 - VOLUME I

11) Test ports shall be provided downstream of the last mist eliminator to enable performance testing. Test ports shall be located at a minimum of eight equally spaced locations around the absorber circumference for vertical flow mist eliminators. Test ports for horizontal flow mist eliminators shall be located at locations acceptable to the KNOC. 12) The Bidder shall provide the mist eliminator washing system. The Bidder shall furnish one(1) mist eliminator washing water tank and 50% × 3 washing water pumps for two(2) units. F.

Gypsum bleed pumps 1) The Bidder shall provide two(2) gypsum bleed pumps per absorber, one is in service and the other is in stand-by for the full range of fuel sulfur content and boiler load. The main purpose of the gypsum bleed pump is to bleed off gypsum slurry from the absorber reaction tank to the gypsum dewatering system. Also, the gypsum bleed pump may be used to bleed chloride from the absorber tank. The gypsum bleed pump shall be designed to ensure the required performance without any disturbance of the SOx absorption and gypsum dewatering. 2) The operation mode of gypsum bleed pumps shall be determined by the Bidder and shall be designed so that the entire FGD system shall not be adversely effected by varying of the inlet SOx, Cl and particulate matter content in flue gas and the boiler loads. The amount of gypsum bleed shall be controlled by solid density of absorber recirculation slurry. 3) The gypsum bleed pumps will transfer slurry from each absorber to one(1) gypsum dewatering feed tank for two(2) units common use. Either continuous or batch transfer of the gypsum slurry bleed is acceptable providing there is no adverse impact on the performance of the Bidder's FGD system. The gypsum bleed system shall be equipped with auto-flushing system. A. Impeller tip speed of gypsum bleed pumps shall be less than 30m/s.

G. Oxidation air system 1) The oxidation air package shall consist of blowers, electric motors, lubrication systems with cooler, humidifier, distribution piping, absorber internal distribution system, isolation valves, associated 6.26-12 KHABAT TPP UNITS 1&2 - VOLUME I

instrumentation and controls and all required accessories to supply a fully functional system. 2) Oxidation air blower shall be of a single stage centrifugal type and shall provide oil free air. The bearing type of oxidation air blower is sleeve bearing with forced oil lubrication system or air bearing without oil system. The flow control method of oxidation air blower is inlet vane or outlet vane with actuator. 3) Humidifier shall be provided to pre-saturate the oxidation air. The spray water from the humidifier shall not flow into oxidation air blower. 4) The blower system and its associated enclosure shall be designed to the limit noise level. 5) Each blower of forced oil lubrication type shall be supplied with a complete lubrication system to supply oil at suitable pressures and temperatures to the blower and driver bearings, gears and couplings, as applicable. Provision in the lubrication system shall be made to allow the unit to shutdown and achieve a full stop condition without bearing damage in the event of lubrication system failure. Reservoir fill openings shall be equipped with a strainer. In addition, the reservoir shall be provided with an oil level indicator and sufficient degasification capability with adequate vent and a breather filter. 6) The water or oil cooler, if required, shall be a removable bundle shell and tube type arranged for maximum maintenance access without disturbing piping connections. Coolers shall meet the requirements of ASME Section Ⅷ, Division 1 and TEMA Class R heat exchangers and should be code stamped if required. Coolers shall be constructed of stainless steel. 7) The impeller may be made of aluminum-forged alloy or equivalent. After the final machining, the impeller and gear assembly shall be dynamically balanced in the manufacturer's plant. The rotor assembly shall be designed so that its design resonant speed is less than operating speed. 8) The bearing of the oxidation air blowers shall be provided with temperature measuring instruments with temp. transmitter which shall be alarmed and logged in the control system. The instrument shall be installed to proper area around the bearing. 6.26-13 KHABAT TPP UNITS 1&2 - VOLUME I

9) Gear casing shall have one smooth flat surfaces tapped to permit the installation of vibration probes provided by the Bidder. And the blower of air bearing shall have one vibration probe to get the axial movement. H.

Wastes and drainage transfer system 1) Drainage and flush water from pumps, piping and other FGD system facilities along with washing down water in FGD system shall be collected in the absorber slurry sump through pipes or trenches. 2) The collected slurry in the absorber slurry sump shall be returned to the absorber reaction tanks utilizing absorber slurry sump pumps furnished by the Bidder. 3) The absorber slurry shall be drained into the piping system through the absorber drain line. The absorber slurry sump pumps shall then transfer the slurry to the emergency storage tank. 4) The Bidder shall provide two(2) 100% capacity absorber slurry sump pumps for one(1) absorber. The absorber slurry sump pump shall be designed with sufficient capacity to pump the entire contents of the absorber reaction tank into the emergency storage tank within eight(8) hours.

I.

Emergency storage tank and transfer system 1) When it is necessary to empty the absorber, the absorber slurry will be drained to the emergency storage tank. The absorber slurry shall be transferred two ways. a) Utilizing the absorber slurry sump pumps b) Utilizing the gypsum bleed pumps. 2) The Bidder shall furnish one(1) emergency storage tank to serve two(2) units. 3) The emergency storage tank shall be equipped with two(2) 100% duty emergency storage pumps to reclaim the collected slurry from the emergency storage tank to each absorber reaction tank. In addition, the emergency storage pumps shall be able to feed the slurry collected in the emergency storage tank to the gypsum dewatering system for processing.

6.26-14 KHABAT TPP UNITS 1&2 - VOLUME I

4) The emergency storage pumps shall be sized to return, within eight(8) hours, the absorbent slurry to the absorber reaction tanks. 5) The emergency storage tank shall be constructed of carbon steel plate with a suitable corrosion/erosion resistant lining. The emergency storage tank shall be designed and constructed to drain the slurry completely. 6) The emergency storage transfer system shall be equipped with autoflushing system. J.

Absorber off-load cleaning system The absorber internals may be cleaned during normal unit maintenance outages. The absorber will be cleaned by the mist eliminator washing water and/or the make-up water from the mist eliminator washing header. The make-up water may be utilized to clean the spray headers manually by flexible hose connected from the mist eliminator-washing header by quick coupling connection. The Bidder shall provide one(1) quick coupling connection at the ground level, absorber inlet duct and mist eliminator washing spray header level for make-up water.

6.26.3.2 Flue gas system A.

General description Flue gas from the one(1) boiler will be transferred to one(1) GGH (untreated side) by means of two(2) CID fans located upstream of GGH. The flue gas will then enter the absorber where SOx is removed. And then, from absorber, treated flue gas will flow via the GGH treated side to the stack. The Bidder shall design a optimum flue gas system and absorber & aux. system in order to minimize the pressure drop across the whole FGD system, and provide the optimum and accurate gas pressure condition. The Bidder shall design and furnish all ductwork required. The ductwork shall be complete with expansion joints, access doors, flanges, insulation, lining, supports and hangers.

B.

Components The FGD flue gas system for each unit shall be composed of, but not be limited to the following :

6.26-15 KHABAT TPP UNITS 1&2 - VOLUME I

1) One(1) gas-gas-heater (GGH) 2) Flue gas ductwork 3) Expansion joints as required to allow for differential thermal expansion 4) Isolation dampers at FGD inlet duct 5) Isolation damper at FGD outlet duct 6) Isolation dampers at emergency bypass flue gas duct 7) Emergency quenching system 8) GGH washing water sump pumps & agitator 9) Purge air fan C.

Gas gas heater(GGH) 1) Flue gas treated by the absorber system shall be reheated to prevent visible plume and corrosion of duct and stack and to improve the diffusion efficiency into the atmosphere. The GGH shall be capable of reheating the treated flue gas temperature to 90℃ or higher at the stack inlet without supplemental heat input, based on MGR load. The GGH shall be designed and constructed for operation under all flue gas conditions and designed to provide the specified duty during all modes of operation including on-line mist eliminator washing. 2) For one(1) unit, one (100% x 1) rotation type regenerative counter flow GGH, that are vertical shaft, bi-sector rotary regenerative type, shall be furnished. 3) The GGH must be fabricated of materials proven to be resistant to the corrosive environment within the FGD system, and be suitable for emergency gas temperature excursions. a) The basket, rotor structures and untreated gas inlet connection duct shall be constructed of low alloy corrosion resistant steel plates (ASTM A588 or DIN equiv.), with a 50% increase in thickness for corrosion allowance. The rotor housing, both side outlet and treated gas inlet connection ducts shall be carbon steel plates with minimum thickness of 2 mm flake glass lining. b) The heat transfer element, not less than 1.2 mm total thickness, shall be made of low carbon steel covered with porcelain coating enamel or equiv.

6.26-16 KHABAT TPP UNITS 1&2 - VOLUME I

c) The radial, axial and by-pass seals, the face of sealing plates, retractable cleaning equipment and sealing plate adjusting mechanisms shall be fabricated from ASTM B575(14.0% Mo.) or equiv. 4) The GGH shall include, but not be limited to, the following main equipment a) Heat transfer surface b) Rotor drive The primary rotor driving mechanism shall consist of a drive motors, coupling, speed reducer and pinion gear. An auxiliary air drive system shall be supplied with the GGH and start automatically upon failure of the main drive motor, or remote manually or locally. The GGH rotor shall be supported at the bottom by a self-aligning thrust bearing assembly and guided at the top by a spherical roller bearing assembly. Both bearing assemblies shall be lubricated by oil baths or grease, and equipped with a complete shop assembled oil or grease lubrication system with oil level/temperature gauges. Water cooling shall be incorporated in the guide bearing oil circulation system to maintain proper oil temperature. c) Two stationary water washing devices Each stationary water washing device shall consist of a straight pipe with spray nozzles spaced to distribute washing water evenly over the heat transfer surface. These devices shall be used only for off-line washing. The pipes shall be located, one each, in the untreated gas inlet and outlet ducts integral with the GGH. d) Retractable cleaning devices Two combination, retractable cleaning devices located, one each, in the untreated gas inlet and outlet ducts integral with the GGH shall be supplied. The devices shall be for both regular soot blowing and on-line water washing. Each device shall consist of a single, retractable lance and drive mechanism equipped with separate steam and water nozzles, and limit switches to signal end of travel in both directions. The swivel and rotary retractable cleaning device is not acceptable. The Bidder shall provide two(2) high pressure wash 6.26-17 KHABAT TPP UNITS 1&2 - VOLUME I

water pump for two(2) units. The material of the GGH soot blowing and on-line/off-line washing nozzles, lances and connectors shall be constructed of ASTM B575(14.0% Mo.) or equivalent. -

On-line water washing system Material of on-line washing pipe shall be STS316 or higher.

-

Soot blowing system


An automatic soot blowing system shall be sequentially selective, retractable and furnished complete with all components for adequate operation.




If the supplied steam conditions are not suitable for GGH cleaning, the Bidder shall furnish the necessary means to attain the required steam pressure and enthalpy at all soot blowers. The Bidder shall furnish the electric heater to increase the steam enthalpy during low load.




The soot blowing system shall be equipped with equipment to prevent nozzle plugging and fouling.




The soot blowing steam line diameter shall be suitably determined to prevent from

excess

warming-up and

deterioration of steam quality. e) Scavenging system The material of fan and duct associated with scavenging fan shall be constructed of duplex stainless steel. The Bidder shall provide equipment to prevent opposite rotation when the scavenging fan is trouble during the FGD system operation time. -

Hot end leakage control system

-

Rotor Stoppage Alarm

5) Casings shall be furnished with provision to absorb differential expansion between the casing and rotor, and be fabricated of welded construction, properly ribbed and stiffened to prevent reverberation and amplification of vibrations. This may include, but not necessarily be limited to, both sliding bearing plate as well as any guidance structures required. 6) The maximum GGH leakage shall be less than two(2) percent of the gas flow entering the GGH at all load specified herein without operating of scavenging fan. 6.26-18 KHABAT TPP UNITS 1&2 - VOLUME I

7) Access for replacement purposes of all GGH baskets shall be provided. Suitable beams, lifting hoists and monorails, which shall be permanently installed, shall be provided for basket replacement. 8) Access doors shall be gas-tight when closed and shall be of adequate size for inspection, cleaning, and replacement of parts. The Bidder shall also furnish grating type walkways as required for maintenance and inspection of heating element and other internal. 9) A properly sized and designed drainage system complete with sampling points, valves and piping shall be provided under GGH hoppers. The Bidder shall design and supply a system to smoothly divert the ash collected in GGH hoppers and the washing water drained from GGH to the GGH washing water sump. D.

Ductwork 1) The Bidder shall provide all necessary flue gas ductworks, breeching, plenums, sampling connections, washing down and dropout hoppers, expansion joints, splitter plates/turning/guide vanes, gaskets/bolting materials, and access facilities for the scope of duct supply. 2) The superficial velocity of gas in the ductwork shall not exceed 20 m/sec at any location at the FGD design condition(115% BMGR Condition). Gas ducts shall be provided with suitable sampling connections. The test connections shall be located so as to be easily accessible and shall be provided with suitable caps to seal them when not in use. 3) Each duct described herein shall be constructed of the following materials or the approved equivalent. Materials Duct Zone

Plate / Thickness

Clad Material/ Thickness Clad

FGD Inlet Damper to GGH Inlet (Untreated Gas)

CRLS or EQ / 6mm

N/A

GGH Outlet to Absorber Inlet

SS400 or EQ / 6mm

Nickel-Base Alloy(14% Mo) or EQ. / 1.6mm

SS400 or EQ.

Wet Dry Zone

Nickel-Base Alloy(14% Mo) or EQ. / 6mm

N/A

SS400 or EQ.

Stiffener

Inner Stay

SS400 or A588 or EQ EQ / 6mm / 6mm Nickel-Base Alloy (14% Mo)or EQ. Nickel-Base Alloy (14% Mo)or EQ.

6.26-19 KHABAT TPP UNITS 1&2 - VOLUME I

Absorber Outlet to GGH Inlet (Treated Gas)

SS400 or EQ / 6mm

Nickel-Base Alloy(14% Mo) or EQ. / 1.6mm

SS400 or EQ.

GGH Outlet (Treated Gas) to FGD Outlet

SS400 or EQ / 6mm

Nickel-Base Alloy(14% Mo) or EQ. / 1.6mm

SS400 or EQ.

Nickel-Base Alloy (14% Mo)or EQ. Nickel-Base Alloy (14% Mo) or EQ.

All ductwork shall be designed to withstand the flue gas high temperature and pressure excursion situation. 4) Gas duct shall be furnished with supports to carry weight of duct, insulation, dust on the bottom, and vertical live load on horizontal projection of roof surface of 250 kg/㎡(outdoor duct). Ducts shall have a minimum thickness of 6 mm including a minimum of 1.6 mm for corrosion allowance. Gas duct shall be reinforced with stiffener having a minimum thickness of 6 mm. All duct internal material shall be constructed of the same material as the connected duct. Access doors shall be located at inspection point and area where access for maintenance is required. Doors shall have all necessary safety equipment such as stair and handrails. Access doors shall be fabricated of steel plate with positive closing mechanism, gas and airtight. Minimum size opening shall not be less than 500mm on vertical and horizontal axis. Steel plates bolted over access openings are not acceptable. 5) All plates to be field welded shall be shop-beveled or otherwise prepared so that the field welding may be done without additional field preparation. Clips shall be shop-welded to each section to facilitate alignment of the plates during field welding. 6) Abrupt turns with a radius with a less than five(5) diameters shall be avoided, but if such turns are required, guide vanes shall be provided. Guide vane shall be not thinner than 3 mm, spaced to minimize draft loss, suitably welded, supported, and reinforced. Distribution plates and other corrective devices, such as teardrop vanes, shall be incorporated as required on duct transition pieces. 7) Permanent scaffold brackets shall be provided where required for maintenance. Access platforms shall be provided at all hopper outlets. 6.26-20 KHABAT TPP UNITS 1&2 - VOLUME I

8) The drain piping and its valves shall be arranged at suitable locations on the flue gas duct for draining any condensate from the ducts. Drain piping materials shall be corrosion and acid resistant with the same property of the related duct plates. Especially, the Bidder shall consider the proper drain facilities for absorber outlet horizontal duct. Drains shall be collected in the GGH washing water sump. E.

Expansion joints 1) All expansion joints shall be of nonmetallic flexible belt type of gas tight construction and belt material shall be viton or equivalent. The belt and frame/bolt materials shall withstand the appropriate temperature and pressure associated with the design conditions specified and the appropriate safety margins without damage and shall be corrosion and abrasion resistant and non-vibration. 2) Expansion joints located at the interface with other equipment such as dampers and fans, or at the limit of the FGDs scope of supply shall have bolted flanges for the interface connection. Expansion joints adjacent to dampers shall have adequate clearance to preclude interference with damper moving parts. 3) Expansion joint belt material shop tests shall be conducted at the time of manufacture, and the test results shall be submitted to the KNOC for approval prior to delivery of the expansion joints. 4) Expansion joint flange materials shall be constructed of the same materials as the connected duct materials. Expansion joint flanges shall be insulated and lagged. 5) Expansion joints located in horizontal duct runs which are exposed to wet flue gas shall be provided with drains molded into the expansion joint belt material. Drain fittings shall be fabricated of FRP or the approved equivalent.

6.26-21 KHABAT TPP UNITS 1&2 - VOLUME I

F.

Dampers 1) All necessary dampers for equipment isolation and flow rate control shall be furnished by the Bidder for each FGD system. All dampers for flue gas shall be installed in a horizontal duct. 2) The damper assembly shall be designed to withstand the flue gas temperature excursions and pressure excursion situation (Min. CID Fan Test Block Pressure) without damage, binding, warping or leakage. 3) Limit switches shall be provided with all dampers to indicate fully open and fully closed positions. These limit switches shall be independent of those provided with the drive units (Limit switches and other damper I & C components shall have protection provision). 4) Electrical equipment that will be exposed to outside ambient conditions shall be housed. 5) Provision shall be provided to allow manual locking of the damper blade in the open and closed positions by the Bidder. The damper operator shall be equipped with a handwheel for manual operation. 6) Dampers in wet or low temperature flue gas shall be provided with drains. 7) The damper frame shall be designed to support damper actuators, seal air systems and other auxiliary equipment. The structural design of the damper frame shall be capable of withstanding a minimum of full actuator stall torque. 8) The damper operator shall have a rated torque output of not less than 300 percent of all combined dead and live loads at the maximum differential pressure across the closed damper under any operational condition. 9) Specific requirements for the isolation damper a) The Bidder shall provide the double multi-louver or tandem dampers per unit as the follows. -

Emergency bypass dampers for the full flue gas bypassing at emergency situation.

-

FGD inlet dampers in FGD inlet ducts.

-

FGD outlet damper for isolation of FGD system

b) Especially, the emergency damper shall be double multi-louver type. 6.26-22 KHABAT TPP UNITS 1&2 - VOLUME I

c) The emergency damper’s full close to full open time shall not exceed 10 seconds. When emergency damper is closed, the flue gas stream in power plant and FGD system shall be not affected by the pressure change. 10) The emergency damper shall be opened and the other isolation dampers shall be closed, whenever following conditions happen: a) Electric power failure b) Boiler master fuel trip c) CID fan trip d) Emergency quenching system start e) Too high temperature at the FGD inlet f) Too high or too low pressure at the FGD inlet g) Other conditions, the Bidder deems necessarily in order to ensure a safe operation Trip of single CID fan will open associated emergency damper and close isolation dampers. The other fan will continue operate. 11) The FGD dampers shall be constructed of the following materials or equivalent. Description

Emergency Damper

Internal Frame

Blade

Seal

ASTM B575 Up(14.0% Mo.), ASTM ASTM A588 or equiv. ASTM A588 or equiv. stream B265(Grade 2) or equiv.

Emergency DownDamper stream FGD inlet damper

FGD outlet damper

ASTM B575 (14.0% Mo.), ASTM B265(Grade 2) or equiv.

ASTM B575 (14.0% Mo.), ASTM B265(Grade 2) or equiv.

ASTM B575 (14.0% Mo.), ASTM B265(Grade 2) or equiv..

ASTM B575 (14.0% Mo.), ASTM ASTM A588 or equiv. ASTM A588 or equiv. B265(Grade 2) or equiv. ASTM B575 (14.0% Mo.), ASTM B265(Grade 2) or equiv.

ASTM B575 (14.0% Mo.), ASTM B265(Grade 2) or equiv.

ASTM B575 (14.0% Mo.), ASTM B265(Grade 2) or equiv.

12) The combined axial compression and bending stress shall not exceed 60 percent of yield at design conditions.

6.26-23 KHABAT TPP UNITS 1&2 - VOLUME I

13) Maximum blade deflection at the center of the span shall not exceed dimension of the blade divided by 360(L/360). Louvers shall overlap by a minimum of 14 mm to provide a positive stop to prevent over travel of the damper louvers. 14) Isolation dampers shall be provided with edge seals in addition to the frame seals. Seals shall be properly formed to insure proper sealing when the blades deflect under the differential pressure. Seal shall be bolted to the louvers for easy removal. Bolts, washers and nuts shall be constructed of 317LM stainless steel. 15) All dampers shall be designed for a fail-safe condition. This position, open, closed or in-place will be determined during detail design. 16) Seal air system a) Seal air system of all dampers shall be designed to prevent condensation and provide zero-leakage of flue gas across the damper. Seal air system also shall provide 100% isolation of flue gas from ductwork during non-operation of the seal air with corrosion resistance material. b) Each seal air fan and motor shall be sized to provide the following : -

The design flow shall be two(2) times the expected operating flow. The air heating capacity of each seal air heater shall be designed to maintain the proper range of seal air operating temperature at design flow.

-

The steam shall be used as the heating medium for the seal air heater of dampers. If the supplied steam conditions are not suitable for heating, necessary means to attain the required steam pressure and temperature at all heaters shall be provided by the Bidder.

-

For the design flow, the seal air fan shall be capable of maintaining at least an 80 mmH2O differential pressure between each seal air chamber and the flue gas pressure.

G. Emergency quenching system 1) The inlet duct of each GGH shall be equipped with an automatic emergency quenching system to automatically protect the GGH and absorber from gas temperature excursion during an air preheater

6.26-24 KHABAT TPP UNITS 1&2 - VOLUME I

failure or loss of normal liquid flow to the slurry recycle spray system or loss of electric power to the FGD system. 2) The emergency quenching system shall be designed and fabricated to provide quenching water at an adequate flow and pressure to lower the temperature of the flue gas entering the absorber to a level which will not cause physical deterioration or decrease service life of the FGD module. Quenching system shall be designed of materials suitable for the operating conditions experienced in the GGH inlet. Pipes, nozzles and headers shall be of a non-plugging type and duplex SS or equivalent. After emergency quenching, remaining water shall be fully drained to GGH washing water sump via the GGH wash drain line without inflow to the CID fan. The drain line shall be fully submerged in order to prevent the gas leakage. 3) Initiation of the emergency quenching system shall be alarmed. H.

Purge air fan 1) The Bidder shall provide one(1) purge air fan for each absorber, which ensure for man-safe entry, maintenance, etc. The purge air fan shall use non-leakage type valve or duct to prevent the gas leakage. 2) Each absorber shall be equipped with one(1) purge air fan required for man-safe entry, maintenance, clarification, etc. This purge air fan shall be selected in accordance with the requirements for welding in confined spaces, as contained in NFPA51 and NFPA51B and the OSHA requirement or equivalent. The purge fan shall be sized to permit personal entry within one(1) hour after an absorber is removed from service.

I.

Wastewater and drainage transfer system 1) Condensate and washing water from GGH shall be collected in the GGH washing water sump through pipes or trenches. One(1) GGH washing water sump per unit shall be provided. 2) The collected water in the GGH washing water sump shall be transported to the FGD wastewater treatment system via the GGH washing water sump pumps furnished by the Bidder. The Bidder shall provide associated piping, fittings, automatic isolation valve, etc. 6.26-25 KHABAT TPP UNITS 1&2 - VOLUME I

6.26.3.3 Limestone slurry preparation system A.

General description 1) The limestone slurry preparation system will consist of limestone powder storage silos, screw feeders, pumps, tanks, etc. and one(1) train will be in stand-by for the Max. sulfur oil and maintenance of another train. The limestone slurry preparation system shall be capable of 24 hours operation per day and 7 days operation per week. 2) Limestone powder of [325] mesh size will be delivered from tank lorry. Limestone powder in the tank lorry shall be transported by pneumatic conveying system to two(2) limestone powder storage silos through conveying pipe. 3) Screw feeders shall deliver limestone from the limestone powder storage silos to the limestone solution tanks. Filtrate water shall be added to the limestone solution tank. 4) In the limestone solution tank, limestone slurry will be prepared for 25% wt. concentration. Limestone slurry shall be pumped from the limestone slurry storage tanks to the absorbers of two(2) units by the limestone slurry feed pumps. 5) The limestone slurry preparation system shall be equipped to automatically drain and vent all non-free draining slurry piping upon shutoff of flow to the piping leg. 6) The Bidder shall design and provide facilities to prevent large particles or inert from causing equipment damage, nozzle and pipe plugging in limestone slurry preparation system.

6.26-26 KHABAT TPP UNITS 1&2 - VOLUME I

B.

Number of components The Bidder shall provide, but not be limited to, equipment including the following : Items

Common

A. Air Compressor for Pneumatic Conveyor (include Air dryer)

One(1) set

B. Limestone Powder Storage Silo

Two(2) sets Two(2) sets ( One(1) at each silo )

C. Screw Feeder D. Limestone Solution Tank

Two(2) sets

E. Limestone Solution Tank Agitator

Two(2) sets ( One(1) at each tank )

F. Limestone Slurry Transfer Pump

Two(2) sets (One set standby)

G. Limestone Slurry Storage Tank

One(1) set

H. Limestone Slurry Storage Tank Agitator

One(1) set

I. Limestone Slurry Feed Pump

Two(2) sets (One set standby)

J. Limestone Area Sump Pump

Two(2) sets (One set standby)

K. Limestone Area Sump Agitator

C.

One(1) set

Limestone powder storage silo 1) Limestone powder storage silo shall have minimum 30 days storage capacity based on usable storage volume and a apparent density of [980~1,120] kg/m3 2) The related equipment shall be designed considering the following conditions: a) The limestone powder density - Pneumatic conveyor belts capacities

:

[1,120] ㎏/㎥

- Calculations of drive and pneumatic

:

[1,120] ㎏/㎥

:

[1,820] ㎏/㎥

conveyor belts strength - Structural steel

3) Limestone powder storage silo shall be consist of cylindrical and conical section, skirt plate stiffeners, dust collection system and all attachments, as specified herein.

6.26-27 KHABAT TPP UNITS 1&2 - VOLUME I

4) Provision for emergency off loading of the silo to a truck such as flange connection shall be provided by the Bidder. 5) Limestone powder storage silo shall be made of more than 10mm thick carbon steel with external stiffener and supports.

Plates and

structural steel shall be in accordance with ASTM A36 unless otherwise noted. Plate welds shall be full penetration tested and all welds shall be carefully examined to insure that there are no slag inclusions, craters, cracks, or undercuts. Defects shall be removed by chipping or grinding and then rewelding.

Hoppers shall have a

minimum slope of 60°. 6) Limestone Powder Storage Silo cone shall be lined with stainless steel with a surface profile equal to a 2B finish. 7) All curved plates and structural members shall be figured to the proper shape by pressure and not by blows.

Plate edges for both

shop and field welds shall be manufactured to be beveled and accurately cut. 8) One silo cone with plate shall be shop assembled to check fit before delivery.

Silos shall be shipped in the largest knock down parts to

reduce field welding to a minimum. Equipment and material shall be packed to prevent distortion or damage during shipment. 9) Each silo shall be provided with external ladders, ladder cages, landing platforms, rail guards at the periphery of the silo roof, covered manholes, relief valves, vent filters, and any other attachment required for safe operation and maintenance. 10) Limestone powder storage silo shall be consist of high and low level switches and equipment for the level measurements. Silo level shall be indicated and annunciated locally. 11) Limestone powder storage silo shall be supported equally spaced about the circumference on the support beam (ring beam), beneath the skirt and on the straight side of the silo just above the point of coning. 12) Dust collection system a) General - The design of the dust collection system is the Bidder's responsibility. The dust collection system shall be installed in limestone silo and loading hopper. 6.26-28 KHABAT TPP UNITS 1&2 - VOLUME I

- Limestone Service system, provisions shall be fabricated the containment of limestone dust and the prevention of dust emission to the atmosphere. The dust collection system shall be located outdoor or indoor. The Bidder shall design the detail drawing of dust collectors showing the arrangement. - Dust collection system shall be designed to meet the emission limits. b) The Bidder shall design dust collection systems for silos. The dust collector shall be designed on the basis of continuous operation. Air volume and air to cloth ratio shall be designed on continuous operation at 150 percent of initial design capacity. c) The dust collectors shall have the following safety features ; Pressure differential dial gauge to indicate pressure drop through the collector. d) Dust collectors shall be equipped with necessary supports, platforms, handrails, filter bags and all other items as maybe required. e) Bidder shall perform to assemble all dust collector and accessories, and shall test and ship them.

All piping and valves

shall be shop assembled and tested. All instrument and control components shall be properly protected during shipment and transportation to jobsite. Bidder shall make provisions for lifting assembled units into place without damage. f) Dust collectors shall be available to easy maintenance so that any bag can be replaced without removal of other equipment. g) Duct collector shall be fabricated of galvanized steel more than 3.5mm thickness. h) The top of the collector shall have an upper plenum chamber, which houses the compressed air supply to the bag nozzles for reverse flow pulses of high pressure air at regular intervals. The compressed air supply shall be provided with controls, timers, solenoid valves, nozzles and all interconnecting piping. i) Maximum outlet dust loading of all dust collector shall be less than 50mg/S㎥. D.

Screw feeder 6.26-29 KHABAT TPP UNITS 1&2 - VOLUME I

1) Bin vibrator bottom shall be provided to discharge limestone from the silo to the screw feeder. 2) Screw type weighing feeder and rotary feeder shall control the limestone flow from the silo to the solution tank. 3) Screw feeder shall be adjustable to any feed rate over the full range of designed feed rate.

Load cell shall be designed with built-in

overload protection and shall be compensated for temperature. Screw feeder weigh accuracy shall not exceed ±0.5 percent for 0 to 100 percent of feeder capacity. 4) The screw feeder shall be provided with a local emergency stop pushbutton, local test push button with lockout provision, remote operation, and a feeder discharge plug switch and alarm. 5) The screw feeder shall be designed with variable speed drives and equipped with a manually adjustable flow regulating gate. 6) Screw feeder shall be subject to the requirements for the following, but not be limited to : a) Screw feeder shall be horizontal, heavy duty and supported by structural steel beams. b) Material of the feeder shall be STS304 or equivalence. c) The feeder shall be totally enclosed. 7) The feeder shall be designed to deliver the required rate of flow regardless of the type of limestone being handled. E.

Limestone slurry preparation system 1) Limestone slurry preparation system shall be compose of screw feeder, limestone solution tanks with agitator, limestone slurry transfer pumps, limestone slurry storage tank with agitator and limestone slurry feed pumps. 2) The limestone powder shall be conveyed to limestone solution tank with the help of screw feeder for slurry preparation. In the limestone solution tank, limestone slurry will be prepared for 25% wt concentration. 3) Limestone slurry from limestone solution tank shall be transferred to limestone slurry storage tank by limestone slurry transfer pumps.

6.26-30 KHABAT TPP UNITS 1&2 - VOLUME I

4) Two(2) limestone slurry feed pumps shall be provided for two units. One is in operation, the other in stand-by. The impeller tip speed of limestone slurry feed pumps shall be less than 27 m/s. 5) Capacity of each limestone slurry feed pump shall be 115% at BMCR and max. sulfur oil for two(2) units. The Bidder shall furnish the ceramic ball type modulating flow control valves on the individual limestone slurry feed lines to the absorbers. 6) The limestone slurry feed pumps, feed line to the absorbers, and return line to the limestone slurry storage tanks shall be designed in order to maintain min./max. line velocities with in the proper range. Each line shall be equipped with auto-flushing system. F.

Air compressor One (1) number indoor, screw non-lubricating compressor of suitable capacity and discharge pressure complete with accessories shall be provided to convey limestone powder from tank lorry to limestone powder storage silos. Air compressor shall be reciprocating balanced opposed horizontal. Two stage, two cylinder, double acting, non lubricated, heavy duty, water cooled type and shall be designed for continuous operation with high efficiency to satisfy the performance requirements. Satisfactory operation in parallel shall be ensured without any uneven load sharing, undue vibration. noise etc. Air compressor and their drives provided shall be completely interchangeable. Air compressor shall have dry type suction air filter to protect the compressor. The filter inlet area should be large enough to ensure that frequent filter changes are not required. Self priming oil pump for lubrication of frame and running gear shall be provided for air compressor.

E.

Divertor valve Divertor valve shall be used to discharge limestone powder from each pneumatic conveyer line to required silos. These valves shall be remote operated and shall be of proven design and shall be reliable in operation. The divertor valve shall also be used in the solid pneumatic conveyer line upto limestone powder storage silo. The divertor valve should be of 6.26-31 KHABAT TPP UNITS 1&2 - VOLUME I

proven design and shall be reliable in operation. These in line valve should be provided with proven sealing arrangements to prevent any leakage of compressed air. The inline valve shall be of special proven design. Its flap/disc/dome should not come in contact with the limestone powder during conveying. The general particular of limestone powder divertor valve is as under:

F.

Type

Y / In-line type

Method of

Remote operated through

operation

Pneumatic Cylinder/Actuator

Size

By Bidder

End connection

Flanged

Material

M.S. fabricated (with reinforced backing

Body (Y)

plates )/alloy cast iron

Valve Body

Cast Iron

Valve Shaft

STS 304

Piping All fittings such as bends, lateral etc. shall be of alloy cast iron having wear backs of extra heavy thickness. Material hardness specified shall be uniform throughout the metal thickness and surface hardening will not be acceptable. The minimum radius of the bends in powdered limestone lines shall be minimum five times the nominal diameter of the pipe, a spool piece of specified length shall also be provided at the discharge of each bend at beginning of next pipe line segment. The piping design of pneumatic conveying system shall be such that the joints remain leak tight for a very prolonged period of plant life. All joints should be flanged end. At suitable interval (25 to 30 meters) pipe shall be provided with an expansion joints, which shall take care of piping expansion as well as for clearing of line blockage and easy dismantling of pipe. All the flanges should be alignment type, one flange should have a projection and the other should have groove so that when they are tightened together perfectly aligned joints are there. All expansion joints used in pneumatic conveyer line shall be of proven design for such services.

6.26-32 KHABAT TPP UNITS 1&2 - VOLUME I

Provision of vent pipes with isolation plug valve of DN25/DN50 for detection of line blockage in limestone powder transportation line shall be included in the scope. 6.26.3.4 Gypsum dewatering system A.

General description 1) The gypsum dewatering system shall be capable of 24 hours/day and 7 days/week operation. This dewatering system shall be continuously capable of receiving slurry from the units 1&2 absorbers and producing gypsum. The gypsum dewatering system shall consist of two(2) trains. With one(1) trains in operation, the other train will be in stand-by for Max. sulfur oil and maintenance of another train. 2) The gypsum slurry from the units 1&2 gypsum bleed pumps shall be collected in the gypsum dewatering feed tanks. The gypsum slurry in the gypsum dewatering feed tanks shall then be transferred to the primary dewatering system by the gypsum dewatering feed pumps. 3) Primary dewatering system will consist of 1st stage hydrocyclone. The overflow from 1st stage hydrocyclone will flow by gravity to the filtrate tank. 4) Underflow from the 1st stage hydrocyclone will be routed to the secondary dewatering system. The secondary dewatering system shall be vacuum belt filter and shall be located directly below the 1st stage hydrocyclone clusters. 5) After dewatering, the gypsum cake will be transferred to the gypsum handling system. The filtrate from the vacuum belt filter and 1st stage hydrocyclone overflow will be routed to the filtrate tank for use in the FGD system. 6) The filtrate shall be pumped by the filtrate transfer pumps to the units 1&2 absorbers and the limestone slurry preparation system for reuse. Also, the filtrate shall be pumped to the 2nd stage hydrocyclone to control the chloride concentration in FGD system by the 2nd stage hydrocyclone feed pumps. 7) The overflow from the 2nd stage hydrocyclone will be routed to the FGD wastewater blowdown tank, and pumped to the FGD wastewater treatment system by the FGD wastewater blowdown pumps. The underflow from the 2nd stage hydrocyclone will be routed to the filtrate tank. 6.26-33 KHABAT TPP UNITS 1&2 - VOLUME I

8) Cake washing shall take place in the secondary dewatering system to remove chlorides for achieving an acceptable gypsum product. The washing water shall be discharged to the filtrate tank. 9) All equipment in this system shall be designed as indoor type. 10) The Bidder shall design the wastewater blowdown system and control method to maintain the chloride concentration below 1000ppm continuously in absorber. 11) The related equipment shall be designed considering the following conditions: a) Maximum slope of inclined belt conveyor( if any ) : b) Maximum belt speed (Gypsum conveyor)

15 degrees

: 60 m/min

c) The gypsum density - Storage capacities

:

1,089 ㎏/㎥

- Belts capacities

:

1,120 ㎏/㎥

- Calculations of drive, belt strength and structure steel B.

:

1,920 ㎏/㎥

Number of components The Bidder shall provide, but not be limited to, equipment including the following. Item

Total Number (for two(2) units)

A. Gypsum dewatering feed tank with agitator

One(1) set

B. Gypsum dewatering feed pumps & motors

Two(2) sets (One(1) set standby)

C. 1st stage hydrocyclone

Two(2) sets (One(1) set standby)

D. Vacuum belt filters including necessary accessories

Two(2) sets (One(1) set standby)

E. Filtrate tank with agitator

One(1) set

F. Filtrate return pumps & motors

Two(2) sets (One(1) set standby)

G. 2nd stage hydrocyclone feed pumps & motors

Two(2) sets (One(1) set standby)

H. 2nd stage hydrocyclone

One(1) set

I. FGD wastewater blowdown tank with agitator

One(1) set

6.26-34 KHABAT TPP UNITS 1&2 - VOLUME I

J. FGD wastewater blowdown pumps & motors

Two(2) sets (One(1) set standby)

K. Gypsum dewatering area sump pumps & motors

Two(2) sets (One(1) set standby)

L. Gypsum dewatering sump agitator

C.

One(1) set

Hydrocyclones 1) The hydrocyclone cluster shall consist of multiple cyclones. Each hydrocyclone shall be operated at a constant flow rate. 2) The Bidder shall design the underflow from the 1st stage hydrocyclone to be 40 ~ 50% solids and overflow to be less than 5% solids. And the Bidder shall design the overflow from the 2nd stage hydrocyclone to be less than 1.0% solids. 3) The diameter of the underflow orifice shall be designed so that it controls the underflow-to-throughput ratio. The Bidder shall design the hydrocyclone with a variable underflow orifice size to allow flexibility in meeting the range in design operating condition. 4) The inside walls of the hydrocyclone shall be provided with a smooth, abrasion resistant surface liner such as rubber, polyurethane, ceramic or other suitable lining material. This liner shall also be provided on the overflow nozzle. The hydrocyclone housing shall be coated with corrosion and abrasion resistant lining materials. Each hydrocyclone shall be mounted in vertical or inclined orientation. Hydrocyclone orientation shall prevent plugging of the underflow orifice. To facilitate maintenance, the hydrocyclone assembly shall consist of flanged sections or other suitable arrangements. 5) Where considered necessary to avoid siphoning, the hydrocyclone overflow bends shall be provided with vented pipes. 6) Each hydrocyclone cluster shall have 25% redundancy at maximum load operation. 7) 1st stage hydrocyclone cluster distribution manifold shall include piping and manual knife gate valves to allow isolation of individual hydrocyclones. And, 2nd stage hydrocyclone cluster distribution manifold shall include piping and manual knife gate or ball valves to allow isolation of individual hydrocyclones. The valves will be used for isolation only and shall not be used for control. 6.26-35 KHABAT TPP UNITS 1&2 - VOLUME I

8) Hydrocyclone cluster shall be designed to prevent splashing of slurry from the launders. A curtain or similar device is acceptable. 9) Hydrocyclones shall be arranged in a circular configuration and fed from a cylindrical feed chamber, completely lined with rubber. The feed chamber shall contain no internal partitions, baffles and/or obstructions. The feed chamber shall be designed to provide uniform and constant inlet pressure. A full diameter domed removable cover shall be provided for inspection and maintenance. Feed piping shall be from below the feed chamber. 10) A local pressure gauge with diaphragm seal and capillary shall be provided for monitoring the feed chamber pressure. A pressure indicating transmitter shall be provided for input to the FGD control system for alarm and monitoring the feed chamber pressure. D.

Vacuum belt filter 1) The vacuum belt filter shall produce the dewatered gypsum cake, which is contained less than 15% free moisture. The vacuum belt filter shall be of a continuous feed type design utilizing a combination of gravity and vacuum assisted force as the driving force for the process. A detailed description of the construction, design, operation, and maintenance of the belt filter and vacuum pumps shall be submitted. 2) The structural main frame of the belt filter shall be of steel construction with coatings for corrosion resistance and longevity, which are suitable for the intended service. 3) Belt shall be of the endless type. The belt shall be provided for support of the filter cloth. The rubber belt shall be internally reinforced with a minimum of four layers of woven polyester. Belts shall have tensile strength several times greater than the maximum tension to which the belts are subjected. The belt shall be molded with styrene butadiene rubber. 4) A belt washing system shall be provided to clean the belt after the dried cake has been discharged. The belt washing pipe and nozzle shall be housed in stainless steel enclosure and be provided a highpressure water spray to clean the belt of material that blinds the belts. 6.26-36 KHABAT TPP UNITS 1&2 - VOLUME I

A strainer or cleaning system on the belt washing inlet piping shall be provided and the capability to remove, or clean strainers shall be provided without interruption to the water supply. Where multiple stages of cake washing are required, the filter area shall be divided into segments, the washing water from the segments collected and used as washing water for preceding segments. Booster pumps shall be provided to supply washing water to the belt washing water. 5) The filter cloth shall be continuous fabric belt, and continuously washed after gypsum cake is discharged. The cloth shall be guided by a roller mounted, on a fixed support at one end, and on moving support with pneumatic actuator at other end. Continuous cloth tensioning shall be controlled by a movable roller and can also be actuated by additional tension device. The actuator which shifts the position of the cloth alignment shall be provided and controlled by sensors which actuate when necessary. The filter cloth shall be appropriate for the intended service. The filter cloth shall be designed to operate for minimum 4,000 hours of continuous duty without replacement. 6) Movement of the belt and cloth during the filtration cycle shall be proceeded by the tension pulley, traction pulley, and drive assembly which turns the traction pulley itself. The pulley shall be mild steel welded construction with internal reinforcement. Speed variation required by the range of operating conditions is achieved through a frequency variation system that allows motor rotation speed to be varied. 7) A discharge blade shall be provided at the outlet end of belt filter before washing to scrape the gypsum from the belt filter to a collection system. Blade tensioning system parts shall be made of corrosion-resistant material. Double-edged blade shall be provided to reduce frequency of replacement or resurfacing. 8) The Bidder shall design the bearings to be easily accessible for external maintenance and service. Bearings shall be double sealed to prevent contamination. Bearing life shall be designed on the basis of maximum load. 9) Vacuum boxes and drainage piping shall be corrosive resistant materials connected to the vacuum belt filters. The Bidder shall 6.26-37 KHABAT TPP UNITS 1&2 - VOLUME I

design and provide sufficient drainage capacity to allow washing out the vacuum belt filters, as well as to contain waste streams during normal operation. 10) A gypsum cake thickness monitoring system shall measure the gypsum thickness through the ultrasonic level sensor coated corrosion resistant material and increase or decrease the belt speed by the sensing signal. 11) If vacuum assisted force is used for the belt filter, all auxiliary equipment items to support the proper functioning of the filter shall be provided. 12) Vacuum pump shall be provided to furnish the necessary pressure differential across the cake and the filter media. The vacuum pumps shall be liquid ring type. Moisture trap and vacuum receiver shall be provided. Where a liquid ring seal is used, water shall be reused. 13) Vacuum receiver shall be provided to separate air from liquid and may act as a reservoir for the suction line of the self-priming pump. Self-priming pumps are required to carry the water separated in the vacuum receiver to necessary place. 14) Each vacuum pump shall be furnished with inlet filter, silencers, vacuum breakers, valves, fittings, instrumentation and accessories. Each pump shall be driven by its own motor. The vacuum pump and driving motor shall be mounted on a common support frame. 15) The Bidder shall provide the quick coupling connection equipment at the vacuum belt filter area and ground floor. The service water will be utilized to manually clean the floor by flexible hose connected by quick coupling connection. E.

Gypsum dewatering feed and transfer equipment 1) For FGD system of two(2) units, the storage tank shall be designed and furnished as the following. a) One(1) gypsum dewatering feed tank : The tank shall have a minimum available storage capacity of six(6) hours of gypsum slurry produced by FGD system of two(2) units. b) One(1) filtrate tanks : The tank shall have a minimum available storage capacity of four(6) hours of filtrate produced by FGD system of two(2) units. 6.26-38 KHABAT TPP UNITS 1&2 - VOLUME I

c) One(1) FGD waste water blowdown tank : The tank shall have a minimum available storage capacity of two(2) hours of FGD waste water blowdown quantity produced by FGD system of two(2) units. 2) Each gypsum slurry storage tank shall be designed to receive the gypsum slurry products of any absorber for two(2) units. 3) All tanks shall be vertical cylindrical shape and made of carbon steel with corrosion resistant lining, and shall be equipped with agitator for solids suspension. 4) Two(2) transfer pumps for tanks of each service shall be provided, and each pump shall take suction from all tanks of each service. FGD waste water blowdown pumps shall be designed to cover more than maximum FGD wastewater blowdown flow rate produced from the two(2) units. F.

Gypsum dewatering sump pump and agitator Gypsum dewatering sump pumps and agitators shall be provided for gypsum dewatering system area draining.

6.26.3.5 FGD wastewater treatment system A.

FGD wastewater pond and air blower Two(2), 100% capacity air blower shall be provided with all accessories such as air diffuser pipe, sleeve nozzle, sleeve pipe, embedded material, support etc. and the supplied material shall be suitable corrosion resistant material.

B.

pH adjust, reaction and coagulation tank 1) The capacity of pH adjust and reaction tank shall have a 10 minute retention time in order to react with chemical. Coagulation tank shall have a 20 minute retention time. The type of the those tank shall be rectangular, and shall have a agitator. The agitator shall be mounted on the top of those tanks 2) The agitator for pH adjustment, reaction and coagulation tank shall consist of shaft, propeller or paddles, lubricated bearings, constant speed and gear reducer. The tanks shall be made of rubber lined carbon steel and agitator shall be lined with minimum 3mm of FRP or equivalent.

6.26-39 KHABAT TPP UNITS 1&2 - VOLUME I

C.

Chemical injection system(acid, caustic, alum, polymer for coagulation and polymer for dehydrator) 1) The chemical dissolving/injection tank shall be provided with inlet, outlet, overflow, drain, level gauge connection nozzle etc. The dissolved chemical shall be dosed to proper tank automatically by injection pump. 2) The chemical dissolving/storage tank and injection tank shall be constructed by FRP or equal in according with application code. 3) The capacity of dissolving/storage tanks shall be sufficient for three(3) day's usage or minimum 2 ㎥, whichever is bigger. The capacity of injection tanks shall be sufficient for one(1) day usage or minimum 1㎥. 4) The agitator for each chemical dissolving/storage tank and injection tank shall be provided with proper support. 5) All accessories such as platform, ladder, handrail, mono rail etc. shall be provided for chemical dilution, operating and maintenance 6) The chemical tank and pump shall be skid mounted as per each kind of chemical including all accessories such as piping, calibration cylinder, support, electrical and instrumentation etc. 7) Two(2), 100% of each chemical injection pumps shall be provided with the single-acting, internal self relief, positive-displacement diaphragm type including drive motors, reduction gears, stroke and guards 8)

The acid and caustic injection pumps shall be provided with electro stroke controller in order to control of chemical feed rate.

9) Fume scrubber shall provide for acid injection tank. 10) The chemical feeding equipment shall be provided for the equipment using powder chemicals. D.

Clarifier and thickener 1) The clarifier and thickener shall be made of A283 Gr.C or equal in accordance with code and standard and shall be lined FRP with minimum 3 mm thickness including internal facilities. 2) The bottom of clarifier and thickener shall have sufficient slope for solids collection by scraper.

6.26-40 KHABAT TPP UNITS 1&2 - VOLUME I

3) The platform with handrail shall be installed in the top of clarifier and thickener across the center driving device. The driving device shall have a sufficient torque to rotate the rake arm. 4) The thickened sludge from the thickener shall have the 4% solid or more. 5) The Bidder shall design the clarifier as follows; a) Retention time

: 2~5 hours

b) Surface loading

: 15~20 ㎥/㎡.day

c) Efficient depth

: 3~4 m

d) Linear velocity of driver

: 1~2 m/min.

6) The Bidder shall design the thickener as follows;

E.

a) Retention time

:

0.5~2 day

b) Surface loading

:

25~40 kg/㎡.day

c) Efficient depth

:

2.5~4 m

ZLD(Zero Liquid Discharge) system 1) The pre-heater, 1'st and 2'nd heat exchanger, evaporators, concentrate tank and filtrate tank shall be made of super austenitic stainless steel(6% Mo or equal). The tube of pre-heater and 1'st and 2'nd heat exchanger shall be made of titanium or equal. The condenser tube shall be made of 316L stainless steel. 2) The evaporator shall be the forced recirculating type by circulation pump. The capacity of heat exchanger shall be designed up to 110% waste water rate. 3) The others material such as pumps, piping, valves etc. in contact with FGD wastewater shall be made of suitable corrosion resistant material. 4) All pressure vessel shall be designed and fabricated in accordance with the requirement of ASME Section VIII including all accessories for the operating and maintenance.

F.

Chemical injection system for ZLD system 1) The Bidder shall provide the cleaning facility with all accessories for ZLD system. The capacity of CIP tank and pump shall be sufficient for evaporator cleaning. The tank shall be made of 316L stainless steel

6.26-41 KHABAT TPP UNITS 1&2 - VOLUME I

and heater shall be made of 316 stainless steel or equal in according with application code. 2) The Bidder shall provide the anti-foam injection facility with all accessories for ZLD system. The capacity of tank shall be sufficient for three(3) day's usage or minimum 2 ㎥, whichever is bigger. The tank shall be made of FRP and agitator shall be made of 316 stainless steel or equal in according with application code. 3) The Bidder shall provide the anti-scale injection facility with all accessories for ZLD system if required. The capacity of tank shall be sufficient for three(3) day's usage or minimum 2 ㎥, whichever is biggest. The tank shall be made of FRP and agitator shall be made of 316 stainless steel or equal in according with application code. 4) The chemical tank shall be provided with inlet, outlet, overflow, drain, level gauge connection nozzle etc. 5) The agitator for each chemical tank shall be provided with proper support. 6) All accessories such as platform, ladder, handrail, mono rail etc. shall be provided for chemical dilution, operating and maintenance 7) The chemical tank and pump shall be skid mounted as per each kind of chemical including all accessories such as piping, calibration cylinder, support, electrical and instrumentation etc. 8) Two(2), 100% of each chemical injection pumps shall be provided with the single-acting, internal self relief, positive-displacement diaphragm type including drive motors, reduction gears, stroke and guards. G. Dehydrator package 1) One(1), 100% capacity of belt press dehydrator with cake hopper shall be provided in order to make sludge with all accessories as follows; a) One(1) 100% cake hopper with air cylinder b) One(1) 100% sludge mixing tank with agitator c) One(1) 100% recycle tank d) One(1) 100% auto strainer e) Two(2) 100% recycle washing pump

6.26-42 KHABAT TPP UNITS 1&2 - VOLUME I

2) One(1), 100% capacity of centrifuge dehydrator for ZLD system shall be provided in order to make crystallized solids with all accessories. 3) One(1), 100% capacity of vacuum dryer package shall be provided in order to make crystallized solids with all accessories. 6.26.4

Instrumentation & controls

6.26.4.1 General A.

All instrument and control systems shall be designed, supplied and erected to operate reliably and safely under the operating conditions without experiencing undue strain, wear, heating, vibration, corrosion or other operational difficulties.

B.

For critical control measurements, such as FGD inlet pressure, absorber differential pressure, absorber slurry pH, temperature for emergency quenching, etc., the Bidder shall install redundant measuring instruments.

C. PLC based control cubicles and complete field instrumentation for the automatically controls and monitoring shall be provided. D. Minimum two(2) operator interface station(per unit) with dual LCD monitor(21” min.) and printer shall be provided. E. The control system shall be designed to enable the operator to supervise and operate the system by using LCD/keyboard in local and OWS in CCR. F. The control system shall be provided with the data communication interface devices with PCS for the supervisory control and monitoring in the central control room. G. Electro-magnetic type flow meter shall be provided for all slurry flow measurements, and the material of sensing element shall be titanium to prevent corrosion free against slurry. H The Bidder shall provide ultrasonic level transmitters for all slurry tank and sump level applications. Level detectors for absorber reaction tanks shall be the differential pressure type level transmitter with flushing connection. Cage float, displacer and gauge glasses are not acceptable for slurry tank level instrumentation. I.

The Bidder shall provide the SO2 analyzer with the probe might be installed on a duct directly. The sensor probe shall be mounted on the side of the duct, which projects into the gas stream. Particulate, moisture, vibration and other gases presented in the measurement gas shall not interfere with its performance. The analyzers with the control unit shall 6.26-43 KHABAT TPP UNITS 1&2 - VOLUME I

provide sufficient output signals for the designed and specified purposes. The probes should be mounted at suitable positions to give representative readings of flue gas components concentration at the FGD plant inlet and outlet. The equipment supplied shall be suitably protected against corrosion, dust, vibration and water ingress. J. The pH values of various sample points of the process circuits shall be measured with standard glass electrode. The analyzer shall have a full auto cleaning device for cleaning the probe. The cleaning cycle shall be programmable. The flushing and cleaning times shall be freely definable. During the flushing, the sensor shall be retracted for cleaning, and during the measuring, the sensor shall enter the measuring position. The cleaning water used for the pH electrode shall not contact the process during its normal operation and cleaning period. K.

Slurry density meter requirements shall be provided to measure the slurry density for optimum control of the oxidation and gypsum slurry bleeding loops. The density meter should not have an affection from the air in the process fluid.

6.26-44 KHABAT TPP UNITS 1&2 - VOLUME I

6.27

Waste Water Treatment System

6.27.1

System description The waste water originating from the power plant can be classified into three categories such as normal waste water, abnormal waste water and oily waste water. The normal waste water is generated from water treatment system, sampling system, boiler CBD, etc. and abnormal waste water is generated during boiler chemical cleaning, E/P washing, A/H washing or boiler start-up. The oily waste water is generated during rainfall season at the fuel oil storage tank area and transformer area as well as from the turbine building, fuel building, workshop building, etc. The surface water generated by rainfall rates of up to the first 5mm shall be collected and treated by the oily water treatment system. The waste water generated from each source of the power plant shall be treated by the wastewater treatment system with physical and chemical method and treated water shall meet the emission regulation.

6.27.1.1

The normal waste water is transferred to the neutralization pond, and mixed/aerated by the surface aerator. The waste water in pond is neutralized with acid and caustic transferred from water treatment system. The pH shall be monitored and recorded. This water is transferred into the clarifier by the neutralized water transfer pump.

6.27.1.2

The oily waste water is transferred into the API oil separator. Oil is removed in the API oil separator and CPI(Corrugated Plate Separator) and treated water flows into the normal waste water pond.

6.27.1.3

The abnormal waste water is transferred to the abnormal waste water pond. The abnormal waste water is neutralized with acid and caustic. This water will be treated by the same method as normal waste water.

6.27.1.4

Alum and alum aid transferred from water treatment system are fed into the clarifer. The suspended solid, organic and inorganic matter in the waste water, is coagulated.

6.27.1.5

The clear water separated in the clarifier is collected into the clarified water pond and the settled sludge is transferred into thickener by sludge pump.

6.27-1 KHABAT TPP UNITS 1&2 - VOLUME I

6.27.1.6

The residual suspended solid and sludge in clear water is removed by an activated carbon filter.

6.27.1.7

The pH of treated water is controlled in the final pH adjustment pond with caustic or acid. This treated water flows into the final disposal channel or is used as filter's backwash water.

6.27.1.8

The water separated in the thickener flows into the neutralization pond. The sludge thickened in the thickener flows into the thickened sludge storage pond and is transferred to the dehydrator by thickened sludge transfer pump.

6.27.1.9

The sludge dewatered by the dehydrator will be treated and the recycled water is returned to the neutralization pond.

6.27.2

System design criteria

6.27.2.1

General The Bidder shall design the wastewater treatment system to treat the wastewater discharged from each source of the power plant, and determine the wastewater treatment system capacity based on the wastewater discharge rate and concentration per each source. The capacity of waste water treatment system shall be designed capable of treating for 16hours/day. When abnormal waste water is generated, the waste water treatment system shall be operated for 24hours/day.

6.27.2.2

Design parameters A.

General All equipment, piping and accessories shall be designed meeting the following conditions: 1) Pressure a) Equipment

Max. allowable

Activated Carbon Filter b) Piping and accessories 2) Temperature, deg. C B.

Working Pressure

1.5

150 lbs class, STD wall pipe Max. 95

Reinforced concrete ponds and/or tanks shall be as follows: 1) API oil separator a) Number of pond, set

One(1) × 100% 6.27-2 KHABAT TPP UNITS 1&2 - VOLUME I

b) Type

Underground, open, rectangular

c) Material

R/C

d) Interior protection

Modified epoxy coating or eq.

2) Oil separated water pond a) Number of pond, set

One(1) × 100%

b) Capacity

Max. oily wastewater rate per day

c) Type

Underground, open, rectangular

d) Material

R/C

e) Interior protection

Modified epoxy coating or eq.

3) Abnormal waste water pond a) Number of pond, set

One(1) × 100%

b) Capacity

Max. abnormal wastewater rate/day

(including chemical cleaning during shutdown period) c) Type

Underground, open, rectangular

d) Material

R/C

e) Interior protection

Modified epoxy coating or eq.

4) Neutralization pond a) Number of pond, set

One(1) × 100%

b) Capacity

Max. normal wastewater rate per day

(including oily wastewater and filter wash water) c) Type

Underground, open, rectangular

d) Material

R/C

e) Interior protection

Modified epoxy coating or eq.

5) Clarifier a) Number of pond, set

One(1) × 100%

b) Type

Abovegroud, open, cylindrical

c) Material

R/C

d) Interior protection

Modified epoxy coating or eq.

6) Clarified water pond a) Number of pond, set

One(1) × 100%

b) Type

Underground, open, rectangular

c) Material

R/C

d) Interior protection

Modified epoxy coating or eq.

7) Final pH adjustment pond a) Number of pond, set

One(1) × 100%

b) Type

Underground, open, rectangular 6.27-3 KHABAT TPP UNITS 1&2 - VOLUME I

c) Material

R/C

d) Interior protection

Modified epoxy coating or eq.

8) Final disposal pond a) Number of pond, set

One(1) × 100%

b) Type

Underground, open, rectangular

c) Material

R/C

d) Interior protection

Modified epoxy coating or eq.

9) Thickener a) Number of pond, set

One(1) × 100%

b) Type

Abovegroud, open, cylindrical

c) Material

R/C

d) Interior protection

Modified epoxy coating or eq.

10) Thickened sludge storage pond

C.

a) Number of pond, set

One(1) × 100%

b) Type

Underground, open, rectangular

c) Material

R/C

d) Interior protection

Modified epoxy coating or eq.

Normal and abnormal waste water treatment System 1) Surface aerator for abnormal waste water pond a) Number of aerators, sets

Two(2) × 50%

b) Type

Surface aspiration aerator(Floating type)

2) Abnormal waste water pump a) Number of pumps

Two(2) × 100%

b) Type

Horizontal, Centrifugal

c) Material - Case SSC 14 or eq. - Impeller SSC 14 or eq. - Shaft STS 316 or eq. 3) Surface aerator for neutralization pond a) Number of aerators, sets

Two(2) × 50%

b) Type

Surface aspiration aerator(Floating type)

4) Neutralized water transfer pump a) Number of pumps, sets

Two(2) × 100%

b) Type

Horizontal, Centrifugal

c) Material 6.27-4 KHABAT TPP UNITS 1&2 - VOLUME I

- Case SSC 14 or eq. - Impeller SSC 14 or eq. - Shaft STS 316 or eq. 5) Clarifier rake a) Number of collector

One(1) × 100%

b) Type

Center Driving

c) Revolution

0.02 ∼ 0.05 rpm

d) Material

Carbon steel with rubbercoating or eq.

6) Clarified water pump a) Number of pumps

Two(2) × 100%

b) Type

Horizontal, Centrifugal.

c) Material - Case GC 25 or eq. - Impeller SSC 13 or eq. - Shaft SM 45C or eq. 7) Activated carbon filter a) Number of filters

Two(2) × 100%

b) Type

Vertical, Cylindrical

c) Linear velocity

10 ㎥/㎡·hr

d) Material

Carbon steel or eq.

e) Interior protection

Modified epoxy coating or eq.

8) Filter backwash pump a) Number of pumps

Two(2) × 100%

b) Type

Horizontal, Centrifugal

c) Material - Case GC 25 or eq. - Impeller SSC 13 or eq. - Shaft SM 45C or eq. 9) Agitator for Final pH adjustment pond a) Number of agitator

One(1) × 100%

b) Material

Carbon steel with rubber lining or eq.

10) Agitator for thickened sludge storage pond a) Number of agitator

One(1) × 100%

b) Material

Carbon steel with rubber lining or eq.

11) Sludge pump a) Number of pumps

Two(2) × 100% 6.27-5 KHABAT TPP UNITS 1&2 - VOLUME I

b) Type

Horizontal, Centrifugal

c) Material - Case GC 25 or eq. - Impeller SSC 13 or eq. - Shaft SM45C or eq. 12) Thickened sludge transfer pump a) Number of pumps

Two(2) × 100%

b) Type

Horizontal, Centrifugal

c) Material - Case GC 25 or eq. - Impeller SSC 13 or eq. - Shaft SM45C or eq. 13) Dehydrator a) Number

One(1) × 100%

b) Type

Belt Press Filter

c) Cake moisture content

80 %

d) Accessory Sludge mixing tank(or thickener) with agitator, recycle tank, recycle washing pump, auto strainer, etc. 14) Cake hopper a) Number of tank

One(1) × 100%

b) Type

Rectangular

c) Material

Carbon steel or eq.

d) Interior protection

Modified epoxy coating or eq.

e) Accessory

pneumatic actuator

15) Pump room sump pump a) Number of pumps

Two(2) × 100%

b) Type

Vertical, Centrifugal

c) Material - Case GC 25 or eq. - Impeller SSC 13 or eq. - Shaft SM45C or eq. 16) Exhaust Fan a) Number

One(1) × 100%

b) Type

Vertical, Cylindrical

c) Material

FRP or eq. 6.27-6 KHABAT TPP UNITS 1&2 - VOLUME I

D.

Oily waste water treatment system 1) Oil separated water pump a) Number of pumps

Two(2) × 100%

b) Type

Horizontal, Centrifugal

c) Material - Case GC 25 or eq. - Impeller SSC 13 or eq. - Shaft SM45C or eq. 2) CPI a) Number of separator

One(1) × 100%

b) Type

CPI

c) Material - Body A283 Gr.C or eq. - Pack FRP or eq. E.

Chemical injection system 1) C-Polymer injection tank for dehydrator a) Number of tank

One(1) × 100%

b) Type

Vertical, Cylindrical

c) Material

FRP or eq.

d) Accessories

Dissolving basket, Electric heater

2) C-Polymer injection tank agitator for dehydrator a) Number of agitator

One(1) × 100%

b) Material

STS 304 or eq.

3) C-Polymer injection pump for dehydrator a) Number of pumps

Two(2) × 100%

b) Type

Diaphragm, Metering

c) Material Head STS 316 or eq. Diaphragm Teflon or eq. Check Ball STS 316 or eq. 6.27.3 6.27.3.1

Design and construction features General

6.27-7 KHABAT TPP UNITS 1&2 - VOLUME I

A.

The waste water treatment plant shall be designed so as to insure continuous, safe, and economical operation providing the maximum reliability without vibration and noise.

B.

Duplication of components shall be maximized to the greatest possible extent so that similar components shall be interchangeable.

C.

Each item of the waste water treatment plant equipment shall be shop assembled, properly aligned, and if required, matchmarked and assembled for shipment, and the Bidder shall state the equipment disassembled and provide subassembly drawings for shipment.

D.

The equipment and all assembly joints or junctions shall include alignment or centering fits as required to ensure accurate reassembly or alignment of all parts.

E.

Structural steel walkways and stairways shall be provided, and the walkway shall be extended to the full dimensions of the equipment for monitoring and maintenance.

F.

Accessories for concrete pond, namely, walkway, stairway, ladder, sleeve for piping, handrail etc. shall be supplied by the Bidder, and all accessories for the clarifier and thickener also shall be supplied by the Bidder.

G. The design of all items specified shall conform to OSHA design requirements. H.

The waste water treatment system shall include the equipment to measure the flow, temperature, pH, SS and COD of the final treated water.

6.27.3.2

Waste water treatment system A.

Normal and abnormal waste water treatment system The normal waste water which is drained into each sump or pit from the waste water sources (building drain, laboratory, etc.) shall be transferred into the neutralization pond by sump pump and stored there. The abnormal waste water shall be transferred into the abnormal waste water pond by sump pumps. And then, abnormal waste water shall be transferred into the normal waste water pond by pumps. Chemical injection shall be done in the abnormal and normal waste water ponds, clarifier, the final pH adjustment pond and the sludge mixing tank. Cleaned water from the clarifier shall be transferred to the activated

6.27-8 KHABAT TPP UNITS 1&2 - VOLUME I

carbon filter by pumps. Thickened sludge will be treated and dewatered by dehydrator. The cakes shall be collected and removed. 1) Surface aerator An electric motor driven propeller aspirator aerator, which induces the flow of atmospheric air below the surface of the water, shall be provided. Aerator elements shall be suitable for continuous operation and structural frames, anchoring cables and floats shall have maximum corrosion resistance in severe waste water environments. 2) Activated carbon filters After removing SS and COD in the clarifier, the influent shall be filtered by the activated carbon filter. a) Two(2) activated carbon filters shall be provided and shall be of the vertical type, preassembled, piped, wired, and tubed. b) The filters shall contain filtering media and shall be furnished in accordance with AWWA standards for filtering media. If required, support media shall be provided. Each filter shall be equipped with all automatic valves required to operate the unit and bypass pipe. Service, backwash, rinse, and drain valves shall be of the automatic butterfly type. c) Two(2) filter backwash pumps, each of 100% capacity, shall be provided. Two(2) backwash pumps shall be used for backwashing. d) Activated carbon filter shall be fabricated of A 515 Gr.60 or eq. in accordance with ASME code section Ⅷ. The vessel interior shall be lined with a minimum modified 0.3mm of epoxy. The internal upper and lower distributors shall be constructed of STS316L and shall evenly distribute all flows. Internals shall be factory assembled. 3) Sludge handling units a) The sludge from the clarifier shall be collected in the thickener by the sludge pumps. The sludge shall be thickened in the thickener prior to dewatering. By thickened sludge transfer pumps, the sludge shall be supplied to a belt press system. The sludge shall be dewatered by the belt press and removed by KNOC. b) The clarifier and thickener rake shall consist of rake arms driven by a variable speed drive. As a part of the drive unit an overload 6.27-9 KHABAT TPP UNITS 1&2 - VOLUME I

protecting

device

shall

be

furnished.

Take-up

motor

and

accessories shall be provided on the drive mechanism. c) The rake arm will remove the settled sludge to a central discharge point. The blade shall be bolted to the bottom chord of truss structure of rake arm. The rake and rake support parts submerged below the liquid level shall be STS 316 or eq. for protection against abrasion and corrosion. 4) Chemical injection system a) Chemicals (acid, caustic, alum, alum aid) will be supplied from water treatment system. b) C-polymer injection tank shall be provided with a hinged cover, structural steel supports, overflow, drain, fill connections, and walkways, stairways and handrails including all accessories for the operation, inspection and maintenance. The capacity of the tank shall be sufficient for one day's usage. The chemical tank shall be provided with agitator. c) Chemical injection tank shall be constructed of FRP or equivalent. d) Two(2) flooded suction positive displacement, diaphragm type pumps shall be provided for each chemical with accumulators for dehydrator. On-off valve for the protection of siphon shall be installed at the chemical injection pump discharge. e) The injection tank and pump shall be skid mounted including piping, support, electrical and instrumentation etc.. B.

Oily waste water treatment system Oil contaminated water is led to each sump from the plant area. Oily water shall be transferred to the API oil separator by sump pumps and pretreated in the API oil separator. The pretreated oily waste water is led to the oil separated water pond. The pretreated oily waste water is transferred to the CPI and treated. The treated water is led to the neutralization pond through piping.

6.27.3.3

Pipings & valves A.

The Bidder shall supply all piping, valves, fittings, supports and appurtenances necessary to make a completely self supporting system.

6.27-10 KHABAT TPP UNITS 1&2 - VOLUME I

B.

The Bidder shall provide piping from the discharge of chemical unloading and transfer pumps to the waste water treatment system.

C.

All piping design shall be in accordance with ASME B31.1 power piping. The Bidder shall fabricate piping spools ready for installation. Particularly lined pipes shall be the same.

D.

Piping connections of DN50 and smaller shall be the socket weld type and piping connections of DN65 and larger shall be the butt-weld type. Flanges shall be provided where required for connections to lined pipes, equipment and valves.

E.

The Bidder shall furnish all chemical feed piping. All piping in contact with strong or dilute acid shall be made of lined pipes or equivalent. The lining shall be sealed with an applicator approved by the KNOC. No welding shall be done on the lined pipe. All piping in contact with caustic, alum and alum aid shall be low carbon austenitic stainless steel(A 312 TP 316L,Welded) or equivalent.

F.

The piping between the discharge of the neutralization pond, abnormal waste water pond and the inlet of the clarifier shall be polypropylene lined carbon steel.

G. All drain valve connections shall be located at least 200mm above the floor. H.

The Bidder is responsible for the sizing of piping within the terminal points of the supply scope.

I.

All flanges of piping including terminal points shall be in accordance with ANSI B 16.5 standard.

J.

The valve in contact with chemical waste water shall be the diaphragm type or equivalent.

K.

Branch lines and valves including all accessories for the discharge shall be installed at all pipings.

6.27.3.4

Pumps and accessories A.

Pumps shall be designed to receive and support all forces and moments associated with start-up, normal operation, and temperature changes. Duplicate pumps for the same service shall be designed to operate in parallel, at reduced flows, without undue noise and vibration and danger of shaft breakage.

6.27-11 KHABAT TPP UNITS 1&2 - VOLUME I

B.

Pump casings, motor supports, and counter flanges and bases shall be capable of withstanding the forces resulting from all conditions of steady and transient operating conditions during startup or shutdown of pumps.

C.

The Bidder shall draw up and provide the list of materials which he recommends and guarantees under the specified conditions of operation, and shall completely describe the proposed material by specification and analysis.

D.

Impellers shall be the enclosed type, keyed to the shaft for pump rotating assemblies which are dynamically balanced.

E.

Sealing shall be standard packing gland. The glands shall be constructed to permit their inspection and packing removal without disturbing other parts of the pump. Adequate provision shall be made to collect gland leakage and drain it from the pump. The Bidder may submit, as an alternative to standard packing glands, a mechanical seal which he recommends for the service. Seal water shall be applied to all packed pumps.

F.

Pump shafts shall be provided with replaceable sleeves where they pass through the stuffing boxes. The sleeves shall be hardened and sealed adequately to prevent air or liquid from leaking between shaft and sleeve. Sleeves shall be rigidly positioned without set screws.

G. Pumps shall be provided with replaceable wearing rings. H.

All pump and motor bearings shall be heavy duty, oil or grease lubricated. Oil lubricated bearings shall be suitable for lubrication with turbine oil. Constant level oilers shall be provided for oil lubricated bearings.

I.

Flanges shall be faced and drilled according to ANSI 16.5 standards.

J.

Pump shafts shall be accurately machined and ground and of adequate size and strength to maintain all clearances and withstand safely all stresses resulting from weight to be supported.

K.

Pumps shall be horizontal, radially split, frame mounted, single suction type, complete with drive motor, base plate, and all required accessories for complete operable units.

L.

Baseplates shall be either fabricated steel or cast iron, with drip lips and 20mm minimum drain connections. The baseplates shall extend completely under both pumps and drivers.

M. Coupling shall be spacer type (stainless steel double disk flexible type), where required to allow dismantling of the pumps without disturbing the 6.27-12 KHABAT TPP UNITS 1&2 - VOLUME I

motors or the pump pedestals. Metal coupling guards shall be provided to cover coupling exposed keyways. N.

Chemical injection pumps shall be the metering, positive displacement diaphragm type and shall be furnished complete with drive motors, reduction gears, stroke control devices, Y-type strainer and guards, all mounted on a common baseplate.

O. Pump flowrate and head shall be determined by the Bidder and shall be of adequate capacity to allow the system to perform as specified. P.

Strainers(Y-Type) for the pumps shall be installed on the open concrete ponds except settled and thickened sludge storage ponds.

6.27.3.5

Instrumentation and controls A.

All automatic and manual control action shall be possible through local LCD monitor and PCS's LCD monitor in central control room. And all engineering work shall be possible through the LCD monitor.

B.

Instrumentation and controls shall be designed in accordance with the section 8 of this technical specification.

C.

PLC based control system and complete field instrumentation for the automatically controls and monitoring shall be provided.

D.

Operator interface station with two(2) dual type LCD monitor and printer shall be provided.

E.

The control system shall be designed to enable the operator to supervise and operate the system by using LCD/keyboard in local and OWS of PCS in CCR.

F.

The control system shall be provided with the data communication interface devices with PCS for the supervisory control and monitoring in the central control room.

G. The flowmeter type shall be magnetic on the inlet of each waste water pond, weir or flume with ultrasonic level detector on the outlet of the disposal channel. H.

The Bidder shall furnish all necessary sensing elements, transmitters, and related devices to provide specified annunciations.

I.

Analyzers 1) pH measurement 2) SS measurement 3) COD measurement

6.27-13 KHABAT TPP UNITS 1&2 - VOLUME I

6.27.3.6

Structural and miscellaneous steel All structural steel material, plate and miscellaneous structural fittings shall comply with the ASTM A36, A7, A242.

6.27-14 KHABAT TPP UNITS 1&2 - VOLUME I

6.28

Sewage Water Treatment System

6.28.1

System description The sewage water treatment system shall be designed according to requirement stated on this specification. The sewage water treatment facility shall be designed to meet the quality of the final effluent before being discharged to the river.

6.28.2

System design criteria

6.28.2.1

Design conditions A.

The design capacity of sewage water treatment system for two uints shall be as following, but it is changable for the detail design by Bidder.

B.

The Bidder shall guarantee that the equipment, materials and all accessories furnished shall be entirely suitable for all operation condition required in this specification. The sewage water treatment systems shall conform to all applicable codes, satisfactorily meet all conditions of performance and design requirements specified herein, and be capable of continuous operation at any condition without detrimental effects.

C.

The Bidder shall also guarantee that all equipment furnished is free from defects in design, workmanship and material, and is of sufficient size and capacity and of proper materials to satisfactorily fulfill the specified operating conditions in this specification.

6.28.2.2

Design parameters A.

Sewage water treatment system 1) Number :

100%×1

2) Capacity (Changable for detail design) :

min. 60㎥/day

3) Type :

Biological method

4) Location :

Underground

5) Material :

by Bidder

6) Assessories : Chlorination equipment B.

Final disposal pump 1) Number of unit :

100%×2

2) Capacity The capacity shall be able to discharge sufficiently the treated sewage water. 3) Type :

Submersible 6.28-1 KHABAT TPP UNITS 1&2 - VOLUME I

4) Material - Casing : GC250 or eq. - Impeller : SSC13 or eq. - Shaft : STS410 or eq. C.

Instrumentation and automatic control equipment 1) Pressure guage a) Type :

Diaphragm Seal Type

b) Size :

Min. 100 mm Round Daial

c) Accuracy :

± 1.0% of F.S

d) Range :

0~1.5 times of Max. operation pressure

2) Level switch

D.

a) Type :

Quick Float Type or Electrode Type

b) Rating :

10A 120V AC, 0.5A 125V DC

c) Enclosure :

NEMA 4X

The control panel for sewage water treatment system and final disposal pump including channel base, anchor bolts, nuts and etc.

E. 6.28.3

Others

Design and construction features

6.28.3.1

The sewage water treatment system A.

The sewage water into treatment system shall at least be treated by screening and primary sedimentation, biological clarification in activated sludge basins, sedimentation for removing the activated sludge and as a last stage an effluent disinfection for discharging into the river. The sewage sludge should be periodically emptied and cleaned by an external company.

B.

The sewage water treatment system(including type, size, capacity and material) shall be adequately manufactured and furnished according to regulation related with sewage water treatment.

C.

The sewage water treatment system shall be stably operated under various quantities of sewage water flow or shall be installed with the type of system which uniformly maintain the inflow quantities of sewage water produced from various condition.

6.28.3.2

Piping system The piping system shall be designed and installed to be successfully

6.28-2 KHABAT TPP UNITS 1&2 - VOLUME I

performed the hydrostatic test, pneumatic test and air tightness test without any defect. 6.28.3.3

Instrumentation and control system A.

The Bidder shall provide the instrument and control equipment which certificated and approved in accordance with the applicable cords and test regulations.

B.

Local control panel 1) The local control panel shall be supplied with one(1) feeder from motor control panel and shall be automatically operated according to the water level. The sewage water treatment system shall be capable of manual control by local control panel. 2) Space heater shall be provided. Thermostatically controlled space heaters equipped with dehumidifier shall be provided so that the temperature inside each panel shall be maintained above the dew point temperature for the conditions of operation and protect the instrument from freezing during the winter. 3) The local control panel shall be capable of the following; a) Automatic/manual start-up and stop of sewage water treatment system and pumps b) Shift operation of operation pump and standby pump

6.28.3.4

Construction features A.

The design of welding and pipework shall meet with requirements stated in ASTM B 31.1 All flange shall meet with requirements stated in ANSI B 16.5.

B.

All equipment shall be shipped and delivered after complete assembling, except in case of conflict with the limitation of regulation related with shipping and delivery.

C.

The Bidder shall submit the welding procedure when the welding is required for manufacture and assembling of equipment. The Bidder shall provide satisfactory electrode in accordance with applicable codes and standards.

D.

All pressure parts shall be performed the hydrostatic test in accordance with applicable code and standards and pumps shall be performed the performance test in accordance with applicable code and standards.

6.28-3 KHABAT TPP UNITS 1&2 - VOLUME I

6.29

Sump Pump

6.29.1

System description The sump pump with completed accessories will be used to transfer waste water & sanitary water through the related piping system to the waste water & sewage water treatment system or ditch.

6.29.2

System design criteria

6.29.2.1 Design conditions A.

General The sump pump system shall be designed throughout so as to insure continuous, safe and economical operation providing the maximum of reliability and without undue noise, vibration, instability, unbalance, scaling, plugging, overheating, abrasion and corrosion.

B.

Design conditions System design shall be based on following conditions 1) Sewage water O Quality Assumed BOD5(mg/l)

min. 300

Assumed Suspended Solids(mg/l)

min. 200

Assumed Nitrogen(mg/l)

min. 60

2) Oily waste water O Quality Assumed pH

6–9

Assumed Oil and Grease(mg/l)

50 - 200

3) Boiler blowndown water O Quality Assumed pH

9 - 11

Assumed Temperature(℃)

Max. 100

4) Chemical waste water O Quality Assumed pH

2 - 11

6.29-1 KHABAT TPP UNITS 1&2 - VOLUME I

C.

Design parameters As the type of waste water, the material and pump type shall be as follows : Items

Sewage

Chemical Water

Oily Water

Storm Water

Pump Type

Submersible

Vertical

Submersible or Vertical

Submersible

Casing & Strainer

GC250 or eq.

SSC16 or eq.

GC250 or eq.

GC250 or eq.

Impeller

SSC13 or eq.

SSC16 or eq.

SSC13 or eq.

SSC13 or eq.

Shaft and sleeves

STS304 or eq.

STS316L or eq.

STS304 or eq.

STS304 or eq.

Sump cover plate and base plate

A36 or eq

A36 or eq

A36 or eq

A36 or eq

The sump pumps to transfer the waste water & sewage water are as follows. But the additional sump pump required transferring the waste water generated besides below mentioned area and the pump capacity, head and sump size shall be determined by the Bidder based on the design conditions in this specification. 1) Sewage water sump pumps Type

Number

Workshop BLDG. Sump Pump

Submersible

100% x 2

Administration BLDG. Sump Pump

Submersible

100% x 2

Security Gate House Sump Pump

Submersible

100% x 2

Submersible

100% x 2

Submersible

100% x 2

Submersible

100% x 2

FGD waste water treatment BLDG. Sump Pump

Submersible

100% x 2

Unloading entrance gate Sump Pump

Submersible

100% x 2

Name

FGD Control BLDG. Sump Pump Operation & Maintenance Management BLDG. Sump Pump Water & Waste Water Treatment BLDG. Sump Pump

6.29-2 KHABAT TPP UNITS 1&2 - VOLUME I

Chiller BLDG. Sump Pump

Submersible

100% x 2

No.1, 2, 3 Guard Tower Sump Pump

Submersible

100% x 2 (per Sump)

Type

Number

Unit 1 Boiler Area Sump Pump

Vertical

100% x 2

Unit 2 Boiler Area Sump Pump

Vertical

100% x 2

Chemical Storage Area Sump Pump

Vertical

100% x 2

Type

Number

Unit 1 TBN BLDG. Area Sump Pump

Submersible

100% x 2

Unit 2 TBN BLDG. Area Sump Pump

Submersible

100% x 2

Unit 1 Transformer Area Sump Pump

Vertical

100% x 2

Unit 2 transformer Area Sump Pump Fuel Oil Storage Tank Area Sump Pump Fuel & Light Oil Pump House Sump Pump Fuel Oil Emergency Tank Sump pump

Vertical

100% x 2

Vertical

100% x 2

Vertical

100% x 2

Vertical

100% x 2

Light Oil Storage Tank Area Sump Pump

Vertical

100% x 2

Workshop BLDG. Sump Pump

Vertical

100% x 2

Emergency Diesel BLDG. Sump Pump

Vertical

100% x 2

AUX. Boiler Area Sump Pump

Vertical

100% x 2

Type

Number

Submersible

100% x 2

2) Chemical water sump pump Name

3) Oily water sump pump Name

4) Other sump pump Name Raw Water Intake Canal Area Sump Pump

6.29-3 KHABAT TPP UNITS 1&2 - VOLUME I

6.29.3

Design and construction features

6.29.3.1

General A.

The Bidder shall provide sumps and sump pumps wherever wastewater will be generated in the power plant.

B.

Pumps will be of advanced and well-proven design suitable for handling abrasive and corrosive waste water & sewage water. All components of the waste water transfer pumps which come into contact with the waste water & sewage water will be made of corrosive and abrasive resistant material with excellent durability for the intended service.

C.

Each sump pump shall be a vertical/submersible, centrifugal, electric motor-driven, non-clog unit of the wet-pit type with suction screen.

D.

Each pump and its components shall be constructed of the best materials available for the most severe service conditions under which each pump will be required to operate. All materials of construction shall be identified with ASTM or ASME specification numbers.

E.

The Bidder shall design the maximum noise level of pump and motor not to exceed 85dB(A) of overall sound pressure level at a distance of one(1) meter from each equipment.

F.

The pump shall be capable of operating over the whole operation range with efficiencies as high as possible, and be free of harmful effects from vibration, cavitation or recirculation.

G. The pumps shall be installed to be capable of service without any intervention while one(1) operate and one(1) stand-by or two(2) operate at the same time. H.

The pump shall be able to be both automatically operated by level switch and manually operated by local control panel. Level switch shall be provided with adequate material and type about the fluid.

I.

The Bidder shall guarantee the following performance of pumps and motor drives 1) The performance guarantee of pump 2) Rated Capacity 3) Total Differential Head 4) Pump Speed 5) NPSH required or minimum submergence 6) Efficiency at Rated Capacity 7) B.H.P at rated capacity 6.29-4 KHABAT TPP UNITS 1&2 - VOLUME I

8) Acoustic Requirement(dB(A)) 9) Vibration(Shaft, Housing) 10) The performance guarantee of motor drive 11) Rated Output 12) Full Load Speed 13) Efficiency at 100% Rated Load 14) Power Factor at 100% Rated Load 15) Temperature Rise 16) Maximum Starting Current at Rated Voltage 17) Full Load Torque at 100% Rated Voltage J.

Pump shall not be damaged by reverse flow due to check valve failure in discharge line.

K.

Pumps shall be of a proven heavy duty, liberal design to assure equipment as maintenance free as possible, and long life reliability.

L.

Pumps designed for same service and operating conditions shall be identical in all respects so that pump parts are interchangeable, in so far as general arrangement permits.

M. To avoid excessive vibration, the Bidder shall verify that the nearest critical speed of each combined pump unit specified herein (each motor and pump) is at least 25% below or above the motor operating speed. The vibration levels as measured on the thrust bearing housing or the top motor bearing (if the thrust bearing is located in the motor) shall not exceed the level specified by the Hydraulic Institute at design speed and flow conditions. The same vibration level also shall not be exceeded when pumps are coming up to speed or are operating at less than full flow. N.

Pump discharge column shall be of such design so as to permit removal of the entire pump unit for maintenance and repair without dismantling any portion of the discharge column.

O. Bolts, nuts, studs and screws shall have threads conforming to ANSI standards, coarse thread, or equivalent, and shall be finished in accordance with the latest approved practice for the duties involved. P.

The Bidder shall provide the discharge pressure gauges with root valve.

6.29-5 KHABAT TPP UNITS 1&2 - VOLUME I

6.29.3.2

Shaft and impeller A.

Impellers shall be vortex, non-plug or semiopen, depending on the Bidder's standard. Impellers shall be statically and hydraulically balanced radially to ensure smooth operation under all conditions.

B.

Each impeller shall be securely keyed and locked to the shaft.

C.

Shafts shall be designed to withstand all stresses, including those from rotor weight, hydraulic loads and thrust, and full voltage starting. Pump shaft shall be of suitable steel type and of ample diameter to prevent any whipping action or other disturbance under any operating conditions.

6.29.3.3

Bearing A.

Pump bearing capacity shall be over than 130 percent of the maximum load imposed when pumping the maximum amount of solids. Bearings shall have an average life rating over than 5 years continuous operation. All pump bearings shall be equipped with either a forced grease feed system or a sight feed lubrication system. Grease fittings or oil cups shall be located above the pump baseplate or above sump cover plate. Intermediate guide bearings shall be provided

B.

Rotating equipment in access controlled areas shall be sealed for life bearings or grease lubricated bearings, size permitting, or where oil lubrication is used slinger rings and oil collection devices shall be used to collect and contain leakage rather than let it drip or spill to base plates or floors.

C.

The intermediate and case bearings shall be the sleeve, dry lube type for all pumps.

6.29.3.4

Couplings Couplings for vertical wet-pit sump pumps shall be solid flanged steel flexible couplings, statically balanced, and designed for the pump load.

6.29.3.5

Casing A.

Castings shall be uniform so that the deviation of thickness shall be less than 10 percent from Bidder's standard. Each casting shall be sound and free from cracks, pits, or nodules.

B.

Waterways shall be finished of good commercial quality.

C.

Bolt holes on all flanges, including nozzles, case-to-cover joints, etc., shall be commercial standard. Bolt holes shall straddle centerlines. 6.29-6 KHABAT TPP UNITS 1&2 - VOLUME I

6.29.3.6

Cover plate A.

The sump cover plate shall be designed for non-gaslight installation. Bolt holes shall be drilled in the pump manufacturer's standard locations.

B.

Each cover plate shall adequately support the equipment, under static and dynamic conditions, without sagging more than 0.1 inch and shall be not less than 1/2 inch thick. The Bidder shall provide any structural steel stiffeners for the sump cover that may be required.

C.

Provisions shall be made in the design of the sump cover plate so that each individual pump can be removed as a unit without disturbing the operation of the other pump.

D.

The pump baseplates shall be not less than 1/2 inch thick. The baseplate shall be fitted with above the floor flanged discharge connection and bolt holes drilled to match those in the sump cover plate.

E.

The size of manhole shall be big enough for access inside sump during maintenance. Final arrangement of the pumps and accessories will be indicated on Bidder's general arrangement drawings.

6.29.3.7

Submersible pump A.

The Bidder shall provide guide support, guide pipe, guide holder chain for automatic installation & removal and pump lifting device, which include chain, power cable, cable holder, guide support and automatic connection discharge pipe for pump lift to out of sump or pond, to maintain easily.

B.

Shaft seal for sewage water sump pump shall be exclusive mechanical seal for sewage water only and shall protect from entrance of water and solid into the motor.

C.

The material of submersible equipment including casing, shaft, bolts and nuts, etc. shall have abrasion and corrosion resistance quality.

6.29.3.8

Drives A.

The Bidder shall provide the pumps with motors in accordance with Section 7.

B.

Motor rated horsepower shall not be exceeded at the specified pump rating by the impellers selected for the service. The service factor may be used infrequently, but the horsepower shall not be exceeded by any operating condition that can be developed by the installed impellers.

6.29-7 KHABAT TPP UNITS 1&2 - VOLUME I

6.29.3.9

Piping & valves The Bidder shall supply all piping, valves, fittings, supports and appurtenances necessary to make a completely self supporting system except where specifically excluded. All piping systems shall include flanged connections, in accordance with ASME/ANSI B16.5, to permit convenient disassembly of sections and removal of installed components for maintenance and replacement. Valves shall be designed for the maximum pressure, temperature, and chemical conditions to be utilized. The pipe materials will be the following: 1) Sewage(above ground), oily water(above ground), Storm water(above ground) : Carbon steel pipe 2) Sewage(underground),

oily

water(underground),

Storm

water

(underground) : HDPE pipe 3) Chemical water : Carbon steel pipe with rubber lined 4) Boiler Blowdown water : Stainless Steel pipe The facing of connection flange for the discharge connection will be the following: 1) For Steel Pipe : RF Type 2) For HDPE Pipe : FF Type 6.29.3.10 Instrumentation and controls A.

The Bidder shall provide completely all local instruments and accessories required for the operation of the sump pump.

B.

The Bidder shall supplied local control panel for the sump pump control.

C.

Instrumentation and controls shall be designed in accordance with the section 8 of this technical specification.

D.

Local control station shall be provided with voltage free contact for Plant Control System(PCS) as follows 1) Pump fault (common for main pump & standby pump) 2) Sump level extra high

6.29-8 KHABAT TPP UNITS 1&2 - VOLUME I

6.30

Piping

6.30.1

General 1)

Scope of work The design, manufacture, installation and testing of piping systems shall be in accordance with approved ASME B31.1 code During the design , the Bidder shall supply to the KNOC schedules of the piping systems provided under this Contract. The schedules shall state, for each piping system, the design code, pressures and temperatures, the piping materials and contents, the valve type and materials, corrosion allowances, piping supports and insulation proposals and any other data relevant to the mechanical design of the piping system or part thereof. Unless otherwise specified or approved, all pipes shall be of seamless drawn carbon or alloy steel. In any one system or piping service all piping and fittings shall be of the same material or similar analysis. All piping shall be routed to provide a neat and economical layout so that full access is provided for the operation and maintenance of equipment and that removal or replacement of equipment can be achieved with the minimum dismantling of piping. The number of joints shall be kept to a minimum necessary. Tees and bends shall be to standard dimensions. Bends shall be of the pulled type or forged. Hot bending with packing may be used for larger sizes according to facilities available, but hot bends in alloy or stainless steels shall be subject to approval of the KNOC. No crimping or flattening of the bend will be accepted. Where employed for low pressure piping, gusset or miter bends shall be designed to the relevant piping code. Where piping is subject to mechanical cleaning (pigging) the bend radius shall be not less than 5 pipe diameters. Piping work shall include piping design, procurement, manufacturing and delivery of materials, installation, cathodic protection if required, test, 6.30-1 KHABAT TPP UNITS 1&2 - VOLUME I

cleaning, painting, commissioning and their drawings or reports. Piping includes fitting, flange, valve, trap, strainer, flexible hose or expansion joint, support, thermal insulation and lagging and accessories. Major pipe’s size and wall thickness calculation, main steam, reheat steam, HP & LP bypass steam and boiler feed water pipe’s stress calculation and analysis shall be submitted. Design drawings especially piping arrangement shall be approved by KNOC. Isometric and support drawings shall be submitted for information. Vendor drawings especially piping specialty, that is, steam trap, expansion and flexible joint, strainer, flow nozzle, desuperheater drawings, etc. shall be submitted for information by Bidder. Drawings of the high pressure pipe work which show amongst others the magnitude and direction of the thrust on the turbine steam chest, boiler superheater outlet header, economizer inlet header, feed pumps, feed heaters, brine heaters and reducing stations, both in the hot and cold condition, shall be submitted to the KNOC for information. The responsibility, however, lies with the Bidder. Provision shall be made for steam blowing and chemical cleaning. All such branches serving the purging and cleaning process shall have flanged connections type. Blank flanges shall also be provided. The Bidder shall supply the isometric drawings for information including supports, branches and expansion joints. The isometric drawings will be accompanied by a complete nomenclature. The Bidder shall complete sets of all isometric drawings in an agreed format for each line or system, properly classified and will keep it continuously updated with the latest revisions of the isometrics. Pipe welding, cleaning and hydrostatic or pneumatic test procedure shall be submitted prior to execution of their work and inspection or test result 6.30-2 KHABAT TPP UNITS 1&2 - VOLUME I

report shall be submitted. During the contract, the Bidder shall supply to the KNOC schedules of the pipe work. The schedules shall state, for each pipe system or parts of a pipe system, the design and operating pressures and temperatures, the fluid transmitted, the piping and valve materials, the types of valves, any corrosion allowances, the piping design code, insulation proposals, pipe supports and any other data relevant to the mechanical design of the pipe work or part of a pipe work. The Bidder shall submit detailed comprehensive pipe and valve specifications for approval. After contract, the bidder should submit pipe line designation list based on P&ID This specification shall state in minimum design and operating pressure and temperature, the fluid transmitted, the piping and valve materials, types of valves, any corrosion allowances, piping design code, insulation proposals and piping supports. 2) Piping material Systems operating in the area of materials creep rupture strength shall be designed for a system live time of 200,000 hours. In this and other parts of this Specification the term high pressure refers to steam piping where the design pressure exceeds 17 bars and to other systems where these values exceed 24 bars. Piping operating temperature exceeded 400 ºC shall not use of carbon steel material. The use of cast iron pipes will not be allowed without KNOC’s approval. The steels shall be suitable to withstand the temperature 6.30-3 KHABAT TPP UNITS 1&2 - VOLUME I

and pressure conditions involved in the operation of the plant under all circumstances. In any one system or pipe service all pipe work and fittings shall be of the same material or similar analysis unless specified or agreed by the KNOC. No crimping or visible flattening at the bend will be accepted. The following standard pipe sizes shall be used for the different systems: Diameter in DN 25, 40, 50, 80, 100, 150, 200, 250, 300, 350, 400 etc. Diameter larger than DN 600 pipe size may be fit in AWWA standard. Pipes with a diameter size smaller than DN 25 may be used only for control air, control oil, chemical dosing, sealing water, instrument connections, cooling water connections to equipment, sampling pipes and input pipes. Any plastic piping required to be used in outdoor applications shall be fully suitable to withstand the effects of sunlight over the life of the plant and shall be subject to the KNOC’s approval. Plastic pipes above 150 mm nominal diameter shall not be site run and design arrangements shall be submitted to the KNOC for approval. Where plastic pipe work is used it shall be arranged to minimize the risk of accidental damage during plant operation or maintenance. Flanges shall comply with the requirements of the code to which the piping is designed. Flanges having ratings less than ASME class 150 or AWWA class B will not be permitted except where agreed with the KNOC. Bolts, studs, nuts and washers for flanges are shall be galvanized for carbon steel and plastic flanges, and stainless steel for stainless steel 6.30-4 KHABAT TPP UNITS 1&2 - VOLUME I

flanges. Jointing of thermoplastic piping shall be carried out in strict accordance with the manufacturer’s recommendation. Demineralized water, potable water, instrument air piping shall be stainless steel. The Bidder shall complete the detail piping material specification sheets by piping classes according to the following applicable service of piping material data sheets and these shall be approved by the KNOC. Corrosion allowances as noted below shall be used in design calculations of all pressure components and this shall be in addition to any allowances for manufacturing tolerances and tube thinning during manufacture: All major pressure part components such as the steam drum, Headers, and down comers shall include 2.5 mm All Water wall, roof and hanger tubes shall include 1 mm or 10% of minimum calculation thickness which ever is the larger. In order to prevent the possible conversion of the carbide phase of carbon steel tube and pipe materials to graphite they shall not be employed when metal temperatures exceed 425°C. Similarly to avoid the use of extrapolated stress data found in some design codes the following maximum design temperatures shall be used in relation to the low alloy materials described:




1-1½% Cr steels, maximum allowable design temperature 480°C




2-2¼

Cr steels, maximum allowable design temperature

520°C


9-12% Cr steels, maximum allowable design temperature 580°C

6.30-5 KHABAT TPP UNITS 1&2 - VOLUME I

Applicable service of piping material data sheets Applicable Service

Pipe Material

Service Air Raw Water (above ground) Closed Cooling Water

ASTM A53B

Waste Water (A/G, non-chemical) Service Water (A/G) Misc. Vents & Drains BFP Suction COP Suction LP Heater Extraction Steam Aux. Steam Light Oil Pump Suction

ASTM A106B

COP Discharge Deae. Extraction Steam Light Oil Pump Discharge Cold Reheat Steam Chilled Water

ASTM A53B with Galvanized-Flanged

Main BFP Discharge

ASTM A106C

Boiler Feedwater FWH#5,6,7 Ext. Steam

ASTM A335P11

LP Bypass (PCV Downstream)

ASTM A335P11

LP Bypass (PCV Upstream)

ASTM A335P92 or Equivalent

Fuel Oil

API 5L - Gr B

Main Steam

ASME/ASTM A335P92 or Equivalent

Hot Reheat Steam

6.30-6 KHABAT TPP UNITS 1&2 - VOLUME I

Demi. Water Potable Water Condensate Transfer

ASTM A312TP304

Instrument Air Sanitary Water Chemical Feed Hotwell Sampling Pump Suc. LP Sampling

ASTM A312TP304L

Chemical Feed Condensate Sampling Condensate Sampling Hot Reheat Steam Sampling Main Steam Sampling

ASTM A312TP316

Feedwater Sampling

Circulation Water (A/G - DN65& Larger)

ASTM A53B with Rubber Lined

Circulation Water (U/G)

GRP

Chemical Waste Water Fire Fighting (A/G)

ASTM A53B with Galvanized

Non Chemical Waste Water – Under Ground Floor & Equip. Drain – U/G

HDPE or GRP

Potable Water (U/G) Fight Fighting (U/G)

Note; a) The Bidder may propose alternative materials to those specified above. In each case, the Bidder shall demonstrate to the satisfaction of the KNOC that the proposed alternative materials are equivalent to or superior to those specified.. b) All boiler pressure parts shall be designed and constructed to withstand the forces and moments applied through the main steam,

6.30-7 KHABAT TPP UNITS 1&2 - VOLUME I

cold and hot reheat, feed and integral pipework under all service conditions. c) . Plastic pipe shall not be used to convey chemical reagent solutions of >5% w/w strength or where the fracture of the pipe could pose danger to personnel. 3) Corrosion protection All above ground fuel pipes shall be protected against corrosion in accordance with the Painting and Protection requirements defined in this specification. Buried portions shall be protected against corrosion with factory applied coating and cathodic protection, suitable for the ground conditions. The selection of coating and method of application shall be to the approval of the KNOC and shall be taken to ensure mechanical and electrical compatibility with the cathodic protection system.

4) Cathodic protection Cathodic protection shall be applied by the impressed current method to all buried pipework. The cathodic protection shall be brought into operation immediately upon completion of the pipeline construction with the protection designed and installed in accordance with the requirements

as

defined

in

the

Cathodic

Protection,

This

Specification. Particular note shall be taken of the presence of other buried services in the area of gas pipeline and the procedures of the relevant internationally recognized codes and standards : Part 1 shall be followed.

5) Fire main The pressurized fire main shall be designed on a ring main basis and sized to cater for the maximum water demand in accordance with NFPA 24. Valves (normally locked open) shall be fitted at appropriate 6.30-8 KHABAT TPP UNITS 1&2 - VOLUME I

points in the main to allow isolation of discrete sections of the site. All thrust blocks (if required), valve pits, vent and drain connections and corrosion protection measures are to be provided. The capacity and layout of the main, and the position of hydrant outlets shall be submitted for approval. Above ground piping shall be ASTM A106 seamless carbon steel or approved equivalent, galvanized and painted in red. The pipe size up to DN50 shall have pipe schedule 80 having screwed joints and above DN65 to be standard schedule with flanged joints. The pipe material including fittings, flanges and bolting etc. shall meet the appropriate codes requirement of ASTM and ASME standards. The valve material shall be steel body and bronze trim and shall meet the design rating of the system. The material for buried pipework, valves and fitting up to the above ground connection point at the valve station shall be ductile iron (ISO 2531) with mechanical joints, cement lined (AWWA C104) with external bituminous coating and polyethylene wrapped (AWWA C105). Buried valves shall be grey cast iron body complying with the requirement of MSS SP70 and ANSI B16.1. All buried pipework shall be accommodated in trenches which are excavated and backfilled to ground level with the requirements of the relevant internationally recognized codes and standards, the depth of cover over the crown of the pipe shall be not less than 900 mm. 6.30.2

Layout A.

Piping arrangement The layout of the piping shall be subject to approval by the KNOC. The Bidder shall submit with his Proposal, layout drawings illustrating the proposed distillate oil supply ,heavy fuel oil and crude oil supply and transfer systems including the pumping station, the piping arrangement in the tank area and all major items of equipment. The drawings shall indicate the position of all supports, drainage points, fittings and all closing pipes. However, all piping systems shall be 6.30-9 KHABAT TPP UNITS 1&2 - VOLUME I

arranged to allow for adequate slopes in the direction of flow. All piping shall be routed to provide a neat and economical layout and requiring the minimum number of fittings. Piping shall be arranged so that full access is provided for the operation and maintenance of equipment, and that removal or replacement of equipment can be achieved with the minimum dismantling of piping. Overhead piping, inclusive of fittings, insulation and support steelwork, shall have a minimum vertical clearance of 2.1 meters above access platform and walkways and 6 meters above roadways. As far as it is possible all process pipes shall be above ground on pipe supports. Wherever the pipes have to cross roads or other facility, this shall be achieved by proper pipe trench. No direct buried pipes are acceptable for fuel oil in the plant battery limit. At the point of drainage, drain pockets of sufficient size and approved construction shall be fitted Drain piping shall be separately run to the blow down tank or drain tank as may be appropriate. The venting system shall serve as a safe removal system for all possible hydrocarbon vapour occurring during regular operations or emergencies. All vent gases shall be collected in a closed piping system which shall direct the gases to a venting stack, where they are vented safely. The drains from gas scrubbers and gas filters and from other points shall be led to a common underground concrete pit from where the same will be pumped via effluent pumps to mobile tankers. All gas vessel nozzles shall be flanged, and equipment shall be fitted with isolation valves to permit removal for maintenance without interrupting the gas supply

6.30-10 KHABAT TPP UNITS 1&2 - VOLUME I

The meter shall be located such that sufficient straight lengths of piping are provided both upstream and downstream of the device.

1) High pressure and high temperature pipe work All branch connections shall be designed with due consideration to both reinforcement and compensation. Where forged steel tees are used, they shall be of similar material analysis to the adjacent pipe, and they shall match correctly the bore of the adjacent piping and shall be proportioned to avoid stress raisers. The main steam pipe work shall be designed to the maximum safety valve lift pressure and the maximum design temperature condition. Air release and drain branches shall be provided where necessary, arranged in such a way that the drains and air release valves in they locations can be operated easily. Drain and air release pipe work shall be designed for the maximum pressure of the service line to be drained. Drains shall run separately to the point of discharge. Each high-pressure drain and vent with pressure-temperature rating of ASME class 600 and above shall be fitted with two valves at the nearest drain point at basement level in an approved manner. The valves arrangement shall allow a convenient operation. Provision shall be made to prevent scalding during operation. All steam pipes minimum drainage fall shall be 1/200 (0.5%) at any hot or cold condition. The desuperheating pipe work shall be designed to withstand the maximum pressure of the feed pump and the final feed temperature.

6.30-11 KHABAT TPP UNITS 1&2 - VOLUME I

2) Feed water pipe work The feed water pipe work shall be designed to withstand the closed valve pressure of the feed pump and the final feed temperature. Boiler feed water pump minimum flow pipe work up to and including minimum flow control valve shall be designed for the closed valve pressure produced by the feed pump as specified in the schedules. Minimum flow piping shall run to the feed water storage tank and shall be connected to an internal diffuser pipe fitted inside the tank.

3) Fuel oil pipe work, valves and fittings All fuel oil pipe work shall be designed, constructed, installed and tested in accordance with ANSI B31.3 or equivalent internationally recognized standards. All buried fuel oil pipe work shall be accommodated in trenches which are excavated, prepared and backfilled in accordance with; the depth of cover over the crown of the pipe shall be not less than 900 mm. All isolating valves in the fuel oil systems shall be of the nonlubricated ball type with Teflon seals and resilient faces, where applicable. The valves shall be of the fire-safe design. Threaded valves shall only be used where required for equipment compatibility. Cast iron valves shall not be used for oil service. All piping and equipment shall be protected against excess pressure utilizing pressure relief valves. Over pressurization of blocked or isolated pipelines and equipment by solar heating and ambient temperature changes shall be considered in the design.

Relief valve discharge shall be piped

to the return header or pump suction, as required. Vents and drains equipped with a ball valve shall be provided at strainers and all high points and low points respectively. In addition, connections required for periodic tests shall be equipped with valves 6.30-12 KHABAT TPP UNITS 1&2 - VOLUME I

and threaded nipples which shall be protected by threaded caps. 4) Lubricating oil pipe work Supporting systems must prevent vibration under all possible operating conditions. Welding shall be used as far as practicable. Where screw joints are used they will be properly secured against loosening by vibration. Arrangement and support of all oil piping shall be such that detrimental vibrations do not occur under any possible operating condition. Thermowells shall be welded to the pipes. Piping shall be prefabricated in the factory and be dispatched fully acid-pickled and properly sealed and protected against corrosion. The Bidder may consider stainless steel in order to facilitate a fast track programme for oil flushing. Within the boiler block, for ease of pipe fitting on Site, the fitting lengths installed in the various pipe runs shall be flanged to avoid welding on prefabricated pipes. The fitting lengths shall be cleaned and acid-pickled before installation.

5) Compressed air pipe work All compressed air pipe work shall be hot dip galvanized throughout conforming to the relevant internationally recognized codes and standards. All galvanizing shall wherever possible be carried out after fabrication work. Where pipes are cut or screwed after galvanizing this shall be made good. All galvanized pipe connections shall be threaded, or flanged, but not welded. All branches shall be taken from the top of the mains. Each branch pipe to compressed air points shall terminate in a standard fitting. The mains shall have a suitable slope to allow drainage and shall be 6.30-13 KHABAT TPP UNITS 1&2 - VOLUME I

fitted with automatic drain traps and the necessary isolating and bypass valves. Instrument - and control air connections from the mains to the consumers shall be made of 316L stainless steel pipes with screw fitting joints. Similarly 316L stainless steel piping shall be utilized between the air compressors and the dryers.

6) Ductile iron pipe work and fittings Ductile iron cement lined pipes and fittings, as used in potable water distribution for underground piping systems, shall comply with the requirements

of

ISO

specifications

as

regards

methods

of

manufacturing, tolerances, marking and testing. The pipes, fittings and rubber rings used for jointing shall be suitable to withstand the operating requirements and ambient weather conditions. Pipes shall be supplied in standard lengths with mechanical joints wherever possible. The specification, dimensions and thicknesses of pipes and fittings, unless otherwise stated, shall comply with the requirements of the latest edition of ISO 2531 standard. Where ductile iron pipes and fittings are supplied with sockets for push-on joints, mechanical or rubber ring, thrust blocks shall be provided at all changes in direction etc. unless the Bidder can justify otherwise. Glands shall be of ductile cast iron of the same quality as the fittings and tested for tensile strength and hardness. Glands shall be marked with the manufacturer’s name, date of manufacture and nominal diameter and coated with a 4 mm thick bituminous compound. For easy maintenance all valves and interconnection sections shall be flanged. All fittings with flanged ends of 600 mm diameter and smaller shall be in accordance with ASME B16.1/B16.5. Bolts and nuts shall be of galvanized mild steel and gaskets shall be of rubber and reinforced, of thickness not less than 3 mm and shall conform to AWWA C11.

6.30-14 KHABAT TPP UNITS 1&2 - VOLUME I

7) Floor and wall opening collars, wall boxes and weather hoods At all points where pipes pass the through concrete or other similar floors and walls, suitable floor collars or wall boxes shall be provided. The floor collars shall have raised curbs of suitable height, which shall not be less than 75 mm. The wall boxes shall be flush fitting and of neat design and approved finish. The Bidder shall provide all necessary fittings for the passage of pipes through external walls and roofs, together with the supply of all necessary components for weatherproofing or vermin proofing. Wherever possible, service pipes running adjacent to each other shall pass through a common box. Where pipes of varying bore pass through a common box, a neat “fillin” cover plate shall be provided between the pipes and the box. In the case of flanged pipe work, boxes shall be large enough to permit the passage of the flange.

8) Vents and drains Adequate provision shall be made for safely venting, purging, and where necessary, draining those sections of pipework and equipment which have to be isolated during construction, commissioning and maintenance. The venting system shall be suitable for the disposal of vented or emergency relief gases. All vent gases containing hydrocarbon vapours, e.g. during stream purge on shut down operation, shall be piped to safe locations or to a vent stack. Block and bleed with integral vent arrangements shall be provided, where necessary, to ensure plant safety, and purge vents shall include facility for connection of gas detection equipment. Vents and drains only needed for tests shall be plugged and sealwelded; all others shall be equipped with blind flanged or blind plugged gate or ball valves. Vents and drains shall have a minimum 6.30-15 KHABAT TPP UNITS 1&2 - VOLUME I

diameter of DN25. The vent system shall be designed to remove the largest amount of vent gas, which could occur during any reasonably assumed plant condition or emergency expected throughout the power station. Basic and detailed design shall be subject to KNOC’s approval

9) Terminal connections All welding and flange connections shall be carried out unless otherwise specified, by and under the full responsibility of the Bidder. For flange connections the Bidder shall also supply, where appropriate, the companion flange and the necessary jointing material. In case of weld connections the Bidder shall, where appropriate, make good the final joint, pipe protection and reinstatement. Termination points shall be as indicated in the Bidder drawing. The Bidder shall be responsible for finalizing the connection requirements at each termination point and shall agree the precise location and scheduling of interconnection work with KNOC to minimize disruption to existing plant and services. 6.30.3

Fluid vlocities The following maximum fluid velocities are guidelines to be used for the purpose of pipe sizing during the preparation of Bidders. The final selection of fluid velocities and pipe sizing after contract award shall be the responsibility of the Bidder, such selection being subject to review and approval by the KNOC The maximum allowable velocity of flow in pipes shall be as follows:

High-pressure live steam

75 m/s

Low pressure steam lines for FWH Extraction

60 m/s

Saturated steam

40 m/s

Service air

15 m/s

Instrument air

10 m/s 6.30-16 KHABAT TPP UNITS 1&2 - VOLUME I

Feed water

7.3 m/s

Water piping(discharge)

3 m/s

Water piping(suction)

1.8 m/s

Aux. Cooling water in heat exchangers and piping

3 m/s

Fuel oil(discharge)

2 m/s

Fuel oil(suction)

1 m/s

Higher values may be approved in special applications or for systems used intermittently. Pipes of diameter less than DN25 may only be used for control/impulse and chemical dosing. The rating of discharge piping of pumps shall be a minimum of 1.05 times of pump maximum outlet pressure or pump shut-off pressure, whichever is the largest. 6.30.4

Stress calculation The Bidder shall provide, as required by the KNOC, stress calculations and diagrams or print outs from a stress analysis computer program to show the location and magnitude of the stresses and the magnitude and direction of the thrust and resultant bending moments at the terminal points and at each point of restraint in a piping system after contract. The calculations shall be based on the most arduous combination of the specified operating conditions. In minimum, a stress analysis must be performed for all piping systems with an operating temperature≥200℃. The load cases “dead load” and “thermal expansion”, “occasional & seismic load” and “internal pressure” must be verified using the ASME B31.1 criteria. Adequate provision for expansion of the pipe work shall be made. Expansion joints or bellows shall be used only where they can be justified technically and economically and with KNOC’s approval. Piping connected to axial bellows units shall be adequately guided and anchored. 6.30-17 KHABAT TPP UNITS 1&2 - VOLUME I

6.30.5

Cleaning of pipes All items shall be prepared for shipment in such a manner to avoid damage of atmospheric corrosion to inside or outside surface during storage period and while in transit. Plain or bevel ends shall be protected with a non-metallic cover The Bidder is responsible for ensuring that the internal and external surface of all pipelines is thoroughly clean before the pipelines are placed in commission and painting. The internal cleaning may be performed by one of steam, air or nitrogen blowing or chemical cleaning or launching the pig. The procedure adopted is to include the following and may be more specifically described elsewhere in the specification. Thorough cleaning of all internal surfaces prior to erection to remove accumulations of dirt, rust, scale, and welding slag due to site welding before erection. Prior to, and during erection, all parts shall be inspected to make sure that they are clean, and adequate steps shall be taken to prevent entry of foreign matter both during and after erection. Each section erected shall be cleaned out before being connected into the previous section. All headers shall be cleaned before closing up. In the case of high temperature piping, a cycle of heating, cooling and blowing or flushing is to be repeated several times to ensure that any remaining slag or scale which would otherwise become loosened during service, is removed before commissioning. The Bidder shall provide all necessary facilities in the pipe system for carrying out the requirements of items above including any temporary pipe work, valves and supports.

6.30.6

Pipe supports 6.30-18 KHABAT TPP UNITS 1&2 - VOLUME I

Piping shall be supported and anchored in an appropriate manner in accordance with the provisions of ASME B31.1 or the Standard to which the pipe work is designed. Supports shall not be dependent for flexibility on the flexure of supporting rods or straps. Supports shall be positioned before the pipe has been erected and near to valves wherever possible. Supporting straps around flanges or welded joints will not be accepted. All supports shall be provided with means of adjusting the tension of springs, the height of supports and the length of rods or straps. All such adjusting devices shall be capable of being securely locked. Parts of supporting elements for high working temperature piping shall be made of suitable alloy steel or shall be protected so that the temperature of the supporting member will be maintained within the appropriate temperature limits of the material. The supporting arrangements of all piping systems shall be designed with due regard to any additional loads imposed during hydraulic or hydrostatic testing, and cleaning and steam blowing operations. Particular attention shall be paid to sliding surfaces in guides and sliding supports and to the springs employed in variable and constant load supports. The Bidder shall provide stainless steel and low friction plastic for important sliding surfaces. Where necessary, constant load supports shall be provided. The Bidder shall take all necessary precautions to ensure that the piping shall be free from vibration by the installation of sway braces and/or vibration dampers or other acceptable means. Except for springs, all supports shall be designed for a safety factor of not less than 5, based on the ultimate strength of the material. Outdoor piping support systems shall be designed to withstand the environmental conditions. 6.30-19 KHABAT TPP UNITS 1&2 - VOLUME I

Supports shall be so designed and fabricated that, in the event of spring failure, they do not release the pipe. The spring hangers, counter poise support, etc. on pipe work shall have scale showing hot and cold (static and dynamic) load settings marked by punching. Springs shall be of the helical compression type and shall be provided with means to prevent misalignment, buckling, eccentric loading or excessive travel, with a working stress not exceeding 10 N/mm2 at the most favorable loading conditions. The Bidder shall prepare pipe work layout or other similar drawings marked to show the position of every pipe support on all high-pressure piping. Each of the supports marked on these drawings shall be assigned a unique plant reference number by the Bidder. The Bidder shall prepare the drawings of all these supports for submission to the KNOC before erection. The support drawings shall, as a minimum, state the support reference number, the type of support, the directions of freedom of movement, and the magnitude and direction of pipe movement from the cold installed to the hot operating conditions. A spring support drawing shall also be provided to the KNOC and included in the operating manuals, which as a minimum, states the support reference numbers, the spring rates, the hot operating load, and the magnitude and direction of travel from the cold installed to the hot operating conditions. 6.30.7

Underground ppe wrk All underground pipe work shall be designed in order to withstand the loading from covering soil as well as from traffic. Underground piping systems shall be self-anchoring, i.e. no thrust blocks for loadings resulting from test and operation pressure are permitted except in specific areas where partially encased thrust blocks may be provided as reviewed case by case. The cathodic protection system for underground pipe work wherever 6.30-20 KHABAT TPP UNITS 1&2 - VOLUME I

deemed necessary in addition to the insulation proposed by the Bidder shall be approved by KNOC. Where guiding tubes or sleeves for penetrations such as through building walls, walls or dikes of tank farm, etc., of steel are practicable, such material has to be supplied and proper sealing and outside protection carried out by the Bidder. 6.30.8 1)

Valves General All valves shall be manufactured from first quality material, have superior designed parts, dust-tight construction, and have easily maintained lubricating systems. All valve parts shall be arranged for ease of accessibility in the installed position. The design and manufacture of all valves shall be to the approval of the KNOC. Valve information shall be detailed in the appropriate technical data sheets to be included in the Bidder and shall include operating pressure range, nominal set pressure, and type of actuator. Valves shall be suitable for the service intended, with materials suitable for the medium to be handled, and certified as acceptable by relevant codes and standards for the service and duty intended. For the boiler package, the Bidder’s Standard will be considered. Manually operated valves with a nominal size greater than DN250, which have to be opened or closed very quickly or with minimum manual effort shall be provided with a suitable gear system. All isolating valves which are required to open or close during normal operation of the plant, including start up and shut down shall be equipped with an installed actuator and shall be capable of being locked in both the open and closed positions. The Bidder shall provide the necessary devices and locks. The internal diameter of all valves at the ends adjacent to the pipes shall be the same as the internal diameter of the pipes to which they are jointed unless 6.30-21 KHABAT TPP UNITS 1&2 - VOLUME I

otherwise approved by the KNOC. Valves shall have butt weld or flanged ends in accordance with the piping system requirements. Butterfly valves shall only be used when specifically approved. Cast iron, bronze or brass valves are not permitted for any piping system except as specifically mentioned herein. All valves and pipe fittings material shall be as indicated in ASTM code or approved equivalent. All valves of sizes up to and including DN 50 shall be globe valve type and shall have an ASME Class 600 rating for all services. Where globe or angle style valves are used they shall be installed with the normal flow entering beneath the disc. Check valves shall be of the inner-shaft type and no stuffing box or counterweight type check valve shall be permitted. Check valves shall be non-slamming type. Examination and/or replacement of parts shall be possible without removing the check valve from the line. Check valves in vertical pipe runs should be avoided, however, where necessary these shall be provided with by passes and drain valves. Cast or steel-forged bodies shall be used for high-pressure valves >25 bar) with a nominal bore larger than DN 65, and for smaller bore, steel forged bodies shall be used. For low-pressure valves (