P All

CNE/015/2002
P1
Interfaces
WORKING DOCUMENT
Part P1 Interfaces Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
PAGE
GENERAL ..................................................................................................................................... 1
SCOPE .......................................................................................................................................... 1
INTERFACE POINT IDENTIFICATION CODE............................................................................ 1
INTERFACE POINTS................................................................................................................... 3
4.1
MECHANICAL INTERFACES.......................................................................................... 3
4.1.1
General Guidelines....................................................................................... 3
4.1.2
List of Mechanical Interfaces...................................................................... 3
4.2
ELECTRICAL INTERFACES ........................................................................................... 6

4.2.1
General Guidelines....................................................................................... 6
4.2.2
List of Electrical Interfaces......................................................................... 7
4.3
INSTRUMENTATION AND CONTROL INTERFACES................................................... 9

4.3.1
DCS Cubicles in Package D scope and Man-Machine Interface in the
CCR................................................................................................................ 9
4.3.2
Maintenance Telephone System (P27/D8)............................................... 10
4.3.3
Interfacing with Package S 400 kV Switchgear................................... 10
4.3.4
Package L 400 kV Overhead Line ......................................................... 11
4.4
CIVIL INTERFACES....................................................................................................... 11
4.4.1
General Guidelines..................................................................................... 11
4.4.2
List of Civil Interfaces................................................................................ 11
P1_Interfaces_Working_Doc.doc
Page: 1
GENERAL
As the scope of works of the Jebel Ali Power and Desalination Station L Phase I has been divided
into four packages, the interfaces between these packages have to be clearly defined.
The successful Contractor for each Package shall co-ordinate his work in every phase of his
activity like design, engineering, workshop testing, construction, erection, site testing and
commissioning directly with the respective Contractor for all other Packages.
During the design period, the concerned Contractor for any Package shall contact directly
Contractor(s) for other Packages in all matters concerning required data for his detailed technical
design to get the necessary information. The other Package Contractor(s) is obliged to provide
timely all necessary information as may be required by other Package Contractor(s). Copy of the
correspondence shall be submitted to the Employer/Engineer.
The concerned Package Contractor may arrange for technical meetings with other Package
Contractor(s) for the same reason. The timing and agenda shall be submitted to the
Employer/Engineer in due time before the meeting for information and decision whether or not to
attend the meeting. In case of non-attendance a copy of the Minutes of Meetings shall also be
distributed to the Employer/Engineer.
2
SCOPE
This specification part P1 Interfaces describes the interfaces of the Package P - Power Station
of the Jebel Ali L, Phase I., station.
The scope of systems under this package is outlined in part G4.1.
The detailed scope of each system is described in the clause Scope of the Particular Technical
Specification of that system.
3
INTERFACE POINT IDENTIFICATION CODE
Each interface shall be clearly identified by a unique identification code. Since every interface point
appears in the interface list of both involved systems, the interface shall use the exact same
identification code in both systems.
The following numbering system for interface points has been used in the tables below:
Xx/Yy-z
with
X, Y
Package Letter
P = Power, D = Desalination, S = 400kV Substation, L = 400kV Overhead Lines,
E = External
The package letter shall always be in the following order: P>D>S>L>E
x, y
System Number, as given in the table on the following page
(The number is the same as used for the Particular Technical Specification X2.x
e.g. System P8 as specified in Part P2.8 = Condensate and Feedwater System)
Sequential number
For example:
P7/D4-3
Interface point number 3 between the system P7 (Steam

Systems) and system D4 (Seawater Supply)
Page: 2
System Numbers
P - Power
D - Desalination
P0
P1
D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
P2
P3
P4
P5
P6
P7
P8
P9
P10
P11
P12
P13
P14
P15
P16
P17
P18
P19
P20
P21
P22
P23
P24
P25
P26
P27
P28
Common
GTs Turbine Units and Auxiliaries
including bypass stack
HRSGs and Auxiliaries
Auxiliary Boilers
Fuel Oil storage and supply system for
GTs and Boilers
Gas systems for GTs and Boilers
Steam Turbine Units and Auxiliaries
Steam Systems
Condensate and Feedwater Systems
Closed Cooling Water System
Black Start / Emergency Power Supply
Instrument and Service Air
not used
Steam / Water Sampling System
Steam / Water Circuit Chemistry /
Dosing
Demineralised Water Plant
not used
Chemical Laboratory
Waste Water Treatment Plant
Sewage Treatment Plant
Sump Pumps
Cranes and Hoists
Workshop and Store Equipment
Station Fire Fighting and Fire Detection
Systems
Heating, Ventilation and Air
Conditioning
Emission Monitoring System
Electrical Equipment
I&C Systems
Civil Works
Common
Desalination Plant
Potable Water Pumps Station
Blending Station
Seawater Supply and Screening Systems
Chemical Stores
Cranes and Hoists
I&C Systems
Civil Works
Seawater Chlorination Plant
Plant Potable Water and Service Water
Systems
S 400 kV Substation
S0
S1
S2
S3
S4
Common
400 kV Substation
I&C Systems
Civil Works
L 400 kV Overhead Lines

L0
L1
L2
L3
L4
Common
400 kV Overhead Lines
Structure
Civil Works
E External
E0
E1
E2
E3
Common
Natural Gas Pipeline
Fuel Oil Pipeline
Potable Water Pipeline
Page: 3
INTERFACE POINTS
4.1
MECHANICAL INTERFACES
4.1.1
General Guidelines
Generally, to prevent interference, it shall be avoided as much as possible that the (sub-)contractor
working on one of the 4 packages has to work in the area of any of the other 4 packages.
The bulk of mechanical interfaces are between packages P and D; and those interfaces shall
preferably be near the E220 coordinate (piperack) or S1700 or S2000 coordinate (centerline or
north end road).
Furthermore the number of interfaces shall be minimised, i.e. wherever possible there shall be
common interface points for a system and sub-distribution in a package shall be done be the (sub-)
contractor responsible for that package.
To determine which package contractor has the lead responsibility for a mechanical interface the
following order of priority shall be used:
P>D>S>L
The contractor who has the lead responsibility for the interface will be responsible for the
coordination and for the physical completion of the interface. This includes providing the necessary
material (such as bolts, gaskets, flanges, weld ...) and carry out the necessary work (such as
aligning pipes, welding, tightening bolts, ...).
The identified interfaces have been listed below. Further interfaces, if required for the
completeness of the plant / system, shall be provided by the Contractor with no extra costs.
4.1.2
List of Mechanical Interfaces
System / System /
Interface Medium
P0
Common
P0/D11-1 Potable Water

P1
Location / Description
(coordinates are approximate)
Tie-in point on common potable water supply line

approx. at crossing (E220 / S2000 coordinates)
GTs Turbine Units and Auxiliaries including Bypass Stack

none
P2

none
P3
Auxiliary Boilers
none
P4
Fuel Oil Storage and Supply System for GTs and Boilers
P4/E2-1
Diesel Oil
P5
Gas Systems for GTs and Boilers
At pump station in Jebel Ali port
Page: 4
System / System /
Interface Medium
P5/E1-1
Natural Gas
At tie-in point on NG pipeline in the south-east corner of the

plant
P6
Steam Turbine Units and Auxiliaries

none
P7
Steam Systems
P7/D1-1
LP Steam
At MSF steam inlet valve, nearby pipe rack between P and

D area (E220), 1 per each MSF unit
P7/D1-2
IP Steam
At MSF steam inlet valve, nearby pipe rack between P and

D area (E220), 1 per each MSF unit
P8
Condensate and Feedwater Systems
P8/D1-1
Return Condensate
P9
P9/D4-1
Sea Water Supply
At CCW Cooler inlet flange
P9/D4-2
Sea Water Return
At CCW Cooler outlet flange
P9/D1-1
CCW Supply
nearby CCW cooler / pumps, on ground level
P9/D1-2
CCW Return
nearby CCW cooler, on ground level
P10
On pipe rack between P and D area (E220), 1 per each

MSF unit
none
P11
Instrument and Service Air
P11/D1-1 Service Air

MSF unit
P11/D1-2 Instrument Air

MSF unit
P11/S0-1 Service Air
At the east side of the GT Machine Hall (if required)
P12
not used
P13

none
P14
Steam / Water Circuit Chemistry / Dosing

none
P15
P15/D1-1 Distillate (in)
Connection at distillate header of the desalination plant to

the distillate transfer pumps suction line
Page: 5
System / System /
Interface Medium
P15/D3-1 Supply of Caustic Soda

to Demin. Water Plant
Connection flange at caustic soda bulk storage tank of the

Blending Plant
P15/S0-1 Demineralised Water
Connection flange at the 400 kV S/S terminal washing

system
P16
not used
P17
Chemical Laboratory
none
P18
P18/D4-1 Treated Waste Waters
at seawater outfall channel (if not drained into seepage

trench/pit)
P18/D4-2 Cooling Sea Water
At auxiliary seawater header
P19
P19/D4-1 Treated Sewage Water
At seawater outfall channel if not used for irrigation.
P19/D0-1 Sewage Waste Water
Tie-in point on common sewage water collection line on the

north end side of the plant (S1700 coordinate)
P19/S0-1 Sewage Waste Water

P20
Sump Pumps
P20/D0-1 Chemical Waste Water

Drains
Tie-in points at the waste water sump pump suction lines of

the various plant systems
P20/S0-1 Chemical Waste Water

Drains
P21
Cranes and Hoists

none
P22

none
P23
Station Fire Fighting and Fire Detection Systems
P23/D0-1 Fire Water
Tie-in point on common fire water supply ring line on the

north end side (S2000 coordinate) or south end side
(S1700 coordinate) of the phase 1 area
P23/S0-1 Fire Water
Tie-in point on common fire water supply ring line on the

west end side (E370 coordinate) of the substation
P24
Heating, Air Conditioning and Ventilation

none
P25
Page: 6
System / System /
Interface Medium
none
4.2
ELECTRICAL INTERFACES
4.2.1
General Guidelines
Generally, to prevent interference, it shall be avoided as much as possible that the (sub-)
contractor working on one of the 4 Packages has to work in the area of any of the other 4
Packages.
The bulk of interfaces are between the 11 kV unit Auxiliary Supply of Package P and the 11 kV
sub-distribution boards of Package D.
Generally all 11 kV-Power cable connections and all related control, pilot wiring protection and
interlocking cables form 11 kV unit boards to 11 kV sub-distributions and direct to 11 kV station
service boards connected 11/0.4 kV transformers of other Packages will be part of Package P.
In the same way, the LV Power Cables and control cables from the central Emergency Distribution
board in Package P to the 0.4 kV boards of other Packages will be the part of Package P. To
minimise the total number of these cable connections between Package P and Package D the
subcontractor of Package D has to provide an emergency-sub-distribution board and only two
connecting cables will be provided.
Cable trays shall use the division of work as defined in clause 4.1.1, i.e. cable trays in an area shall
generally be provided by the contractor who is responsible for that area, regardless of which
contractor the cable belongs to.
To determine which package contractor has the lead responsibility for an electrical interface the
following order of priority shall be used:
S>L>P>D
The contractor who has the lead responsibility for the interface will be responsible for the
coordination and for the physical completion of the interface. This includes providing the necessary
material except the cable (such as cable shoes and clamps) and carry out the necessary work
except pulling the cable (such as attaching the cable shoes and connecting to the junction box).
Electrical works for road lighting including lighting poles within the Site will be divided by coordinate E 226. East of it is in the supply of Package P and west in Package D.

4.2.2
No.
Page: 7
List of Electrical Interfaces
System
Voltage
[V / kV]
Location
P26/S1-1 Unit Step up transformers GT1,

GT2, GT3, ST1 and ST2
400 kV
400 kV SF6 connection box of

the transformer, flanges for
direct connection of SF6 bus
ducts to the 400 kV substation
P26/S1-2 Generator / Unit Step up

Transformer protection &
synchronisation
400 kV
Feeder related local control

cubicles (400 kV switchgear
room) and relay room of the
400 kV Substation,
(CT, VT)
+ Control and
interlocking,
Synchronisation +
intertripping and
relay setting
coordination
P26/S1-3 11 kV Switchgears 10BBA and

10BBB
Outgoing feeders to 11 / 0,4 kV
Aux. Transformers of the 400 kV
Substation including the 11 kV
power cables and control cables
11 kV
+ Control and
interlocking +
intertripping
400 kV Substation
0.4 kV Switchgear room
P26/S1-3 SCADA/EMS and Power Station

DCS
P26/D1-1 11 kV Unit auxiliary switchgears:
11BBA / 11BBB (cable feeders to

Desalination units 1; 2 and 3
including the 11 kV power cables
and control cables)
400 kV Substation, Transformer

boxes 11/0,4 kV Aux.
Transformers, 11 kV cable
terminals of both transformers
400 kV Substation and CCR

respectively electronic room
and related power plant
equipment
11 kV
+ Protection, control
and interlocking +
intertripping and
relay setting
coordination
Desalination plant, Switchgear

buildings of desalination units 1;
2; 3; 4 and 5:
Incoming feeders of 11 kV
Switchgears Des. Units 1; 2; 3
12BBA / 12BBB (cable feeders to

and control cables)
Switchgear Des. Units 4; 5; 1
13BBA / 13BBB (cable feeder to

and control cables)
Switchgear Des. Units 3; 4; 5
Page: 8
No.
System
P26/D4-1 11 kV Unit auxiliary switchgears

11BBA/1BBB
12BBB
13BBA
(cable feeders to 11 kV switchgears
Seawater Pump House including
the 11 kV power cables and control
cables)
P26/D2-1 11 kV Unit auxiliary switchgears
11BBA
12BBA/2BBB
13BBB
(cable feeders to 11 kV switchgears
Potable Water Pump House
and control cables)
P26/S1-4 380 V Emergency Distribution
Board
Cable feeders to 0,4 kV Switchgear
of the 400 kV Substation including
the LV power and control cables
(power supply for emergency supply
in case of grid black out)
P26/D1-7 380 V Emergency Distribution
Board
Cable feeders to 380 V Emergency
Subdistribution Board Desalination
Plant
including the LV power and control
cables (power supply for safe shut
down and emergency supply in
case of grid black out)
P26/S1-5 Earthing system
Cross connections to the earthing
loops of the 400 kV Substation
(Building and outdoor equipment)
P26/D1-8 Earthing system
Cross connections to the earthing
loops of the Desalination Plant
(Buildings and outdoor equipment)
Voltage
[V / kV]
Location
11 kV
Switchgear building Seawater

Pump House
and interlocking +
intertripping and
relay setting
coordination
11 kV
and interlocking +
intertripping and
relay setting
coordination
Switchgear Seawater Pump
House
Switchgear room Potable Water

Pump House
Switchgear Potable Water
Pump House
380 V
400 kV Substation
+ Control and
interlocking +
intertripping
380 V Switchgear room
380 V
Desalination plant, switchgear

building Seawater Pump
House, 380 V switchgear room
+ Control and
interlocking +
intertripping and
relay setting
coordination
Incoming feeders of 380 V

Emergency Subdistribution
Board
Earthing system of the

substation,
Earthing system of the

Desalination Plant

4.3
Page: 9
INSTRUMENTATION AND CONTROL INTERFACES
The following interfacing with other Packages shall be considered for Package P
4.3.1
DCS Cubicles in Package D scope and Man-Machine Interface in the CCR
Interface / System
Provisions made for interfacing and interfacing work to be performed
P27/D8 I&C
By Package D
By Package P
DCS Cubicles
DCS cubicles in the local

electronic rooms in the
Desalination plant and Seawater
switchgear buildings for all
Package D process systems
Extension and laying of the DCS

plant/highway bus from Package P
electronic room DCS up to the
Package D DCS cubicles
Plant/Highway Bus
connection
DCS cubicles communication /

coupling modules for the plant /
highway bus
Connection of the DCS plant / highway

bus to the Package D DCS cubicles
CCR MMI
(Hardware)
Installation of CCR MMI hardware

components for the Package D
portion.
Provision of CCR furniture for the

Water Control Desk and cladding /
fixation for Package D large screen
device.
CCR Terminal / LAN

bus
CCR terminal/LAN bus for

Package D scope and connection
to highway bus and to the
Package D Water Control Desk
operator stations and peripheries
in the CCR
Connection and integration of the

Package D CCR terminal / LAN bus
to the Package P portion of the CCR
terminal/LAN bus
MMI Software
CCR MMI software, database,

Integration CCR MMI hardware,
configuration, etc., for Package D software and database for Package D
portion
portion
Documentation,
information and data
Provision of documentation and

information and data for common
and overall tasks 1) for Package
P, preparation of screen pictures
with refreshed values and operator
controls for Package D portion,
provision of calculations and
balances for the Plant
Management system
Remark
Integration of Package D control

tasks into the Plant control and
supervision including, bot not limited to
shared control tasks, Plant Coordinator and Plant Master control,
screen representations, logs and
protocols, with acquired and calculated
data
1)
The following documentation / information shall be timely delivered by Package D to P in a form

as required by package P:
List of all measurements (local and remote), including setpoints, alarms, etc.
Functional diagrams (logic and control diagrams with functional descriptions in clear text
P&I diagrams
MMI screen mimics for the Desalination Plant and proposal for common shared systems
Page: 10
Data for the plant management system, ready to use calculation routines, heat balance
calculations, correction curves, etc.
Layout drawings showing the location of the cubicles and other interfacing points, if any;
Equipment specification relevant for the interfacing;
All necessary engineering data and any other data as required by package P to perform
their specified tasks
Whenever required, the exchanged data shall be provided on PC data carrier.

For the duration of DCS programming by Package P for Package D tasks the latter will delegate
to Package P one competent process engineer familiar with all necessary instrumentation and
control aspects of their package.
Package D shall further support all Package P tasks as far as Package D systems /
constructions are concerned (e.g. providing terminals for the maintenance telephone system,
proposing and releasing locations for Loudspeaker system, etc.).
4.3.2
Maintenance Telephone System (P27/D8)
The interfacing point between the Plant Maintenance telephone system in Package P scope and
the network provided in the Package D scope shall be in the local electronic room of the
desalination unit closest to the central switchgear and control building of Package P.
Package D shall provide one delivery point for electrical and a separate one for I&C network in
their marshalling cabinet.
Package P shall provide the cable and cable laying from their central marshalling place of the
Maintenance Telephone System up to the common interfacing point and connect.
4.3.3
Interfacing with Package S 400 kV Switchgear
The following interfacing tasks shall be considered against Package S:
receiving signals from Package S in order to monitor package S systems in the CCR by the
DCS workstations / large screen and forwarding signals to Package S for transmission to the
LDC
Package S will arrange for interface point against package P in the Control Building in a
convenient place. Package P shall pick-up / deliver signals at this interface point and connect
to the DCS system.
The kind of interfacing shall be commonly agreed between package P and package S.
Conveniently bus interface shall be used, subject to the specific systems offered by the
packages. However, protection signals and vital control signals, if applicable, shall be
interfaced by hard-wiring. For protection signals three-channel connection shall be used.
The package S will deliver basic engineering data, like
List of all measurements, including setpoints, alarms, etc.
Functional diagrams, as far as necessary
MMI screen mimics proposal for package S systems (single line diagrams, etc.)
Data for the plant management system, calculation routines
Layout drawings showing the location of the interfacing point(s)
Page: 11
Cabling and wiring lists and diagrams, connection and terminal diagrams relevant for the
interfacing;
Equipment specification relevant for the interfacing;
Any other data obviously required by package P to perform their specified tasks
Package S shall receive synchronising signals from the plant Master Clock system for their
digital control systems, if applicable. The interface point shall be the same as specified above
for the DCS signals.
Package S will support Package P tasks as far as their systems/constructions are

concerned (e.g. providing terminals for the maintenance telephone system, proposing
locations for Loudspeaker system, providing data for the computerised maintenance
management and spare part management systems, etc.). Whenever required, the data shall
be provided on PC data carrier.)
4.3.4
Package L 400 kV Overhead Line
No direct interfacing between the packages P and L shall be considered.

4.4
CIVIL INTERFACES
4.4.1
General Guidelines
into four packages, the civil works required by each packages will be divided accordingly.
For the buildings, structures, equipment foundations, piperack / busduct foundations, and pipe and
cable trenches required for mechanical/electrical plants and equipments, the interfaces for the civil
works are defined by the interfaces of the mechanical/electrical plants and equipments for which
the civil works are required. Reference is made to the relevant Clauses of mechanical/electrical
interfaces above.
Further interfaces for civil works not related directly to any of those plants, equipments, pipe and
cable racks/trenches, works such as roads, drainage and sewage etc., which need to be defined
area-wise i.e. to be shared by Packages, will be defined below in the Clause 4.4.2.
Works for all of the Station to be executed by a certain Package will be defined in the Part P2.28,
D2.9, S2.4, Clause-Scope of Works accordingly. Otherwise works of general nature mentioned in
the scope of works below are limited to the concerned packages only.
Contractor of the area in which other civil contractor has to work, shall be responsible for the coordination of civil works with regard to sequence of works, accesses etc. Reference is made in this
regard to Part G2-Conditions of Contract, Clause 6.28.
4.4.2
List of Civil Interfaces
4.4.2.1 General
Interfaces between Package P and others are defined below by physical co-ordinates cover civil
works of general nature. Some other works of general nature such as Employer/Engineers Site
office, first aid station for the whole construction site are included in the scope of works for
Package P and thus not specifically stated in the interfaces. In case of different civil contractors
are employed at Site for each Package, the co-ordination between them shall be undertaken by
the responsible contractor of the area.
In case of disputes about the scope of works of other civil contractor in his area, area contractor is
responsible for the completeness and functionality of all civil works in his area.
Page: 12
4.4.2.2 Interfaces between Package P and Package D

For works and services as roads, drainage and sewage lines, cable trenches if utilised by both
packages, landscaping, levelling or other works of similar nature area east of the co-ordinates
approximately E 222 (limits of walkway) will be in the scope of supply of the civil works for Package
P.
4.4.2.3 Interfaces between Package P and Package S
Area confined approximately by the co-ordinates E 372 (end of walkway) and the retaining wall in
east-west direction and by the edge of southern walkway of the access road to Substation at about
S 2065 and till 20m north from the Substation Control Building in north-south direction will be in the
scope of supply of the civil works for Package S for services as drainage and sewage lines, cable
trenches if belongs to both packages gravel covering, landscaping or other works of similar nature.
4.4.2.4 Interfaces between Package P and Package L
There are no common works which would need to be divided by these Packages area-wise except
crossing of under (or above) ground oil pipe line east of retaining wall. Civil works for the pipeline
is in the Package P. All the civil works except those for the foundations of Transmission Towers
and those defined clearly under the scope of works for Package L such as demolishing, removal
of temporary works, labour camps etc., belonging to Package L at the Site and in Contractors laydown areas and grading of areas after completion of works shall be in Package P. Package P
Contractor deemed to be responsible contractor for the area under the Overhead Line route within
the Site area.
CNE/015/2002
P2.2
WORKING DOCUMENT
Part P2.2 HRSGs and Auxiliaries Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
PAGE
GENERAL ..................................................................................................................................... 1
SCOPE OF WORKS..................................................................................................................... 1
EQUIPMENT DESIGN REQUIREMENTS................................................................................... 4

3.1
BASIC DESIGN AND OPERATING DATA OF THE HRSG ........................................... 4
3.2
PRESSURE PARTS......................................................................................................... 6
3.2.1
Steam Drum(s) .............................................................................................. 6
3.2.2
Heat Exchanger Tubes and Headers.......................................................... 7
3.2.3
Economiser ................................................................................................... 8
3.2.4
Evaporator..................................................................................................... 8
3.2.5
Superheaters................................................................................................. 8
3.2.6
Desuperheaters............................................................................................ 8
3.3
SUPPLEMENTARY FIRING............................................................................................. 9
3.3.1
General .......................................................................................................... 9
3.3.2
Burners........................................................................................................ 10
3.3.3
Ignition System........................................................................................... 10
3.4
HRSG STEEL STRUCTURE.......................................................................................... 12

3.4.1
Main Support Structure ............................................................................. 12
3.4.2
Platforms, Galleries, Stairs and Ladders................................................. 13
3.4.3
Casing and Exhaust Gas Ducts................................................................ 14
3.4.4
Stack ............................................................................................................ 17
3.4.5
Thermal Insulation...................................................................................... 18
3.4.6
Hoist and Lifting Appliances..................................................................... 18
3.4.7
Personnel Lift.............................................................................................. 18
3.5
PIPING ............................................................................................................................ 21
3.5.1
General ........................................................................................................ 21
3.5.2
Feedwater Pipework................................................................................... 22
3.5.3
Main Steam Pipework ................................................................................ 22
3.5.4
Drain and Vent Pipework........................................................................... 22
3.5.5
Chemical Dosing Piping ............................................................................ 22
3.6
PUMPS............................................................................................................................ 22
3.6.1
Economiser Recirculation Pumps............................................................ 22
3.6.2
Boiler Circulating Pumps .......................................................................... 22
3.6.3
Blowdown Pumps....................................................................................... 23
3.7
VALVES .......................................................................................................................... 23
3.7.1
Steam Safety Valves .................................................................................. 23
3.7.2
Feedwater Control Valve Stations............................................................ 24
3.7.3
Steam and Feedwater Valves.................................................................... 24
3.7.4
Drain and Vent Valves................................................................................ 25
P2_02HRSGs_Working_Doc.doc
Page: ii
3.8
BLOWDOWN EQUIPMENT............................................................................................25
3.8.1
General.........................................................................................................25
3.8.2
Intermittent Blowdown Vessel ..................................................................26
3.8.3
Continuous Blowdown Vessel..................................................................26
3.8.4
Blowdown Pump .........................................................................................27
3.9
POWER ELECTRICS......................................................................................................27
INSTRUMENTATION AND CONTROL......................................................................................27
SERVICES REQUIREMENTS ....................................................................................................28

5.1
ACID CLEANING AND BLOWING-OUT........................................................................28
CORROSION PROTECTION......................................................................................................28
WEATHER PROTECTION CANOPY.........................................................................................28
QUALITY ASSURANCE, INSPECTION AND TESTING...........................................................29
Page: 1
GENERAL
This specification includes the design, manufacture, procurement, erection, testing &
commissioning of the Heat Recovery Steam Generator (HRSG) and its auxiliary systems with all
necessary monitoring, control and protection devices for this combined cycle power plant. It
describes the main requirements for each HRSG and its associated equipment, which shall be
provided. In addition, all relevant General Requirements being mechanical, electrical, I&C,
corrosion protection, insulation, etc. given in Part G5 shall also be adhered to. The technical
requirements in this specification shall have priority over the general requirements.
The HRSG design shall allow following all operation conditions (including cyclic operation) of the
gas turbine and the desalination load demands. The capacity of the supplementary firing shall be
such that the BPST together with the desalination units can be operated at design capacity and at
fouled conditions between minimum load and base load operation of the gas turbines.
The electrical consumers shall be connected to the unit auxiliary boards at the related gas turbine.
The Contractor shall optimise the HRSG design on the basis of the performance and design
criteria for the whole.
The Contractor shall offer his standard boiler type however, as far as these specification states
specific design requirements, these requirements shall be adhered to. The following configuration for
the Power Generation and Water Production Station is envisaged:
3 GTs + 3 HRSGs with supplementary Firing + 2 Aux. Boilers + 2 BPSTs
Unless otherwise specified, the data indicated below refer to one HRSG but apply to all HRSGs.
The following basic drawings shall be provided with the bid:
Layout drawing,
arrangement drawings,
sectional drawing of the HRSG including pressure part arrangement,
P&I diagrams,
internal insulation details,
Pressure part arrangement.
SCOPE OF WORKS
Unless otherwise specified, the numbers indicated below refer to one HRSG but apply to all HRSGs.
The main scope of equipment comprises the components shown on the drawing Drwg No
CNE/015/2002-W-00-G-D-00009 HRSG P&I Diagram, excluding the Feedwater System (FW
Tank, FW pumps, etc.) which are under the scope of system P2.8, but including all other
equipment necessary for the safe and efficient operation of the plant.
The HRSG shall include but not be limited to the following main components and systems:
All pressure parts, including steam drums, economisers, evaporators, superheaters, headers,
etc.
Supplementary duct burner system for natural gas complete, including low NO x duct burners,
burner frame, flame stabilisers, ignition burner, UV flame scanner(s), view port windows, fuel
gas valves and instrumentation, and control system complete.
Page: 2
Attemperators including spray water control valve station and all pipe work.
Feedwater control valve stations (2x100%, 1x30%) of the HRSG including isolating valves
located upstream and downstream and control valves as well as a manual bypass valve
Isolating and non return valves in the feed water piping upstream of the HRSG
If applicable, 2 x 100 % economiser recirculation pumps including motors, couplings, frames,

isolating valves (located upstream and downstream), non-return valves, strainers, pressure
gauges, etc.
If applicable, 2 x 100 % evaporator circulating pumps including motors, couplings, frames,

isolating valves (located upstream and downstream), non-return valves, strainers, pressure
gauges
If applicable, soot blower system complete
Blow-down system with continuous blowdown flash vessel, intermittent blowdown flash vessel,
drain pump (if necessary), all pipework, valves and vent silencer(s)
At the HRSG steam outlet to the turbine house: stop valves with handwheel. (Motorised valve
and non-return valve to be provided in the live steam line just upstream the HP header under
the scope of Part P2.7)
The integral piping (piping within the boiler proper, boiler external piping and non-boiler
external piping) including all necessary hangers and supports
Drains and vents including collecting headers, valves (hand-operated and motorised) and all
associated pipework
Drum and superheater safety valves including blow-off pipes and silencers
Structural steelwork and bracing for the HRSG and its auxiliaries, buck stays, weather
protection etc.
Interconnection walkway bridges between the 3 HRSG one at the top platforms and one at an
intermediate platform.
Heat exchanger housing
All exhaust gas ducts including expansion joints, supports, hangers, etc.
HRSG main stack with all necessary insulation, platforms, silencers, emission monitoring
systems etc.
Platforms, stairs, walkways for the HRSG and its auxiliaries
One goods lifting hoist including supporting structure
One personnel cum goods lift common for all 3 HRSGs (for specification refer to Part G5.4,
Clause 20, Lift for Control Building (landings for each platform and cabin external surfaces to
be designed for outdoor conditions; cabin door height and width may be amended as
required))
Fire fighting system
Instrumentation and Control equipment
All required electrical motors auxiliary transformers, LV distribution boards etc.
Overall canopy over the boiler and drum
Page: 3
Sun shades for local instrumentation and control equipment
HRSG thermal insulation and cladding
Boiler filling and emptying system, piping connections and valves for chemical cleaning, boiling
out, steam blowing, etc.
Painting and corrosion protection
Nitrogen conservation system for capping and dry lay-up
Dedicated sampling and dosing systems
All special tools for operation, maintenance and repair (one set per HRSG)
Consumables for erection and commissioning as per Part G4.
Spare parts
All electric motors and electric actuators for valves, etc.
All necessary flanges, blind flanges including scalings and screws
All necessary vents, drains, purging connections complete including stop valves
All necessary pipework, thermal insulation, expansion joints, valves, fixed points, supports,
hangers, fastenings, etc.
Utility stations on each elevation for each boiler
Service water and Service air system
All necessary base frames, base plates, anchor bolts, supports, covers, etc.
All necessary earthing connections / earthing studs and potential equalising measures on all
steel parts of the boiler
Necessary noise prevention measures
All necessary safety measures
All necessary steel parts embedded in foundations (shall be of stainless steel material number
1.4571 conforming to DIN 17440 or equivalent)
Complete detailed labelling of all installations and components
Painting including final painting, corrosion protection and painting measures Part G5.5
Any other items necessary to ensure a safety, reliable and proper function of the HRSG as
considered state-of-the-art engineering and which may not be outlined in this specification.
The HRSG equipment shall include the necessary services as laid out in Part G4.1 Scope and
Extent of the Contract.
Page: 4
EQUIPMENT DESIGN REQUIREMENTS
3.1
BASIC DESIGN AND OPERATING DATA OF THE HRSG
Based on the required steam data a single pressure HRSG with supplementary firing is
anticipated. The HRSGs to be provided shall be of outdoor type ready in every respect to serve its
intended purpose and shall be constructed in large, factory-tested, shippable modules to reduce
installation time. The HRSG shall be of proven design, at least three references shall be provided.
The design, manufacturing and erection shall be in accordance with ASME, DIN, TRD or
equivalent. The boiler shall bear a stamp of an independent authority, e.g. ASME, TV, Lloyds,
etc., for design, manufacturing, erection and repairs (if any) and the respective certificates shall be
submitted to the Employer. The HRSG and its auxiliaries shall be designed for proper, safe and
efficient operation at all loads.
Furthermore the HRSG design shall include heating steam for feedwater tank deaerator. This can
be done with an extraction after the economiser or a completely separate once-through loop,
according to the Contractors practice, but to be approved by the Engineer.
The HRSG shall be designed for a lifetime of 250,000 operating hours, taking into consideration
the number of cold starts as given in Part G4.2 Plant Concept. It is as sumed that the steam
turbine shall work under fixed pressure mode. Maximum load gradients and load ramps described
in Part G4.2 shall also be taken into consideration.
The HRSG shall be designed to operate on the exhaust gas of the GT when fired with natural gas
(NG) as the main fuel and Diesel Oil (DO) as the back-up fuel. Fuel analyses are provided in Part
G4.2.2 Fuel. The heating surfaces of the HRSG shall be designed taking into account the
variation of the exhaust gas temperature profile at any load condition of the GT. When designing
the boiler, heed shall be taken to the fact, that each of the gas turbines can be operated with a
different kind of fuel at different loads even on cyclic operation as specified elsewhere in the
specification.
The steam qualities at the outlet of the HRSG shall fulfil the requirements of the VGB guidelines for
normal operation values when the boiler is operated under the conditions given for boiler water in
the same guidelines of the respective pressure ranges. The following values in the live steam
should not be exceeded:
Conductivity
Silica
Total iron
Total copper
Sodium & Potassium
0.2 S/cm
0.02 ppm
0.02 ppm
0.003 ppm
0.01 ppm
In order to minimise the outage time for inspection and maintenance, provisions shall be made to
allow ready access to the HRSG gas path, tubing and other pressure parts. Access doors with
integral seals shall be provided to prevent gas leakage to atmosphere.
The HRSG shall be equipped with the necessary safety valves including silencers.
In order not to exceed the maximum permissible steam temperature at any load and or transient
conditions, steam attemperators shall be provided.
The design of the HRSG shall ensure that steaming in the economisers is prevented over the
whole range of operation.
Page: 5
Start-up, operating and shut down procedure requirements:

Operation of the HRSG only in conjunction with the corresponding gas turbine. Island operation
with forced draught is not required.
Continuous operation (base and part load) at all possible ambient conditions, all gas turbine fuels
and all gas turbine load.
Start-up Procedure:
HRSG start-up in conjunction with GT-start up (normal start-up):

In this case gas turbine and HRSG are started up commonly without use of the bypass
stack for the gas turbine. That means the gas turbine exhaust gas at start-up is directly led
to the HRSG. Before activating the starting procedure, in combined cycle the BMS system
will give the consent to supplementary firing, burners start-up, only if the flue gas purging
system will have correctly fulfilled the purge of ducts and boiler. The purge will be carried
out by the the gas turbine; the procedure shall however be according to the relevant
NFPA code(s).
HRSG start-up at GT operation

The HRSG shall also be capable to start while the GT is in operation. This shall be
achieved by use of the bypass stack damper to control the flow through the HRSG and by
reducing the GT load such that the requirements for boiler purging according NFPA 8506
are fulfilled.
The permissible stresses caused by temperature change transients of drums, headers

etc. shall govern the power raising of the gas turbine and/or the gas turbine exhaust gas
flow through the HRSG.
Rapid start-up of the gas turbine shall not be met by the HRSG design. In this case the
gas turbine exhaust gas shall be led through the gas turbine bypass stack.
Shut down Procedure:
The HRSG shall be shut down in accordance with a normal gas turbine shut down
The HRSG shall be shut down on the exhaust gas side by switching the exhaust gas
diverter damper from boiler operation to gas turbine operation using the bypass-stack.
The Contractor is obliged to consider all components necessary to fulfil the specified
requirements. The HRSG shall be designed to cope with the operational cases (load
points) as specified.
Page: 6
3.2
PRESSURE PARTS
3.2.1 Steam Drum(s)

The HRSG shall be provided with adequately dimensioned drum(s) to ensure stable operation
under all load conditions as specified.
The drum shall be outside the flue gas passage.
The storage capacity of the drum must be large enough to ensure, in case of a cut-off of the
feedwater inlet flow:
a retaining time of at least 2.5 minutes from normal operation level to trip level at normal
steam flow (GT + SF full load)
a safe shutdown of the HRSG without damage after initialising closing the bypass stack
damper (taking into account the closing time of the damper) or trip of the GT and SF at
low low drum level.
Transient operation shall not lead to such strong swelling or fluctuations of the drum level in such a
way that any protection action (holding time, gradient limitation, shutdown) is initiated.
The level difference between normal water level and low water alarm level shall be not less than
150mm.
The normal water level shall be indicated by engraved marks on the drum, repeated on a plate
located outside of the insulation, and on the level gauges.
The drum shall be provided with a manhole at each end, the manhole being arranged to swing
inward on a hinge, attached to the inside of the drum.
The drum with connections shall be fully shop fabricated and fusion-welded throughout. Site
welding directly on the boiler drum is not permitted. Tube stubs, suitably prepared for welding, shall
be provided at the drums if tubes are to be welded at site. Al l nozzles shall be final welded to the
drum. The nozzles shall be long enough to ensure that the base weld is not affected by the
subsequent welding on site and that valves, mountings and fittings can be cut off and re-welded
without damaging the insulation lagging or the drum.
Steam water separators of the e.g. cyclone type shall be arranged in the boiler drum. In addition to
the cyclone separators, the drum shall be provided with all other required steam purifiers and
steam deflecting baffles. The design and arrangement of these internals shall be such that the
mechanical carry over of boiler water in the saturated steam entry to the primary superheater is
limited to <0.1%
The design of the drum internal fittings shall allow quick and easy removal and replacement of all
parts for inspection and maintenance purposes. Arrangement and fabrication of all internal
equipment shall be provided so as to permit removal and replacement through the manholes.
The attachment of internal fittings etc. to the drum shall be such as to prevent movement while the
unit is in service, but, except where specifically approved otherwise, they shall not be welded to
the internal surface of the drum. Bolts and nuts inside drum shall be fitted with cap nuts.
Thermocouples, to measure the differential metal temperature of the boiler drum(s) shall be
provided. The thermocouples shall cover six positions, i.e. three on the bottom and three on the top
of the drums.
In order not to cause any thermal stress on the drum even when feeding the drum with "cold"
feedwater, e.g. when the unit has been stopped, the feedwater inlet pipe to the boiler drum shall be
Page: 7
equipped with thermal sleeve in order to avoid direct contact of the water inflow pipe with the
drums' shell.
Internal fittings shall be provided for the extraction of the continuous blow-down and chemical
dosing over the whole length of the drum. One start-up as well as an emergency blow down shall
also be provided.
Materials in areas of the drum where the temperature and flow velocity is in the range that is
known to cause flow accelerated corrosion shall be corrosion/erosion resistant.
The drum shall be equipped with a nitrogen feed-in system for short time conservation of the steam
sections of the HRSG (capping) with necessary piping and valves . The N2 bottles shall be stored
on ground level under the shaded roof.
3.2.2 Heat Exchanger Tubes and Headers

The heat exchangers shall be pre-fabricated to modules in the shop as far as possible to reduce
site welds.
All tubes used in the HRSG shall of seamless type and can be equipped with fins. The fin density
shall take into account the fuel type and quality and additive dosing, to prevent excessive fouling
and frequent cleaning / soot blowing. The fin thickness shall not be less than 1.0 mm.
The materials used shall be in line with the adopted design standard however, the last stage of the
superheater shall not be inferior to P91. Material of the fins shall be of heat resistant material in
accordance with the temperature range of the HRSG.
Elbows spools in the temperature and flow velocity range that is known to cause flow accelerated
corrosion shall be made of corrosion/erosion resistant material.
The connection tube to header shall be of the full penetration weld type, at least for alloyed
material (i.e. T11, 13CrMo44 or higher) and the header material shall be of the same material as
the tube material.
Headers shall be fabricated from seamless steel pipes. In case of a horizontal type HRSG, all
lower headers shall have a drain of at least DN50. Special provisions shall be made for a
temporary flushing connection at both end of each header. The size of the connection shall be
such that it ensures sufficient velocities during chemical cleaning and it shall also suit for inspection
and for cleaning by hand.
All pressure parts (both water and steam section) shall be fully drainable and ventable, i.e. at every
low point there must be a drain and at every high point there must be a vent. Draining shall be
possible only by gravity, without the need to pressurise the HRSG.
Special attention shall be paid to pressure drop and flow velocity, so that a stable distribution and
faultless cooling of the HRSG's tubular system is obtained under all operating conditions.
Attention shall be paid to the vortex shedding frequency to avoid any resonance resulting in
excessive tube vibration or loud humming of the whole HRSG.
The modules must be supported by steel structure; they shall not rest on internal insulation. The
tubes must be able to expand freely, without any bending. The lateral movement of tubes shall be
restricted in order to prevent dislocation of the tube. Spacer strips which were are welded to tubes
or fins shall normally be of the same material as the tube or fin. However, the Contractor shall
check whether the higher temperature off the strip requires a more heat-resistant material,
Precautions shall be taken to avoid local over heating of the tube walls.
Cross-over piping may be external of the HRSG casing and shall be of the same material as the
tube bank header upstream.
Page: 8
Design shall ensure that no support, hanger, seal/baffle plate shall be around, rest, touch or slide
over bare tube surfaces. When there is a possibility of contact, rubbing or sliding the tubes shall be
protected by proper reinforcement sleeves/saddles.
3.2.3 Economiser
The economiser shall be designed to ensure stable non-steaming operation throughout the full
operating range of the HRSG under all load conditions.
The feed water and flue gas flow must enter and leave the economiser in counter flow pattern
3.2.4 Evaporator
The evaporator systems shall be designed to operate over the full load range of the GT without
drumming or vibration and the design shall ensure an even distribution of water through the tubes.
Natural circulation design is preferred.
The downcomers shall be designed to achieve a uniform circulation ratio to the individual
evaporator tubes over the full load range.
3.2.5 Superheaters
Special attention shall be paid to pressure drop and flow velocity, so that a safe and stable
distribution and faultless cooling of the boiler's tubular system is obtained under all operating
conditions. The superheater stages shall be fully drainable.
The superheater tubes material shall not be inferior to 13CrMo44 (equivalent to T11) for steam
outlet temperatures up to 450oC and shall not be inferior to 10CrMo910 (equivalent to T22) at
steam outlet temperatures above 450oC up to 535oC.
In case the boiler design requires that the steam outlet temperature of the boiler exceeds 535oC,
the material used for the last superheater section shall not be inferior to X10CrMoVNb91
(equivalent to SA T91 respectively P91).
All header materials shall be of equal quality as the tube materials with which they are connected.
An approved number of thermocouples shall be supplied for measuring and recording metal
temperature during pre-commissioning trials and normal operation on a temperature recorder to be
provided under this Contract.
During commissioning the Contractor has to demonstrate that the metal temperatures are not
greater than the design metal temperature as stated in the Data Sheets.
Provision shall be made in all headers and inter-stage piping to accommodate test pressure
gauges and quick response thermocouples.
3.2.6 Desuperheaters
The desuperheaters shall be of the variable spray nozzle type, to ensure proper atomisation over
the whole range of operation. The last attemperator shall be installed upstream of the last
superheater section i.e. water injection into the live steam line upstream of the steam turbine is not
permitted.
In order to reduce thermal stresses on the desuperheaters and the steam pipework to its minimum,
the desuperheaters and the steam piping shall be equipped with thermal sleeves i.e. protection
liners
Page: 9
Feedwater shall be used for spray water, which shall be branched off upstream of the drum level
control valves. Injection water flow measurements shall be provided on the main line as well as on
all branch lines.
3.3
SUPPLEMENTARY FIRING
3.3.1 General
The HRSGs shall be equipped with supplementary duct burners firing natural gas.
The most modern design of burners) shall be used to avoid pulsation and the most up-to-date rules
and regulations for safety and fire hazard shall be observed (e.g. NFPA, TRD) for the firing
equipment. The NO X emission level of the exhaust gases shall only be marginally influenced by the
supplementary firing. The NO X level over the load range of the supplementary firing shall be
guaranteed and stated in the relevant data sheets.
The duct burner must also comply with the environmental requirements stated in Part G4.
Measures to be taken to ensure that there will be no flame impingement under any operating
conditions.
The duct burner shall operate with a 10 to 1 turn down ratio and a stable flame over the entire
range of operation.
Each duct burner shall be provided with ignitors and two UV flame scanners. The flame detector
monitoring system shall incorporate a self-checking facility and shall be arranged so that at the
failure of the two detectors the relevant burner shall trip and initiate an alarm in the control room.
Flame loss shall be detected by the two detectors to trip the relevant burner. Scanner cooling air
shall be provided from redundant air blowers. Flame scanners shall be replaceable on line, isolated
with an airlock and valves. Ignitors shall also be replaceable during operation. Viewing ports shall
allow visual confirmation that all burner rows are firing.
The duct burner shall be capable of local emergency stop and remote operation. Remote operation
from the DCS shall consist of manual and automatic initiation and control over the whole load
range. The duct burners shall be ignited from the control room (operator initiated) and shall be
automatically controlled. Duct burner firing ratio control shall respond to input signals from the
DCS. Shutdown of one burner element shall not cause the other burner elements to shutdown.
The fuel supply to the burners shall be safeguarded by an automatic safety shut-off system. Each
automatic safety shut-off system shall be fitted with double block and vent as a minimum protection
against fuel leaks into the HRSG. Fuel gas flow control valves shall be provided dual redundant
(2 x 100%) for each HRSG unit. The same redundancy shall be provided for the pressure control
system of each fuel. Duty / standby selection facility shall be provided with automatic switchover to
the standby control valve upon failure of the duty valve in a smooth i.e. bumpless transfer. Each
control valve shall have upstream and downstream motorised isolating valves. If pressure control is
provided for fuel gas, it shall also be provided with dual redundant pressure control valve with duty
/ standby concept.
The vent shall terminate in a safe location and shall be protected against accidental isolation and
the ingress of rainwater.
In addition with other components, it shall be possible to prove whether all the shut-off valves in the
system are leak tight.
With the mode of supplementary firing proposed it shall be guaranteed that:
emission values of NO x , CO, SOx and particles are in the specified range
start-up is fast, safe and reliable
Page: 10
combustion is safe and stable at all gas turbine and HRSG loads and load fluctuations
there is no flame carryover into the HRSG during any operating condition.
operation of the burners is easy and safe
the flue gas mass flow and temperature distributions are uniform at the HRSG inlet.
3.3.2 Burners
All burners shall be capable of burning natural gas exclusively.
Good, reliable operation of the burners, without risk of soot formation, harmful flame impingement
or flame instability is essential. There shall be no excessive vibration of part or the whole of the
HRSG, or ducting. These requirements shall apply with the specified fuel, over the whole range of
automatic control.
There shall be no back flow of flue gas into the natural gas fuel system and resultant internal
corrosion to pipes and valves connected with duct burners especially when the burners are not in
operation.
The flames shall not be unstable or blow-off
due to flame scanner cooling air effect
in the case of minimum load on the burner and the maximum turbine exhaust gas flow that can
arrive at the burner
in the event that the highest possible fuel pressure occurs. This may happen if by accident the
control valve opens fully. If the flames would be blown off when the burner is subjected to
maximum fuel supply pressure, the control valve shall be provided with a maximum
mechanical stop to prevent blow off.
Burners and associated equipment shall be capable of withstanding the maximum turbine exhaust
gas temperatures and fuel pressure specified.
The burner elements shall be made form high quality material and shall be mounted on the
individual gas supply line.
Pneumatic quick closing combinations with manually operated shut off ball valves (with limit switch)
shall be installed in the common line to burner elements. In the event of a failure on two flame
scanners, the quick closing valves shall switch off this part of the supplementary firing system.
Supply of the UV cells with cooling air shall be assured from a cooling air system. This system has
to be in operation also when supplementary burners are shut down and the HRSG is only heated
with turbine exhaust gas.
Via the Burner Management System (BMS), the HRSG protection criteria and also the required
signals from and to the GT turbine shall be interlocked. In the BMS the duct burners shall be
interlocked.
The burners shall be grouped for control. The NG system shall be such that the last section of
pipe, which shall have the chance of exhaust gas contact, shall be of non corrosive steel.
Adequate drain facility shall be provided in NG pipes to burners.
3.3.3 Ignition System

Each burner shall be provided with its own ignition unit, which shall include a fixed transformer and
spark igniter, an ignition / pilot burner and a flame safeguard, all suitable for intermittent operation
Page: 11
in pressurised combustion chambers. The ignition / pilot burner shall be designed to have only one
fixed position in the burner. These units shall be fed from the fuel gas main system.
The flames of ignition burners shall be stable on any specified fuel, in the case of the maximum
turbine exhaust gas flow arriving at the main burners.
Trial for ignition time
Ignition of supplementary firing burners shall be fully automatic and safeguarded by sequence
control and flame detection devices. Therefore supplementary fired HRSGs shall be designed to
comply with one of the following criteria for trial ignition.
These two criteria are given in order to cover the two basic types of supplementary fired HRSGs to
which this specification is applicable.
The Dilution Criterion
The dilution Criterion should be applied to HRSGs which are designed for flue gas flow in one
direction only between inlet and outlet and/or contain no dead pockets or areas of possible turbine
exhaust gas recirculation in which ultimately explosive mixtures of fuel and turbine exhaust gas
may accumulate. In addition these HRSGs shall be fired with matrix or other type of multiple
burners which are designed to distribute the heat release evenly across the inlet area of the
combustion chamber and thereby ensuring a good dilution of the fuel in the turbine exhaust gas
stream at start-up. In general, the total fuel gas flow at start-up shall be limited to the extent that
the average fuel/turbine exhaust gas mixture remains well below the lower explosion limit. A
delayed ignition, therefore, will not cause any harmful pressure increase and the ignition time will
not be critical.
Matrix burners or other types of burners may be started individually or simultaneously provided the
following conditions apply:
the turbine exhaust gas flow remains at more than 50% of the maximum load value
the fuel gas flow is limited such that the average fuel concentration in the combustion
chamber remains less than 10% of the average stoichiometric fuel/turbine exhaust gas ratio
the time for verification of main burner ignition shall be in accordance with German Technical
Rules for Steam Boilers TRD 412.
Energy Criterion
The energy criterion shall be applied to HRSGs which are designed for flue gas flow in more than
one direction between inlet and outlet and for this reason contain dead pockets or areas of
possible turbine exhaust gas recirculation in which ultimately explosive mixtures of fuel and turbine
exhaust gas may accumulate.
The trial for ignition time t (s) shall be estimated with the formula:
t=
0.42 V P
G LHV
Where:
V = combustion chamber volume in m 3
G = fuel gas flow rate to the burner under start -up conditions in kg/s
P = Flue gas side design pressure in barG
Page: 12
LHV = Lower heating value of the fuel gas in MJ/kg
This assumes that the combustion chamber and its connected ducting will not suffer severe
damage as a result of an internal pressure increase, of short duration, of up to design pressure.
It does not exclude, however, that some permanent deformation may occur after a sudden
pressure increase.
The trial for ignition time derived from the above formula shall be treated with some reserve. In
principle, if ignition fails, the burner tight shut-off valve shall be closed before the calculated trialfor-ignition time, or the values according to TRD 412 or equivalent whichever is the smaller, has
elapsed. Usually, the very minimum trial-for-ignition time acceptable under automatic start-up
conditions is of the order of 3 seconds.
Burner piping
Piping and piping connections in the immediate neighbourhood of the burners are considered part
of the burner supply. The layout shall be clear and simple and the piping shall be rigid, accessible
and vibration free.
Collection of water and condensate in the common header external to the burner, supplying
Natural Gas shall be eliminated. Rust scale block the burner nozzle holes shall be avoided. The
hoses shall have enough inclination to avoid settlement in the hoses. Condensate or any
bituminous product carry over to the ball valves which arc detrimental to the free operation of the
valves shall be designed with efficient filtering system.
Flexible metal hoses shall be provided for ignition burners and auxiliary air line connection.
3.4
HRSG STEEL STRUCTURE
3.4.1 Main Support Structure

The requirements under Part G5.4.12 General Technical Requirements Civil apply.
In addition, the design of the steel structure for the HRSG shall meet the following requirements:
The supporting structure shall be designed considering the internal forces and expansions, as
well as forces from wind, earthquake, etc.
Consideration shall be made that the steel structure can also take over forces of the steam
and water pipes, which will be supported by the HRSG main columns
In addition to this, the steel structure must be able to withstand the forces resulting from water
filling of the HRSG and pipes during the hydraulic test. Especially heat exchanger module
supports shall be designed for the maximum load, including the load resulting from hydrostatic
testing at site. The material shall be suitable for the most adverse conditions of service. For
high-temperature service, cooled supports are preferred.
Special care shall be given to the design of pipe racks for steam pipes, which must be able to
support these pipes during water filling (hydraulic test or acid cleaning). In order to avoid overstressing of the pipe racks and the associated foundations, the most critical loading condition
shall be considered
Stairs and platforms shall be supported in such a way that no additional forces shall be
introduced into the HRSG body
All nuts, bolts and washers shall be galvanised.
Page: 13
The HRSG shall be arranged with its total pressure parts comprising of steam drums,
superheaters, evaporators, economisers, headers, integral pipework, etc. in the form of a selfcontained unit supported by its own steel structure. In the extent of this item, the following shall be
included but not be limited to:
HRSG main columns and girders
Supporting structure for platforms, stairs and galleries
Supporting structure for the exhaust gas ducts
Pipe racks for pipes located in HRSG area
Supporting structure for the HRSG stack
Supporting structure for goods hoist
Girders for fixing lifting appliances shall be installed above all components having a weight of
heavier than 50 kg when dismantling and assembling equipment for maintenance and
overhaul
Access platforms and galleries for maintenance and operation of all equipment described
(drum manholes, water columns, gauge glasses and their shut off valves, safety valves, all
other valves associated with the operation of the unit, access doors, inspection ports, entrance
doors, etc., for entire unit including economisers, evaporators, superheaters, ducts, etc., steam
temperature control devices, etc.). All valves and instruments shall be accessible from fixed
installed platforms, wherever possible. Mobile facilities will not be accepted.
One set of full height stairs from grade to top platform of unit, shall be furnished and installed
for the HRSG.
All steel structure shall be delivered complete with base plates, anchoring bolts, embedded
items etc.
All parts of steelwork and foundation bolts which are required to be built into foundations, or are
necessary for the support of the plant, shall be the first priority of delivery.
3.4.2 Platforms, Galleries, Stairs and Ladders

The requirements under Part G5.4.12 General Technical Requirements Civil apply.
In addition, the design of Platforms, Galleries and Stairs for the HRSG shall meet the following
requirements:
The free height in all places shall be minimum 2.20 m
The minimum width of walkways shall not be less than 1000 mm, even if access is required
only for control and inspection.
Ladders will not be accepted as means of main access to places where frequent maintenance,
checking and inspection have to be performed. Ladders shall be used only in special cases
with prior approval from the Engineer.
All platforms, walkways, galleries shall be covered with galvanised steel gratings with a
minimum height of 45 mm. Covering of platforms with chequered steel plates shall be done
only if required to avoid or reduce natural draught
Interconnection on passages with the HRSGs top platforms at each HRSG shall be provided
All walkways, galleries and platforms shall be provided with kicker plates of 100 mm height
Page: 14
Railings shall be provided with one handrail and two intermediate rails
All main areas shall have sufficient emergency exits, i.e. at least 2 (two) exits. At least one of the
two must be via stairs, the other one can be a ladder, if it is not frequently used for operation or
maintenance purpose. The requirements for these stairs and ladders are:
The stairs shall be designed in accordance with the following requirements:
The minimum width of the main stairs shall not be less than 1000 mm
The allowable inclination of stairs shall be 45
The treads shall be of galvanised welded gratings of a height of 32 mm with cast abrasive
nosings
The treads shall overlap at least by 20 mm
The landings shall be covered with galvanised steel gratings
In addition to the main stair, independent partial stairs between certain levels shall be
provided, if required
All stairs shall be provided with kicker plates of minimum 100 mm free height on both sides
Handrails shall be provided with two intermediate rails
As the basic requirement, fixed ladders must comply with the safety requirements as stated in the
applicable codes & standards. Furthermore:
Ladders shall be at least 0.40 m wide.
All ladders shall have a walk-through fork extension with a safety barrier at the top.
Any ladder longer than 2.5 meters must have a safety cage.
At least every 16 threads there must be a landing platform.
3.4.3 Casing and Exhaust Gas Ducts

General
Each GT shall be provided with an independent exhaust system to direct the exhaust gas coming
from the gas turbine through the HRSG to the stack. The whole exhaust system shall be designed
to withstand a back pressure of not less than 50 mbar(g). Design temperature shall include a
temperature allowance of 30 K.
Framing members for the HRSG enclosure plates shall be arranged in such a way that they form a
rigid self-containing construction.
The casing plates shall be designed to avoid drumming, vibration and any resonance with the
exhaust gas pulsation under all operating conditions.
The casings shall be arranged in convenient sections adequately stiffened to avoid distortion due
to thermal expansion. Particular care shall be taken to ensure gas tightness, especially where
tubes pass through the casing.
The heat exchanger tube banks of the HRSG shall be mounted in suitable thermally insulated
enclosures, which shall be leak-proof preventing leakage of hot gases.
Page: 15
The ductwork should be of welded steel plate construction suitably stiffened. The wall steel plate
thickness shall not be less than 8 mm for carbon steel material and 6 mm for high temperature
resistant steel.
Guide vanes shall be provided where direction changes, and when required to assure uniform flow
distribution.
The casing concept with application of internal and external or cooled furnace shall be clearly
stated by the Contractor and approved by the Engineer.
The exhaust duct system shall be complete with all necessary expansion joints, vibration isolators,
supporting steelwork, flanges, inspection doors, blind plates, thermal insulation and cladding, and
anything else required to complete the system. The material of the ductwork, expansion joints and
all other parts of the exhaust system shall be suitable in every respect, for thermal cycling and
continuous operation at max. temperature conditions of the GT.
The entire exhaust gas ductwork shall be sufficiently lagged and cladded for protection of
personnel. The lagging and the cladding shall be secured to the ducts in such a way that thermal
expansion of the system does not cause any defects.
The ducts shall be designed in such a way that rain water falling onto the duct shall flow off
completely.
The exhaust duct system shall be designed to avoid drumming, vibration and any resonance with
the exhaust gas pulsations under all operating conditions.
There shall be no restriction to the free expansion of tubes by insulation and sheeting.
The materials shall be adequate for the temperature of service. All sheeting shall be sufficiently
stiffened against damage during transport, erection, operation and vibration.
Stiffening shall not interfere with the free expansion of the casing.
The casing design and construction shall facilitate the removal and/or installation, at site, of tube
bank coils. Also, the design shall allow convenient access for cutting and rewelding of inspection
end caps on headers.
Provision shall be made for wet cleaning of the heating surfaces which shall be manufactured of
finned or plain tubes. Provision shall be made for drainage during cleaning.
The casing wall temperature shall be above the highest dew point temperature of the flue gas
during any operating condition.
If necessary a heat-resistant metal refractory (heat shield) should be foreseen for wall areas with
high temperature. Between the heat shield and the HRSG casing a thermal insulation shall be
provided.
Observation and access
The gas duct system shall be provided with access manholes on all positions of the exhaust
system where inspection and maintenance is required, on both sides of the HRSG. The cross
section of the manhole shall not be less than 600 x 600 mm. At the location of the access manhole
adequate landing supports (made of round steel bar) shall be provided inside the exhaust system,
where there is no obvious landing within 1 meter of the manhole. All doors shall be perfectly tight
when closed.
Page: 16
The Contractor shall supply a suitable number of access lanes between the appropriate tube banks
of the economiser, boiler and superheater sections.
Where applicable, i.e. in the Duct Burner area, observation windows shall be provided and shall
afford an unrestricted view of all burners and flames. The windows shall also allow observation of
all surfaces.
Where necessary, air purging shall be provided to keep observation windows sealed, clean and
cool. The glass shall have external covers to prevent cracking and shall be protected on the hot
side by pivoting metal plates.
It shall be possible to renew the glass during operation, using barrier air or the above mentioned
pivoting metal plates.
There shall also be a sufficient number of access and inspection doors and access space for each
section or tube bank of the HRSG.
Cleaning of the tube banks shall be possible, when the gas turbine and the HRSG are out of
operation.
The minimum distance for access between convective tube banks shall be 800 mm.
Access doors shall have a free opening at least 600 x 600 mm and shall be located on both sides
of access spaces. Hand-rails for a safe access shall be available.
Gas flow induced vibrations
The Contractor shall include in his design all measures necessary to ensure that no part of the
HRSG installation and ductings shall be subject to any vibrations which are induced by gas flow
and which may reduce the design lifetime of any part of the HRSG and ductings, or create
equipment noise exceeding the limitations as per data sheets.
The design measures shall include, if necessary, provision for the installation of damping
equipment after the initial start-up of the HRSG. Baffles shall preferably be installed in line with the
direction of gas flow.
The Contractor shall take particular care in the design to ensure that the frequencies of gas vortex
shedding from the tubes do not excite or resonate with the natural frequencies of the superheater,
evaporator and economizer tubes. In addition, such vortex shedding frequencies shall not excite or
resonate with the acoustic frequencies of the HRSG casing or ductings. That is to say that
standing waves shall not be generated.
The Contractor shall state after contract award, the Strouhal numbers and the gas vortex shedding
frequencies for each tube bank, as well as the lower natural frequencies of the tubes, and the
acoustic frequencies of the HRSG casings.
Ducting shall be designed with the minimum number of bends. It shall be gas-tight and smooth and
bends shall have rounded profiles and be fitted with guide vanes.
Guide vanes shall be designed to avoid resonance and the formation of eddies in the gas turbine
exhaust gas stream. They shall have a tapered and smooth leading edge. Attachment to ducting
shall be by welding and allowance shall be made for differences to thermal expansion.
Ducting shall be sufficiently stiffened against mechanical vibration and distortion. Stiffening shall
not restrict the free expansion of the ducting in any direction.
Effective vibration isolation from the gas turbine is particularly required. It shall be possible to drain
all ducting. All ducting shall be designed such that the free cross-sectional area will provide stable
gas flow and acceptable pressure loss.
Page: 17
Transition pieces between duct sections of different cross-sectional are shall be provided as
necessary. These shall be designed with the objective of preventing flow detachment from the duct
wall and providing the most economical pressure loss.
Duct supports shall be designed so as to remove all loads from the HRSG casing. Sliding supports
shall be designed to allow lateral and axial expansion movements of the ducting.
The design of the HRSG inlet ducting shall be such that the gas turbine exhaust gas mass flow
shall be evenly distributed in particular when burners will be provided. If applicable, guide vanes
shall be foreseen. The distribution to the burners shall meet the requirements of the burner
manufacturer minimum requirement.
No baffle plates shall be installed in the transition part. If applicable upstream of burners a
perforated plate made of stainless steel in order to equalise the TEG flow shall be provided.
Burner flames shall not impinge on duct walls or HRSG tubes or any metal part during any
operating condition.
Expansion Joints
Fabric type with inner sleeves expansion joints shall be installed within the ductwork wherever
required, to prevent undue thermal stresses and shall be able to compensate full movement of the
ductwork.
They shall be of high temperature fabric, multi-layered and reinforced with stainless steel wires or
of metallic type. The fabric shall be protected internally by insulation and metal sleeves. External
protection shall be by stainless steel wire mesh. All metal parts in contact with the expansion joint
fabric shall have rounded edges
Generally the Contractor shall follow his standard design, but they shall however not be of sliding
type and shall be provided with flanges in order to be able to replace them without disturbing the
ductwork. Inside the ducts, all expansion joints shall be protected against ingress of dirt and debris.
Special attention is to be paid to prevent that the joint insulation soaks water or fuel oil from failed
GT starts or washing.
Adequate access shall be foreseen for removal of the joints.
Expansion joints shall be of a make and type approved by the Engineer. Adequately ventilated rain
shields shall be fitted to all expansion joints.
3.4.4 Stack
The design and manufacturing shall be in compliance with DIN 4133 or equivalent standard. When
designing the HRSG stack, the max. wind speed, earthquake factor, etc., as stated in Part G4.2
and G4.3 shall be taken into consideration.
The HRSG stack shall be of carbon steel construction and shall have a sufficient height above the
0 m level of the Plant to meet Dubai Municipality environment regulations. It shall be at least as
high as the gas turbine bypass stack i.e. min. 60 m above the ground level.
It shall be corrosion protected inside and outside in accordance with Part 5.5 Corrosion Protection
and Painting.
In case a horizontal HRSG is provided, the bottom of the stack as well as a height of about 1.0 m
shall be clad with stainless steel plates. A drain valve of minimum DN 50 mm shall be provided.
The HRSG-stack shall be provided with an access door located conveniently in the base section. It
shall also be provided with a platform at the top level around the full circumference. A continuous
ladder with enclosing safety cage and intermediate platforms shall be provided in accordance with
Page: 18
DIN and VGB guidelines or equivalent. The access ladder shall be extended to the top of the stack
for inspection purposes.
Lightning rods shall be provided as well as aircraft warning / position lighting, which may extend
over the specified height, which shall be designed in accordance with the regulations of the
International Civil Aviation Organisation (ICAO) and to be approved by the Dubai Civil Aviation
Authority, Dubai Airport. The exhaust stacks shall be painted red and white as per above
mentioned international and national regulations, respectively as decided by the Employer.
At the mouth of the stack, a deflector ring of stainless steel of adequate external diameter shall be
arranged to prevent down-flow of gases on the outside of the stack at extreme low loads.
Lugs of corrosion resistant material shall be provided externally at the top to allow fastening of
pulley blocks, for inspection and maintenance.
The bottom of the exhaust gas duct system shall be sloped towards a drain collection point. The
drain point shall be provided with sufficient drain pipes (size 80 mm) and plugs, which shall be
arranged for easy access.
In case the Stack is insulated, the insulation shall be in compliance with the Part G5.1 General
Requirements for Mechanical Equipment - Insulation. Personnel protection shall be provided up to
about 4m above the ground level and at all other relevant areas if the chimney will not be
insulated.
Earthing shall be in accordance with the requirements of the relevant electrical specification.
3.4.5 Thermal Insulation

With the exception of the stack, all exposed parts of the HRSG and its auxiliaries with an operating
temperature of more than 60 C shall be thermally insulated. Personnel protection shall be
provided at areas with higher temperatures where insulation is not required.
Since the HRSG casing will be insulated inside, the insulation material used shall not deteriorate in
case it is soaked with water due to a HRSG leak. Materials used for the cladding as well as fixtures
of cladding of inside insulation where the gas temperature exceeds 400 C shall be of high
temperature resistant steel (i.e. equal or better than 1.4561).
Outside cladding of the thermal insulation shall be made of salinity climate resistant aluminium
sheets 0.8 1.0 mm depending on the components/parts to be clad.
However, all the details given under clause G5.1 shall also apply.
3.4.6 Hoist and Lifting Appliances

Sufficient lifting appliances shall be provided for easy maintenance and repair.
Girders for fixing temporary lifting appliances shall be installed above all components having a
weight of heavier than 50 kg for maintenance and overhaul.
As a minimum 1 (one) permanent motorised hoist (500 kg capacity) shall be installed on the top
platform of each HRSG. Landings and access platforms shall be provided at each main platform
(from the ground floor to the top platform.
Further requirements are stated in Part P2.21 Cranes and Hoists.
3.4.7 Personnel Lift

The required number of personnel lift installations shall be one (1) common lift for all 3 HRSGs, at
the HRSG closest to the Central Control Room Building, designed as cable-operated lift with
traction machine, including but not be limited to:
Page: 19
The car two sectional automatic telescopic-sliding doors
The counterweight and cladding of the counterweight runway in the shaft pit
The lift machinery including driving-pulley, gearbox, clutch, brake and motor, as well as the
motor overload protection device
All load and control ropes as well the bottom chain or bottom ropes required for compensating
the weight of carrying ropes
Guides rails for car and counterweight
The necessary devices for monitoring speed and the safety gear at the car
The necessary equipment for floor selection switching and for automatic door operation
The necessary stops, buffers and limit switches for car and counter weight
The shaft lining between the shaft doors where necessary
Complete electrical control equipment, including all contractors, relays time switches, etc., as
well as the control cabinets required for these
All necessary devices for the ventilation of the machinery room such as fans, filters, ducts, etc
The all-pole mains isolating switch (main switch)
All control panels and control switches
Telephone equipment for car and lift machinery room, designed as telephone system for
connection to the internal communication system, including cables and the complete
emergency signalling equipment
Illumination and ventilation of the car
Lift shaft illumination
The auxiliary power supply for alarm signal, ventilation and illumination in the car
The necessary equipment for inspection and moving of the lift
One hand-lamp each, with approx. 6 m connection cable with plug on the top of the car and in
the machinery room
Design Features:
The lift (s) shall be designed, manufactured, erected and tested according to accepted standards.
If the specification contains requirements beyond the requirements of the standards, the
requirements of the specification shall have priority.
The lift shall be heavy-duty industrial construction type suitable for outdoor installation. the steel
structure design shall be capable of transferring the vertical loads to the foundations.
The lift shafts and machinery rooms of the boiler lift will be of all steel construction with sheet metal
cladding and heat insulation on the outside.
The car shall be made of stainless steel. An anti-drumming substance is to be applied on the outer
surface. On the inside, the car shall be provided with skirting strips, a handrail made of anodised
aluminium and two protecting strips made of hardwood.
Page: 20
The floor shall be made of sheet steel and are to be provided with plastic floor covering (PVC or
equivalent)
A fan and illumination are to be fitted in the car ceiling.
During the erection period, the sides of the car (without doors) and the floor of the cars shall be
provided with protective covering (hardboard panels or similar). The protective coverings shall be
removed by the Contractor after the erection period.
The car shall have 1 (one) entrance each, provided with fully automatic telescope-type sliding
doors, made of stainless steel.
Photo-electric light barriers are to be fitted at the car entrance.
A floor indicator with floor symbols and up and down arrow is to be provided in the car.
The car roof is to be fitted with three-sided, twist-resisting railing. A mounting plate fixed to the
railing must be fitted with all equipment and power sockets required for inspection rides, repair
works, etc.
The lift shall be equipped with an adjustable overload protection device with a visual and audible
signal in the car.
The car control panels shall obtain the floor selector buttons, an alarm pushbutton, a door
operating button, visual and audible overload indication, and out-of-service indication, the priority
control key switch and the fan switch.
All floor selector button including the lift call buttons on the outside panels shall be designed in
the form of pushbuttons with call acknowledgement.
At every landing call acknowledgement buttons and an out-of-order sign have to be provided.
The door and locking contacts are to be fully enclosed design, dustproof as far as possible with
additional safety contacts to prevent operation of the lift if the door is not properly closed and to
prevent re-opening of a door not fully closed after the lift has departed. An emergency unlocking
device must be fitted to each door.
Lift shaft illumination shall be provided at each landing and at intervals of not more than 3 m. In the
pit of the lift shaft illumination must also be provided as well as a power socket. One switch each is
to be provided in the machinery room and in the pit of the lift shaft.
The cabin and counterweight guides shall be design in the form of roller guides.
The buffers for the car and counterweights in the pit of the lift shaft shall be of oil-hydraulic design
and must be equipped with a sight glass or dipstick for checking the oil level and also with an
electrical safety device. This device must prevent the lift from operating if the buffers are not fully
extended and/or operational.
The safety gears shall be of the progressive type.
Instantaneous types of safety gear are not progressive type.
The control voltage shall be 220 VAC. The control voltage shall be produced by the control
transformer to be delivered by the supplier of the lifts. The entire switchgear shall be installed in
separate lift machinery rooms provided for this purpose above the shafts.
In the event of failure of the main voltage for car illumination, alarm equipment and ventilation, the
emergency power supply must be able to keep the alarm equipment and ventilation operational for
at least four hours.
During that period emergency illumination must be effective in the car, too.
Page: 21
For the telephone, cabling, screened telephone cable is to be used. The scope of delivery includes
cabling from the car to the machinery room to a connection point outside, including the terminal
box required.
Telephones shall be of a wall-mounting design. In the car, a telephone is to be placed in recesses
next to the car panel. The Employer / Engineer will decide the make and the type of telephone.
Controls are to be provided with a fine adjustment facility, which automatically compensates for the
rope elongation occurring during loading and unloading, and guarantees a constant flush position
of the car.
The fastenings of the lift machinery have to be provided with sound absorbing bases to prevent
excitation of mechanical vibrations.
All motors, switching installation and switchgear must be designed for an ambient temperature of
at least 50 C and must be fully operational at this temperature.
In the machinery rooms forced ventilation shall be provided in order to keep the temperature in the
rooms to a maximum of 50 C. A dust filter must be fitted at the forced ventilation air intake. The lift
machinery shall be equipped with special drive motors, clutches, brakes, brake disc and gears with
drive pulleys.
The brakes are to be designed as double-shoe brakes with magnetic brake motor.
The gears are to completely enclosed and must run in an oil bath.
The drive are to be equipped with electronic control ensuring absolutely continuous and loadindependent control of acceleration and deceleration. During the latter, the mechanical brake must
not operate before complete standstill has occurred.
Controls are to be designed as direction-sensitive two button collective.
The controls for the lift shall be supplemented by a priority control in the car and an external priority
controls shall be achieved by means of key switches.
The lift stops at this main service platform. Controls must be set so that lifts always return there
automatically.
3.5
PIPING
3.5.1 General
The requirements mentioned under Part G5.1 General Technical Requirements Mechanical
Equipment and Piping apply.
In accordance with the codes and standards, all water piping shall be designed for the pump shutoff pressure up to the next downstream pressure reducing valve, unless there is a safety valve
installed, in which case the set point of that safety valve applies with appropriate margin.
Piping stress analysis shall show the values and direction of the forces and resulting bending
moments at the terminal points, e.g. superheater outlet headers, economiser inlet headers, etc.,
when the connected pipe is operating at design pressure and temperature.
Tapping connections for instruments shall be provided in locations required for testing and
operation.
All kinds of hangers, supports, etc., shall be dimensioned to withstand the hydrostatic test of the
pipe system. During the hydrostatic testing, the hangers can be blocked.
Type and make of the hangers shall be approved by the Engineer.
Page: 22
3.5.2 Feedwater Pipework

Requirements as stated in Part P2.8 Condensate and Feedwater System apply for Feedwater
Piping inside the HRSG boundaries.
To avoid water hammering, feedwater piping shall be routed in such a way that unintentional
draining of the pipe during shutdowns is prevented.
The desuperheating pipework shall be designed to withstand the maximum pressure of the feed
pump and the final feed water temperature.
3.5.3 Main Steam Pipework

Requirements as stated in Part P2.7 Steam Systems apply for Steam Piping inside the HRSG
boundaries.
All low-points on the main steam piping shall have an automatic drain.
3.5.4 Drain and Vent Pipework

In general drain and vent pipework shall be designed for the maximum operating pressure of the
service lines to be drained or vented. The nominal diameter of drain pipes shall not be less than
DN 40.
3.5.5 Chemical Dosing Piping

Trisodiumphosphate dosing shall be foreseen at the drums. For this an isolating and check valve,
both made of stainless steel, shall be installed.
For further requirements see Part P2.14 Dosing.
3.6
PUMPS
3.6.1 Economiser Recirculation Pumps

If applicable, 2 x 100% economiser circulation pumps shall be provided.
In order to avoid low temperature corrosion in any part of the economisers or the stack, the
feedwater temperature shall not drop below 3C above the acid dew point of the exhaust gas,
depending on the sulphur content of the fuel. Reference is made to the fuel specifications.
The Contractor shall perform his own calculations and verify the required feedwater inlet
temperature to prevent sulphur acid corrosion.
3.6.2 Boiler Circulating Pumps

If applicable, forced circulation of the evaporators is effected by 2 x 100% motor-operated
circulating pumps ensuring with the designed water / steam circulating ratio. Both an electrical trip
and a pressure differential measurement over the pump shall detect failure of the running pumps.
Manufacturer experiences with regard to the circulating ratio shall be described in the bid.
Both pumps shall be suitable for unrestricted parallel operation.
During normal operation one pump shall satisfy all requirements, the second pump shall only be
switched on in parallel under abnormal conditions or failure of the first pump.
The design data of the pumps shall be chosen by the Contractor according the HRSG water/steam
requirements. Sufficient cooling of respective pump components shall be ensured.
Page: 23
Special care shall be taken in design of the pumps and selection of materials with regard to high
boiler water parameters and the concentration chemicals, suspended solids and other dissolved
solids in the boiler water at a changeable level.
The pumps shall be of the centrifugal type, fitted with mechanical shaft seals. They shall be in the
form of horizontal pumps.
The pumps shall be made of stainless steel or of an approved equivalent.
The pumps shall be designed and suitable for continuous operation and outdoor installation. They
must also be ready for immediate service even after a prolonged period of standstill without any
special measures being necessary.
The pumps are to be designed so that even when operating against a delivery head of 0 bar (g),
no overloading occurs and that damage by cavitation virtually avoided by appropriate design and
selection of materials.
The pumps are to be designed as base units and together with the motor be mounted on a
common base-plate.
The electric motors for the pumps shall be included. The Contractor shall supply all other
components including both coupling parts for the pump sets as well as including assembly of pump
and motor.
The circulating pumps shall be capable of starting locally and from CCR and automatically from the
sequence control.
In addition to this requirements the General Technical Requirements laid shall be considered for
the pumps.
3.6.3 Blowdown Pumps

If the blowdown vessel is lower than the downstream wastewater system, the vessel shall be
equipped with 2 x 100% blowdown pumps.
The pump capacity shall be chosen such that the vessel does not overflow when the drum(s)
emergency drain valve opens at full drum pressure.
3.7
VALVES
3.7.1 Steam Safety Valves

The number and capacity of the safety valves shall be in accordance with the applied standard of
the HRSG. The safety valves setting pressures shall be adjusted in such a way that the valves
blow-off in a predetermined sequence. The difference of the setting pressures of the safety valves
shall not be less than 3 %.
For the lowest set pressure of the drum safety valve, the pressure drop over the superheater has
to be taken properly into account. The opening and closing pressures of the safety valves shall not
exceed the ranges given by the relevant ASME codes.
The safety valve(s) at the superheater outlet shall always open and close before the safety valve(s)
on the boiler drum open and close respectively.
The superheater safety valve(s) shall be of such capacity that the superheater cannot be
overheated when the boiler drum safety valve(s) are discharging, even under the condition that the
superheater outlet is closed when the supplementary firing is in operation at maximum load on
manual firing control.
Page: 24
The set pressures of boiler drum and superheater safety valves shall take into account the
pressure drop between the drum and the superheater outlet at maximum steam flow, plus an
additional pressure drop allowance for longer term fouling of the superheater.
The set pressure of any boiler drum safety valve shall be at least 5% or 2.5 bar, whichever is the
higher, in excess of the maximum working pressure in the boiler drum.
The maximum working pressure is defined as not less than that pressure in the drum when the
boiler is being fired at maximum load and the superheater safety valve(s) are discharging at
maximum allowable rate.
The rating and setting of safety valves shall be in accordance with the applicable standards. The
combined discharge capacity of the drum and the superheater safety valves shall not be less than
100% of maximum capacity of HRSG.
The safety valves shall be of the direct spring loaded type with springs exposed to the open air, i.e.
with open bonnets. They shall be provided with a lifting gear.
Air assisted safety valves with triple steam pressure sensors are also acceptable in special cases
which shall be approved by the Engineer.
Vertical outlets, at least 2000 mm high, shall be provided for safety valves. They shall discharge to
a safe location. Outlets shall have safe drainage facilities which shall prevent the accumulation of
water in them.
All safety valve outlets shall be adequately supported to take care of the reaction forces generated
while the safety valves are discharging.
All safety valves shall be provided with blow down adjusting facility to adjust re-seating pressure.
Steam safety valves shall be provided with silencers in order to meet the noise requirements of the
plant laid down in Part G4 General Project Requirements.
The discharge lines and funnels of the safety valves to be installed between the economisers and
the feedwater control stations shall be amply designed and shall be routed to a safe place.
3.7.2 Feedwater Control Valve Stations

Feed water control stations shall achieve feed water flow to the HRSG. It is assumed that the
economiser outlet temperatures will be close to saturated water temperatures in the drum(s) thus,
the feed water control stations shall be installed downstream of the economisers in order to avoid
evaporation in the same.
The control stations shall consist of the following:
The 2 x 100% feed control valve suitable for controlling the feedwater flow over the whole
operation range (0 100 %)
The feed control valve suitable for controlling the feedwater flow at low load and during start
up (0 30 %)
One motorised and one manual isolating valve (upstream and downstream) of the control
valve.
Manual by-pass valve with non-return valve.
A non-return valve shall be provided downstream of the control station, i.e. upstream of the boiler
drum.
3.7.3 Steam and Feedwater Valves
Page: 25
Design Features
All high pressure valves shall be manufactured from cast steel or forged steel bodies with covers
and glands of proper construction.
The materials used for valve casings shall be of the same composition as for the related pipes or
higher.
Feedwater stop valves and steam stop valves shall close perfectly tight in both directions so that it
shall be possible to perform the hydraulic tests for the HRSG and the feedwater and steam pipes
independently.
Steam Stop Valves and Non-Return Valves
Main steam gate valves for shutting off the HRSG shall be installed in the steam lines leaving the
boiler. The number of shut off valves shall be in accordance with the code requirements. Bypasses
of the valves shall be provided for pressure equalisation and to warm up the line. A motorised live
steam shut off valve and non-return valve shall be provided near the HP live steam header in the
BPST area (under the scope of Part P2.7 Steam Systems).
3.7.4 Drain and Vent Valves

All drain and vent valves required for start-up and/or shutdown operation shall be motorised so that
remote start-up/shut-down of the HRSG unit is possible.
Drain and vent valves shall be combined in groups, connected to common collectors and
discharged to the blowdown vessel respectively.
All funnels for atmospheric drains, for which the possibility of steaming out exists, shall be provided
with covers.
All drain mains shall be installed with sufficient slope for drainage.
All drain and vent valves shall be "heavy-duty" type and shall be designed for the maximum
temperature which can occur at the location of installation, e.g. superheater drain valves shall be
designed for the maximum steam temperature which can occur at the location of the valve
installation. The size of drain valves shall not be smaller than DN 50.
3.8
BLOWDOWN EQUIPMENT
3.8.1 General
Each HRSG shall be fitted with a 2-stage blow-down system:
1.
A pressurised continuous blow-down vessel designed to operate for continuous blowdown

(max. about 3 % of the full load steam flow). The flash vent shall be connected to the
feedwater tank. The drain shall be connected to the atmospheric intermittent blow-down
vessel. The drain line shall be equipped with a control valve for level control of the vessel.
The continuous blow-down system shall be designed for the maximum continuous blow-down
specified. At this rate there shall be no interference with the normal water circulation in the
boiler or drum level control, or other adverse effects.
2.
An atmospheric intermittent blow-down vessel designed to operate for intermittent blow-down,

emergency drain of the drum (e.g. due to high level) and for all other vents and drains in the
HRSG area. The flash vent shall be piped to atmosphere. The drain shall be piped to waste
water system, via a drain pump if required.
Blow-down valves shall be arranged in series with isolating valves for pressure levels equal or
above 65 bar.
The sizing of the blow-down valve shall be adequate to prevent blockages, deposits or corrosion.
Page: 26
In addition, an automatic motor emergency drain valve operated from the steam drum shall be
foreseen by the Contractor to limit to an acceptable level the water volume surge in the steam
drum during boiler start-up and any other operation condition. There shall be no water carry over
into the superheater.
The emergency drum drain shall have its own line to the blow-down vessel.
Each system shall have two valves in series, one block valve and one special blow-down
emergency drain valve.
A mechanical position indicator and a device for locking the blow-down emergency drain valves in
position shall also be provided.
3.8.2 Intermittent Blowdown Vessel

The intermittent and emergency blow-down water and steam shall be led to a blow-down flash
vessel (at least 6 m 3 capacity) and from there to a blowdown basin.
Design and construction of the intermittent blowdown system and ancillaries shall be based on the
following requirements:
The blowdown vessel shall be designed to withstand the adverse effects caused due to
thermal shocks
The vessel shall have facilities such as dispersing baffles to reduce the pressure and velocity
of the incoming drains
Due attention shall be paid to the method of arranging of all drain and condensate lines into
the vessel
The vessel shall be provided at least with one manhole, the size of which shall be at least 600
mm. The manhole shall be provided with hinges or a davit
A spray system for cooling and noise reduction is requested.
The pipe connections to the blowdown vessel shall be of the welded type
At least 3 spare nozzles provided with blind flanges shall be installed on the blowdown vessel
The vent pipe shall be adequately sized and routed to prevent:
Excessive noise. If the limits for sound pressure level specified elsewhere in this
document cannot be achieved with a blow-off pipe led directly into the atmosphere, a
silencer shall be installed.
Carry over of water drops. If necessary, a droplet separator shall be installed. The vent
pipe shall be routed to the HRSG top platform level to prevent the steam cloud from the
vent to cover parts of the HRSG.
Over-pressuring of the blow-down vessel in case of the HP drum emergency drain valve
opening at full pressure, resulting in steam being blown through the drain siphon into the
waste water system.
The blowdown vessel shall be provided with a drain valve
3.8.3 Continuous Blowdown Vessel

The continuous blow-down water shall be led to a separate pressurised blow-down flash vessel (at
least 3 m 3 capacity).
Page: 27
Design and construction of the continuous blowdown system and ancillaries shall be based on the
thermal shocks
of the incoming drain
Due attention shall be paid to the method of arranging the incoming drain and outgoing vent
and drain line.
The vessel shall be provided at least with an inspection hole, the size of which shall allow
inspections, cleaning of the vessel and minor work.
The pipe connections for all connected drains and vents shall be of the welded type
The blowdown vessel will be designed as a pressure vessel; design pressure as the feedwater
tank, and shall be equipped with a separate safety valve and a silencer.
The vent shall be connected to the Feedwater Tank dome.
The drain shall be connected to the Intermittent Blowdown Vessel. The line shall have a
control valve suitable for level control of the Continuous Blowdown Vessel.
3.8.4 Blowdown Pump

See clause 3.6.3
3.9
POWER ELECTRICS
Requirements as given in Part G5.2 and P2.26 Electrical Equipment shall be adhered to.
INSTRUMENTATION AND CONTROL
The general technical requirements for Instrumentation & Control Systems (Part G5.3) shall be
adhered to. The requirements for the main HRSG closed-loop controls are described in P2.27
Instrumentation & Control Systems.
Regarding the HRSG-related instrumentation, reference is made to the following documents:
Part G5.3 and P2.27 Instrumentation & Control Systems
HRSG P&I Diagram ( Drwg. No. CNE/015/2002-W-00-G-D-00007)
Water Steam Cycle P&I Diagram (Drwg. No. CNE/015/2002-W-00-G-D-00008)
In addition to the documents above the minimum requirements shall apply:
All drain and vent valves required for start-up/shut-down operation shall be motorised so that
remote start-up/shut-down of the HRSG unit is possible.
Continuous and intermittent blow down shut off valves shall be motorised.
Emergency blow down valve shall be motorised for quick opening.
Local instruments shall be provided with adequate weather protection / sun shade.
Wall temperature measuring locations (thermocouples) at eight outlet tubes of the final stage
superheater, including Connection head shall be provided.
Page: 28
Wall and wall differential temperature measuring locations shall be provided at the following
components calculated with time dependent strength characteristics (monitoring according to
German Technical Rules for Steam Boiler TRD 508 or equivalent)
superheater
outlet header of superheater
SERVICES REQUIREMENTS
In addition to the general requirements for services as listed under G4.1 Scope of Works and
Extent of the Contract (Supply and Services), the following special requirements apply also for the
HRSGs:
5.1
ACID CLEANING AND BLOWING-OUT
Before the first start-up of the HRSG, it shall be chemically cleaned by acid pickling.
The obligation to perform an acid pickling can be waived if the Contractor can positively
demonstrate that all water and steam pipes, tube bundles and/or harps, etc., are in good condition
before installation, with only minor amounts of mill scale and rust. To ensure this, the Contractor
shall properly protect all equipment against corrosion during manufacturing, shipment and on-site
storage. The proposed process shall be clearly described in the offer. If all these conditions are
met, the acid cleaning can be replaced by a soft alkaline flush or boil out.
No matter if an acid pickling or an alkaline flush is performed, a detailed procedure shall be
provided, including criteria for acceptance of the cleaning for the Employers / Engineers approval.
The cleaning processes shall be designed to ensure that the maximum amount of organic matter,
silica, mill scale, rust and other deposits are removed from the metal surfaces to be cleaned.
Particular attention is drawn to non-drainable sections of the plant to be cleaned, and special
measures shall be taken to ensure adequate flushing to avoid chemical damage.
All chemicals as well as inhibitors and detergents, etc., required shall be provided including
temporary valves or internal parts for valves, strainers, pipework, pumping equipment, etc., needed
for the cleaning as well as for the blowing out process shall be provided.
Provisions shall be made for "blowing-out" of the main steam pipework and any branches by
steam. Thus, all temporary pipework and supports that are necessary shall be provided.
Disconnecting and remaking of joints shall be also included.
CORROSION PROTECTION
Part G5.6 General Technical Requirements - Corrosion Protection and Painting", shall be adhered
to.
The HRSG shall be equipped with a nitrogen capping and dry lay-up system.
WEATHER PROTECTION CANOPY
An overhead corrugated sheet canopy of materials shall be provided to protect operating and
maintenance personnel from sun and rain. The contractor shall provide an efficient and
architecturally acceptable protective canopy over the boiler area.
All canopy sheeting shall be arranged to be supported from the boiler supporting steelwork and all
necessary steelwork, supporting purlins, shall be supplied under this contract. The canopy shall be
self-drainig and provided with adequate drain gulleys and downcomers to ground level.
Page: 29
The arrangement of the weather protection canopy shall be to the approval of the Employer /
Engineer.
The actual firing floor platforms are also to be provided with a ventilated enclosure to minimise the
ingress of dust and to protect the operators.
QUALITY ASSURANCE, INSPECTION AND TESTING
The HRSG with all components shall be tested according to the relevant provisions of the design
codes and with the provisions stated in Part G4.4.6 and G5.6 Inspection & Testing. The minimum
scope of inspections and testing for the HRSG is listed under Part P3.
As mentioned under 3.1, the design shall be in accordance with international quality standards, i.e.
ISO, as well as ASME and/or DIN or equivalent. The boiler shall bear a stamp of an independent
authority, e.g. ASME, TV, etc., and the respective inspection certificate shall be submitted to the
Employer.
CNE/015/2002
P2.3
Auxiliary Boilers
WORKING DOCUMENT
Part P2.3 Auxiliary Boilers Working Doc.
Page: i
TABLE OF CONTENTS
1
GENERAL ..................................................................................................................................... 1
SCOPE OF WORKS..................................................................................................................... 1
2.1
SCOPE OF EQUIPMENT ................................................................................................. 1
2.2
SCOPE OF SERVICES .................................................................................................... 3
DESIGN/CONSTRUCTION REQUIREMENTS............................................................................ 3
3.1
BASIC DESIGN AND OPERATING DATA..................................................................... 4
3.2
DESIGN STANDARDS AND CODES.............................................................................. 5
3.3
VIBRATION AND NOISE LEVEL .................................................................................... 5
3.4
PRESSURE PARTS......................................................................................................... 5
3.4.1
Steam Drums and Headers......................................................................... 5
3.4.2
Economiser ................................................................................................... 7
3.4.3
Evaporator/Furnace walls ........................................................................... 7
3.4.4
Superheaters................................................................................................. 7
3.4.5
Desuperheaters............................................................................................ 8
3.5
PIPING .............................................................................................................................. 8
3.5.1
General .......................................................................................................... 8
3.5.2
Design Features............................................................................................ 8
3.5.3
Desuperheating Pipework (Feedwater Injection) ..................................... 9
3.5.4
Drain and Vent Pipework............................................................................. 9
3.5.5
Chemical Dosing Piping .............................................................................. 9
3.6
PUMPS............................................................................................................................ 10
3.6.1
Economiser Recirculation Pumps............................................................ 10
3.6.2
Boiler Circulating Pumps .......................................................................... 10
3.6.3
Blowdown Pumps....................................................................................... 11
3.7
SAFETY VALVES AND SILENCERS............................................................................ 11
3.8
STEAM AND FEEDWATER VALVES ........................................................................... 12

3.8.1
Design Features.......................................................................................... 12
3.8.2
Main Steam Stop Valve.............................................................................. 12
3.8.3
Control Valves for the Aux. Boiler Water / Steam Cycle & others........ 12
3.9
DRAIN AND VENT VALVES.......................................................................................... 13

3.9.1
General ........................................................................................................ 13
3.9.2
Aux. Boiler Drain and Vent Valves........................................................... 13
3.10
BLOW DOWN EQUIPMENT AND DRUM OVERFLOW............................................... 13

3.10.1
General ........................................................................................................ 13
3.10.2
Blow-Down Valves...................................................................................... 14
3.10.3
Intermittent Blowdown Vessel.................................................................. 14
3.10.4
Continuous Blowdown Vessel.................................................................. 15
3.10.5
Blowdown Pumps....................................................................................... 15
3.11
BOILER FIRING EQUIPM ENT....................................................................................... 15
P2_03Auxiliary_Boilers_Working_Doc.doc
Page: ii
Part P2.3 Auxiliary Boilers Working Doc..

3.11.1
3.11.2
3.11.3
3.11.4
General.........................................................................................................15
Flame Detectors..........................................................................................17
Ignition Equipment .....................................................................................17
Fuel Oil and Fuel Gas Pipes, Atomising Air Pipes, etc..........................17
3.12
AIR AND FLUE GAS SYSTEM ......................................................................................18

3.12.1
Boiler Enclosure .........................................................................................18
3.12.2
Air and Flue Gas Ducts, Expansion Joints..............................................18
3.12.3
Dampers.......................................................................................................20
3.12.4
Observation and access ............................................................................20
3.12.5
Auxiliary Fans..............................................................................................21
3.12.6
Steam Heated Air Heater............................................................................21
3.12.7
Regenerative Air Preheaters .....................................................................22
3.13
FORCED-DRAUGHT FAN ..............................................................................................23

3.13.1
Fan ................................................................................................................23
3.13.2
Fan Capacities and Characteristics..........................................................23
3.13.3
Materials and Construction .......................................................................24
3.13.4
Fan Driving Units ........................................................................................25
3.13.5
Lifting Equipment and Maintenance of Draught Fans............................25
3.14
STACK.............................................................................................................................25
3.15
THERMAL INSULATION AND REFRACTORY MATERIALS......................................26
3.16
LIFTING APPLIANCE.....................................................................................................27
3.17
PRESERVATION SYSTEM ............................................................................................27
3.18
PRE-SERVICE CLEANING AND BLOWING-OUT........................................................27
3.19
STEEL STRUCTURE......................................................................................................28
3.20
THERMAL INSULATION................................................................................................29
CORROSION PROTECTION......................................................................................................30
WEATHER PROTECTION CANOPY.........................................................................................30
INSPECTION AND TESTING.....................................................................................................30
Page: 1
GENERAL
This specification defines the main and more particular requirements for the Aux. Boiler and
associated equipment of the Jebel Ali L, Phase I., Power Station, including the steam and
feedwater/condensate piping systems and the blow-down system in the scope of the Aux. Boiler.
Likewise, all the General Specifications given in Part G General shall be adhered to. The
technical requirements of this part shall have priority for design and construction of the Aux. Boiler
with auxiliaries, before the technical requirements of general nature laid down in Part G.
The specification describes mainly the tasks of the individual equipment, leaving at the same time
space for necessary and possible developments and a certain latitude for the specific standards of
the manufacturer.
As far as the specification states specific design requirements, these requirements shall be
adhered to strictly except the technological development dictates improvement.
The following CCPP configuration is envisaged:
3 GTs + 3 HRSGs with supplementary Firing + 2 Aux. Boilers + 2 STs
Unless otherwise specified, the data indicated below refer to one Aux. Boiler but apply to all Aux.
Boilers.
The following basic drawings shall be provided with the bid:
Layout drawing,
arrangement drawings,
sectional drawing of the HRSG including pressure part arrangement
P&I diagrams,
internal insulation details.
Pressure part arrangement
SCOPE OF WORKS
2.1
SCOPE OF EQUIPMENT
Unless otherwise specified, the number indicated below refer to one Aux. Boiler but apply to all
Aux. Boiler.
The main scope of equipment comprises the components shown on the drawing No
CNE/015/2002-W-00-G-D-00013 Auxiliary Boiler P&I Diagram, excluding the Feedwater
System (FW Tank, FW pumps, etc.) which are under the scope of system P2.8, but including all
other equipment necessary for the safe and efficient operation of the plant.
Each Aux. Boiler shall include, but not be limited to the following main components and
systems:
Complete boiler pressure parts including economiser, drum, downcomers, evaporator,

superheaters, headers, connection pipes, spray attemperators, etc.
Safety valves with silencers
Start up valve with silencer to atmosphere remote control from CCR with position indication
Page: 2
Aux. Boiler-Steam, and feedwater piping and valves including pressure test locks
Fuel oil and fuel gas piping
Fuel control valve stations (Burner stations) for NG and DO
Drainage and vent system
Blow-down system with continuos blowdown flash vessel, intermittent blowdown flash vessel,
drain pump (if necessary), all pipework, valves and vent silencer(s)
Two (2) forced draught fans and electric drives
One (1) steam coil air heater shall be provided, if any dew point corrosion, even at Auxiliary
Boiler cold start-up, cannot be avoided without air heater.
One (1) regenerative air heater shall be provided, if any dew point corrosion, even at Auxiliary
Boiler cold start-up, cannot be avoided without air heater.
All necessary air and flue gas ducts with expansion joints and vibration absorbers
Isolating and control dampers
Complete low NO x burner firing system including ignition system, scanners, valves, &
instrumentation
Fuel oil drain collecting system
Fuel oil Flushing system
Sampling/Dosing system
Stack
Overall canopy
Sun shades for local instrumentation and control equipment
All special tools for operation, maintenance and repair, one set per boiler
Boiler steel structure, platforms, stairs and galleries
Water washing facility for each boiler & auxiliaries
Corrosion protection
Refractories, thermal insulation and cladding
One motorised goods lifting hoist including necessary structures (one per boiler)
Associated instrumentation and control system
Protection for burners and other sensitive equipment
Nitrogen conservation systems for capping
Fire protection system
Interconnection walkway bridge between the 2 Aux. Boiler platforms at minimum two levels
Boiler filling and emptying system, piping connections and valves for chemical cleaning, boiling
out, steam blowing conservation etc.
2.2
Page: 3
The steam, feedwater/condensate piping systems:
HP Main Steam line to the common header in the BPST machine hall,
Feedwater piping up to the economiser,
Injection water system piping for desuperheaters,
All necessary inter-connecting pipes, including hangers, supports, vent and drain systems,
valves, strainers, traps
The complete necessary insulation of the pipes, valves and tanks
All necessary base plates, supporting steel structures, mountings, fittings for pumps,
tanks, valves and pipes.
SCOPE OF SERVICES
The Aux. Boiler equipment shall include the necessary services as laid out in Part G4.1 Scope
and Extent of the Contract. Additional special services are described in clause 3.19.
DESIGN/CONSTRUCTION REQUIREMENTS
The Aux. Boiler shall be designed to operate with the associated Steam Turbine, which generates
electricity and also provides process steam for the desalination plant.
The general layout and the systems are shown on the following drawings:
Drawing No.:
General Layout Plant
CNE/015/2002-X-00-G-D-00025
Water/Steam Cycle Flow Diagram
CNE/015/2002-W-00-G-D-00003
Steam/Condensate P&I Diagram
CNE/015/2002-W-00-G-D-00010
Aux. Boiler P&I Diagram
CNE/015/2002-W-00-G-D-00012
The Aux. Boiler and its auxiliaries shall be designed for safe and efficient operation at all design
and site conditions. The general design conditions are stated in part G4.1 General Requirements
however, 100 cold starts per year shall be taken into consideration when designing the boiler. The
steam conditions shall be based on the parameters required at the turbine inlet. These parameters
also consider the requirements of the desalination plant process.
The Aux. Boiler shall be designed for its optimum when fired with Natural Gas (NG) as main fuel,
but continuous operation with Diesel Fuel Oil (DO) as back-up fuel must be possible. This includes
that the boiler shall be capable of firing in mixed fuel operation mode on any proportion of NG &
DO, and it includes automatic change over from NG to DO when the gas pressure falls below the
required level. The Aux. Boiler design shall include heating steam for deaerator, atomising steam
and steam coil preheater and any other aux. consumers as applicable. The heating surfaces,
burners and fuel system shall be designed accordingly.
The analyses for NG, as well as DO are stated in part G4.3.3 Fuel Data.
The factors that lead to a satisfactory, modern and economic design of the steam generating units
shall be taken into consideration when designing the Aux. Boiler and the auxiliaries. In order to
achieve high boiler efficiency, a high combustion efficiency, minimum excess air, low NO x emission
Page: 4
and a low exhaust temperature to the stack has to be ensured. Certainly the minimum exhaust
temperature is determined by considerations of the flue gas dew point, low temperature corrosion
and fouling of the flue gas air heater (if installed).
The boiler efficiency for the NG main fuel must be stated in the offer.
3.1
BASIC DESIGN AND OPERATING DATA
The Aux. Boiler shall be of the drum type boiler with natural circulation, membrane water walls and
pressurised furnace. The boiler must be designed to operate with the associated Back Pressure
Steam Turbine and Desalination Plant. The boiler shall be suitable for outdoor installation at the
prevailing ambient conditions and shall be of top or bottom supported design. When designing the
boiler it shall be taken into consideration that the boiler will be out of service for prolonged periods
of time during the year. Hence, adequate conservation measures as well as corrosion protection
measures shall be foreseen. It shall also be possible to suitably box the boilers up when taking
them out of operation.
The Contractor shall optimise and suggest the operating design data for optimum efficiency for
both electricity and steam generation. The steam data shall be checked and approved by the
Employer / Engineer and then become the basis of this specification as given in part Guarantee
Data of the Contract.
The Maximum Continuous Rating (MCR) of one (1) Aux. Boiler when either fired with natural gas
or diesel oil shall equal the capacity of one HRSG when operating the GT at base load and shall
provide sufficient steam to the BPST in order to ensure that the desalination units can produce
water at design load at clean as well as at fouled conditions within the specified seawater
temperature ranges.
The HRSG shall, in accordance with the BPST operation design at fixed outlet pressure mode.
The minimum stable load of the Aux. Boiler shall not be higher than about 20% of MCR.
All pressure parts shall be fully drainable.
The spacing between tube bundles must be accessible by suitable placed manholes.
The Aux. Boiler tubes shall be made of seamless tubes.
All boiler pressure parts tube shall have minimum corrosion allowance at 1.0 mm
To avoid high-temperature corrosion in the superheater and low temperature corrosion in the flue
gas path and connecting ducts, the impurities in the fuels shall be taken into consideration when
designing the Aux. Boiler.
Two (2) forced draught fans, two (2) steam coil air heaters and one regenerative air heater shall be
considered for the combustion air and flue gas design. It shall be possible to start and operate the
boiler up to approx. 60% nominal load with only one fan in service.
3.2
Page: 5
DESIGN STANDARDS AND CODES
The design, materials, manufacturing, erection, operation, inspection and testing shall be in
accordance with ASME, DIN, TRD or equivalent. The boiler shall bear a stamp of an independent
authority, e.g. ASME, TV, Lloyds, etc., for design, manufacturing, erection and repairs (if any)
and the respective certificates shall be submitted to the Employer.
The mechanical design calculations, welding procedures and welding reports of the pressure parts
as well as the steel structure shall be submitted to the Engineer for checking and approval.
Water and steam qualities of the Aux. Boiler shall fulfil the requirements of the VGB guidelines for
boiler feedwater, boiler water and steam of boilers of the respective pressure range.
The steam qualities at the outlet of the Aux. Boiler shall fulfil the requirements of the VGB
guidelines for normal operation values when the boiler is operated under the conditions given for
boiler water in the same guidelines of the respective pressure ranges. The following values in the
live steam should not be exceeded:
Conductivity
Silica
Total iron
Total copper
Sodium & Potassium
0.2 S/cm
0.02 ppm
0.02 ppm
0.003 ppm
0.01 ppm
When designing the burner systems safety standards of the latest edition (e.g. NFPA, TRD, etc.)
shall be taken into consideration.
3.3
VIBRATION AND NOISE LEVEL
The stipulations laid down in part G4.2 shall be considered.
3.4
PRESSURE PARTS
3.4.1 Steam Drums and Headers

The Aux. Boiler shall be provided with adequately dimensioned steam drum to ensure stable
operation.
The drum plates shall be of the same chemical composition, shall have the same physical
properties and shall be supplied by the same steel manufacturer
The drum shall be provided with a manhole in each end.
The drum with connections shall be fully shop fabricated and fusion-welded throughout. Welding
on the boiler drum after the final heat treatment is prohibited.
Site welding (including auxiliary welds for erection, scaffolding, thermal insulation) directly on the
drum is not permitted, except for minor repairs (to be checked and stamped by the Inspection
Authority).
Adequate drum internal fittings of approved design and manufacture shall be fitted in the steam
drum. The drum shall be provided with all required separators steam purifiers and steam deflecting
baffles. The limits for carry-over components mentioned in the VGB guidelines shall not be exceeded to ensure the quality of steam required by the BPST and Desalination manufacturer.
The attachment of internal fittings inside the drum shall be by means of bolting to lugs, plate
sections or brackets which shall have been welded to the drum in the works prior to the drum
annealing process. Bolts and studs inside drums shall be fitted with cap nuts and tack welded.
Page: 6
Arrangement and fabrication of all internal equipment shall be provided so as to permit removal
and replacement through the manholes.
The riser tube shall end below the water level.
Tubes shall be connected to the drum by welded connection on tube stubs.
sections of the Aux. Boiler (capping) with necessary piping and valves. The N2 bottles shall be
stored on the ground level under a shaded roof.
All nozzles and tube stubs shall be final welded to the drum. The nozzles shall be long enough to
ensure that the base weld is not affected by the subsequent welding on site and that valve,
mountings and fittings can be cut off and re-welded without damaging the lagging or the casing
and the drum body.
Steam water separators of the cyclone type shall be arranged in the boiler drum. In addition to the
cyclone separators, the drum shall be provided with all other required steam purifiers and steam
deflecting baffles. The design and arrangement of these internals shall be such that the
mechanical carry over of boiler water in the saturated steam entry to the primary superheater is
limited to <0.1%
Materials in areas of the drum where the temperature and flow velocity is in the range that is
known to cause flow accelerated corrosion shall be corrosion/erosion resistant.
Internal fittings shall be provided for the extraction of the continuous blow-down and chemical
dosing over the whole length of the drum.
Thermocouples, to measure the differential metal temperature of the boiler drum(s) shall be
provided. The thermocouples shall cover six positions, i.e. three on the bottom and three on the top
of the drums.
The capacity of the blow down system shall consider the quantities of continuous blow down and
intermittent blow down (drum over flow during start up condition).
The headers shall offer provisions for the visual inspection with the endoscope. The closing piece
for these inspection openings shall be a permanent cap fixed with a fully penetrating butt-weld to
permit cutting and re-welding.
Headers shall be fabricated from seamless steel pipes. All lower headers shall have a drain of at
least DN50. Special provisions shall be made for a temporary flushing connection at both end of
each header. The size of the connection shall be such that it ensures sufficient velocities during
chemical cleaning and it shall also suit for inspection and for cleaning by hand.
Welding on headers after the final heat treatment is prohibited.
The connection tube to header shall be of the full penetration weld type, at least for alloyed
material (i.e. T11, 13CrMo44 or higher)
Headers shall be arranged in such a way that they do not impede the fitting or removal of heating
surfaces.
The storage capacity of the drum must be large enough to ensure, in case of a cut-off of the
feedwater inlet flow:
a retaining time of at least 2.5 minutes from normal operation level to trip level at normal
steam flow
a safe shutdown of the boiler without damage after initialising a trip of the burners at low
low drum level.
Page: 7
Transient operation shall not lead to such strong swelling or fluctuations of the drum level in such a
way that any protection action (holding time, gradient limitation, shutdown) is initiated.
The level difference between normal water level and low water alarm level shall be not less than
150mm.
The normal water level shall be indicated by engraved marks on the drum, repeated on a plate
located outside of the insulation, and on the level gauges.
All pressure parts (both water and steam section) shall be fully drainable and ventable, i.e. at every
low point there must be a drain and at every high point there must be a vent. Draining shall be
possible only by gravity, without the need to pressurise the HRSG.
3.4.2 Economiser
The economiser shall be designed to ensure stable non-steaming operation throughout the full
operating range of the boiler under all load conditions.
The feed connections to the drum shall be fitted with thermal sleeves, in order to avoid undue
stress on the connecting nipples and in the drum shell due to corrosion fatigue cracking. The
thermosleeves shall be fitted inside the drum.
The kind of connection of the economiser outlet to the drum should be optimised to obtain
minimum differences in water level over the drum length.
The feed water and flue gas flow must enter and leave the economiser in counter flow pattern
The economiser header, inner casing, outer casing and outer casing and framing angle shall be
shop assembled (if possible)
Economiser casing shall be completely watertight and self-draining. Equipment for off-load water
washing with suitable water sprays and water drainage points shall be provided. All necessary
valves, piping/hoses with flanged outlets shall be provided.
3.4.3 Evaporator/Furnace walls

The evaporator systems shall be of natural circulation and shall be designed to operate over the
full load range of the Aux. Boiler without drumming or vibration and the design shall ensure an
even distribution of water through the tubes.
The furnace shall have water tube type walls, not refractory type.
The furnace walls utilise a gas-tight welded membrane construction and shall have provisions for
access and inspection.
The downcomers and furnace wall tubes shall be designed to achieve a uniform circulation ratio to
the individual evaporator tubes over the full load range.
3.4.4 Superheaters
The superheater steam temperature shall be controlled by a spray attemperator in line. The
superheater steam temperature shall be kept constant at the turbine inlet over the load range of
60 % load to MCR.
Special attention shall be paid to pressure drop and flow velocity, so that a safe and stable
distribution and faultless cooling of the boiler's tubular system is obtained under all operating
conditions. The superheater stages shall be fully drainable.
Page: 8
The superheater tubes material shall not be inferior to 13CrMo44 (equivalent to T11) for steam
outlet temperatures up to 450oC and shall not be inferior to 10CrMo910 (equivalent to T22) at
steam outlet temperatures above 450oC up to 535oC.
In case the boiler design requires that the steam outlet temperature of the boiler exceeds 535oC,
the material used for the last superheater section shall not be inferior to X10CrMoVNb91
(equivalent to SA T91 respectively P91).
All header materials shall be of equal quality as the tube materials with which they are connected.
An approved number of thermocouples shall be supplied for measuring and recording metal
temperature during pre-commissioning trials and normal operation on a temperature recorder to be
provided under this Contract.
During commissioning the Contractor has to demonstrate that the metal temperatures are not
greater than the design metal temperature as stated in the Data Sheets.
Provision shall be made in all headers and inter-stage piping to accommodate test pressure
gauges and quick response thermocouples.
Superheater steam temperature shall be controlled by spray attemperators with the individual
spray water through measurement control stations.
3.4.5 Desuperheaters
The desuperheaters shall be of the variable spray nozzle type, to ensure proper atomisation over
the whole range of operation. The last attemperator shall be installed upstream of the last
superheater section i.e. water injection into the live steam line upstream of the steam turbine is not
permitted.
In order to reduce thermal stresses on the desuperheaters and the steam pipework to its minimum,
the desuperheaters and the steam piping shall be equipped with thermal sleeves i.e. protection
liners
Feedwater shall be used for spray water, which shall be branched off upstream of the drum level
control valves. Injection water flow measurements shall be provided on the main line as well as on
all branch lines.
3.5
PIPING
3.5.1 General
This paragraph covers Boiler Property Piping, Boiler External Piping and Non-boiler External
Piping.
In addition to the requirements specified in part G5.1 General Technical Requirements
Mechanical Equipment and Piping, the steam and feedwater piping system shall be designed on
the basis of drawing No.. CNE-015/2002-W-00-G-D-00013 Auxiliary Boiler P&I Diagram.
The above mentioned flow diagram shows only the basic design.
3.5.2 Design Features

For piping in general seamless pipes shall be used.
The velocities of the fluids or steam shall be in accordance with the values as specified in
recognised guidelines and standards (e.g. VGB).
Page: 9
Materials, design, fabrication, installation and testing of the piping shall be in accordance with the
adopted design codes and standards e.g.: ASME; ANSI, TRD, DIN.
In any case, the computation and design of all piping shall be performed so that the resulting
piping has a small wall thickness for elastic operation and the resulting stresses under design
conditions are according to the relevant standards.
Computer-calculated stress analysis and proper isometric drawings of the pipework shall show
among others the magnitude and direction of the thrusts and resulting bending moments at the
terminal points like BPST chest, superheater outlet headers, economiser inlet headers and
reducing stations of the connected pipes for hot and cold conditions and shall be submitted for
Engineers approval.
The piping system shall be free of disallowable stress and reactions at equipment connections for
all operating temperatures.
The complete spray water system (Desuperheating Pipework) including piping, flow measurement
control valves, by pass valves and stop valves shall be taken into consideration.
For the piping system and the Aux. Boiler provision shall be made for chemical cleaning and steam
blowing. Additional pipes, valves, internal parts for valves, strainers in fact all parts needed for
cleaning, pressure tests and blow-out process shall be supplied.
Tap connections for instruments shall be provided in the location required for testing and operation.
All kinds of hangers and supports shall be amply dimensioned and designed to be capable of a
hydrostatic test of the pipe system. Blocking up of hangers is allowed during the hydrostatic test.
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 as the
adjacent pipework, they shall match correctly the bore of the adjacent piping and shall be
proportioned to avoid stress raisers.
Double shut off valve arrangement has to be applied for safety reasons at all HP piping, drains and
vents ( 64 bar).
3.5.3 Desuperheating Pipework (Feedwater Injection)

The desuperheating pipework shall be designed to withstand the maximum pressure of the feed
pump and the final feed water temperature.
3.5.4 Drain and Vent Pipework

If not covered by the design code the part G5.1 General Technical Requirements - Mechanical
Equipment and Piping shall be taken into consideration.
In general drain and vent pipework shall be designed for the maximum operating pressure of the
service lines to be drained. The nominal diameter of drain pipes shall not be less than DN 50 mm;
vent pipes not less than 40 mm.
3.5.5 Chemical Dosing Piping

At the point of injection, an isolating and check valve is in the scope of this specification. Further
details are subject of the Technical Specification P2.14 "Steam / Water Circuit Chemistry Dosing".
Page: 10
3.6
PUMPS
3.6.1 Economiser Recirculation Pumps

If applicable, 2x100% economiser circulation pumps shall be provided.
In order to avoid low temperature corrosion in any part of the economisers or the stack, the
feedwater temperature shall not drop below 3C above the acid dew point of the exhaust gas,
depending on the sulphur content of the fuel. Reference is made to the fuel specifications.
The Contractor shall perform his own calculations and verify the required feedwater inlet
temperature to prevent sulphur acid corrosion.
3.6.2 Boiler Circulating Pumps

If applicable, forced circulation of the evaporators is effected by 2x100% motor-operated circulating
pumps ensuring with the designed water/steam circulation ratio. Both an electrical trip and a
pressure differential measurement over the pump shall detect failure of the running pumps.
Manufacturer experiences with regard to the circulating ratio shall be described in the bid.
Both pumps shall be suitable for unrestricted parallel operation.
During normal operation one pump shall satisfy all requirements, the second pump shall only be
switched on in parallel under abnormal conditions or failure of the first pump.
The design data of the pumps shall be chosen by the Contractor according the boiler water/steam
requirements. Sufficient cooling of respective pump components shall be ensured.
Special care shall be taken in design of the pumps and selection of materials with regard to high
boiler water parameters and the concentration chemicals, suspended solids and other dissolved
solids in the boiler water at a changeable level.
The pumps shall be of the centrifugal type, fitted with mechanical shaft seals. They shall be in the
form of horizontal pumps.
The pumps shall be made of stainless steel or of an approved equivalent.
The pumps shall be designed and suitable for continuous operation and outdoor installation. They
must also be ready for immediate service even after a prolonged period of standstill without any
special measures being necessary.
The pumps are to be designed so that even when operating against a delivery head of 0 bar (g),
no overloading occurs and that damage by cavitation virtually avoided by appropriate design and
selection of materials.
The pumps are to be designed as base units and together with the motor be mounted on a
common base-plate.
The electric motors for the pumps shall be included. The Contractor shall supply all other
components including both coupling parts for the pump sets as well as including assembly of pump
and motor.
The circulating pumps shall be capable of starting locally and from CCR and automatically from the
sequence control.
In addition to this requirements the General Technical Requirements laid shall be considered for
the pumps.
Page: 11

See Clause 3.10.5.
3.7
SAFETY VALVES AND SILENCERS
Safety Valves of approved manufacturer, number, design and capacity shall be provided for the
drum and superheater in accordance with the requirements laid down by the relevant design code
(e.g.: ASME, TRD, BS). The safety valves shall be arranged to blow-off in a predetermined
sequence.
Safety valves shall be provided with silencers so that the noise levels as required in part G5.1
General Technical Requirements - Mechanical Equipment and Piping shall not be exceeded.
The number and capacity of the safety valves shall be in accordance with the applied standard of
the Aux. Boiler. The safety valves setting pressures shall be adjusted in such a way that the valves
blow-off in a predetermined sequence. The difference of the setting pressure of the safety valves
shall not be less than 3%.
For the lowest set pressure of the drum safety valve, the pressure drop over the superheater has
to be taken properly into account. The opening and closing pressures of the safety valves shall not
exceed the ranges given by the relevant ASME codes.
The safety valve(s) at the superheater outlet shall always open and close before the safety valve(s)
on the boiler drum open and close respectively.
The superheater safety valve(s) shall be of such capacity that the superheater cannot be
overheated when the boiler drum safety valve(s) are discharging, even under the condition that the
superheater outlet is closed when the firing is in operation at maximum load.
The set pressures of boiler drum and superheater safety valves shall take into account the
pressure drop between the drum and the superheater outlet at maximum steam flow, plus an
additional pressure drop allowance for longer term fouling of the superheater.
The set pressure of any boiler drum safety valve shall be at least 5% or 2.5 bar, whichever is the
higher, in excess of the maximum working pressure in the boiler drum.
The maximum working pressure is defined as not less than that pressure in the drum when the
boiler is being fired at maximum load and the superheater safety valve(s) are discharging at
maximum allowable rate.
The safety valves shall be of the direct spring loaded type with springs exposed to the open air, i.e.
with open bonnets. They shall be provided with a lifting gear.
Air assisted safety valves with triple steam pressure sensors are also acceptable in special cases
which shall be approved by the Engineer.
Vertical outlets, at least 2,000 mm high, shall be provided for safety valves. They shall discharge to
a safe location. Outlets shall have safe drainage facilities, which shall prevent the accumulation of
water in them.
All safety valve outlets shall be adequately supported to take care of the reaction forces generated
while the safety valves are discharging.
All safety valves shall be provided with blow down adjusting facility to adjust re-seating pressure.
The discharge lines and funnels of the safety valves to be installed between the economisers and
the feedwater control stations shall be amply designed and shall be routed to a safe place.
Page: 12
3.8
STEAM AND FEEDWATER VALVES
3.8.1 Design Features

If not covered by the design code, part G5.1 General Technical Requirements - Mechanical
Equipment and Piping shall be taken into consideration.
All high pressure valves shall be manufactured from cast steel or forged steel bodies with covers
and glands of approved construction.
The materials used for valve casings shall be of the same composition as for the related pipes or
higher.
Feedwater stop valves and steam stop valves shall close perfectly tight in both directions so that it
shall be possible to perform the hydraulic tests for the HRSG and the feedwater and steam pipes
independently.
3.8.2 Main Steam Stop Valve

Main steam gate valves for shutting off the Aux. Boiler shall be installed in the steam lines leaving
the boiler. The number of shut off valves shall be in accordance with the code requirements.
Bypasses of the valves shall be provided for pressure equalisation and to warm up the line. A
motorised live steam shut off valve and non return valves shall be provided near the HP live steam
header in the BPST area (under the scope of Part P2.7 Steam Systems).
3.8.3 Control Valves for the Aux. Boiler Water / Steam Cycle & others
Feedwater
Feed water control stations shall achieve feed water flow in the required quantity to the Aux.
Boilers. It is assumed that the economiser outlet temperatures will be close to saturated water
temperatures in the drum(s), if this is the case, the feed water control stations shall be installed
downstream of the economisers in order to avoid evaporation in the same.
The control stations shall consist of the following:
The 2 x 100% feed control valve suitable for controlling the feedwater flow over the whole
operation range (0 100 %)
The feed control valve suitable for controlling the feedwater flow at low load and during start
up (0 30 %)
One motorised and one manual isolating valve (upstream and downstream) of the control
valve.
Manual by-pass valve with non-return valve.
A non-return valve shall be provided downstream of the control station, i.e. upstream of the boiler
drum.
All control valves shall be provided with a manually operated bypass control valve.
3.9
Page: 13
DRAIN AND VENT VALVES
3.9.1 General
The size of vent valves shall not be smaller than DN 40.
The size of drain valves shall not be smaller than DN 50.
Part G5.1 General Technical Requirements - Mechanical Equipment and Piping shall be taken
into consideration.
3.9.2 Aux. Boiler Drain and Vent Valves

All Aux. Boiler drain and vent valves, of an approved type for draining the Aux. Boiler shall be
provided. Each drainage and venting point shall comprise two isolating valves. Drain valves on
lower headers shall be at least size DN 50.
Drain and Vent valves shall be combined in groups, connected to common collectors and
discharged to the boiler blow down flash vessel.
All funnels for atmospheric drainage for which the possibility of steaming out exist, shall be
provided with covers.
All drain mains shall be of the self-draining type.
All drain and vent valves required for start and/or shut down operations shall be motorised so that
remote start-up/shut down is possible.
3.10 BLOW DOWN EQUIPMENT AND DRUM OVERFLOW

3.10.1 General
Each Aux. Boiler shall be fitted with a 2-stage blow-down system:
1.
A pressurised continuous blow-down vessel designed to operate for continuous blowdown

(max. about 3% of the full load steam flow). The flash vent shall be connected to the feedwater
tank. The drain shall be connected to the atmospheric intermittent blow-down vessel. The
drain line shall be equipped with a control valve for level control of the vessel.
The continuous blow-down system shall be designed for the maximum continuous blow-down
specified. At this rate there shall be no interference with the normal water circulation in the
boiler or drum level control, or other adverse effects.
2.
An atmospheric intermittent blow-down vessel designed to operate for intermittent blow-down,

emergency drain of the drum (e.g. due to high level) and for all other vents and drains in the
Aux. Boiler area. The flash vent shall be piped to atmosphere. The drain shall be piped to
waste water system, via a drain pump if required.
Blow-down valves shall be arranged in series with isolating valves for pressure levels equal or
above 65 bar.
The sizing of the blow-down valve shall be adequate to prevent blockages, deposits or corrosion.
In addition, an automatic motor emergency drain valve operated from the steam drum shall be
foreseen by the Contractor to limit to an acceptable level the water volume surge in the steam
drum during boiler start-up and any other operation condition. There shall be no water carry over
into the superheater.
The emergency drum drain shall have its own line to the blow-down vessel.
Page: 14
Each system shall have two valves in series, one block valve and one special blow-down
emergency drain valve.
A mechanical position indicator and a device for locking the blow-down emergency drain valves in
position shall also be provided.
3.10.2 Blow-Down Valves

The blow down valves shall be of an approved design and shall be arranged in series with an
isolating valve. The blow down valve for intermittent operation shall be operable from the Central
Control Room (with position indication).
Only for determining the dimension of the continuous blow-down valve a quantity of water equal to
3 % of the full load steam flow of the Aux. Boiler shall be taken into consideration.
3.10.3 Intermittent Blowdown Vessel

The intermittent and emergency blow-down water and steam shall be led to a blow-down flash
vessel (at least 6 m 3 capacity) and from there to a blowdown basin.
Design and construction of the intermittent blowdown system and ancillaries shall be based on the
thermal shocks
of the incoming drains
Due attention shall be paid to the method of arranging of all drain and condensate lines into
the vessel
The vessel shall be provided at least with one manhole, the size of which shall be at least
600 mm. The manhole shall be provided with hinges or a davit
A spray system for cooling and noise reduction is requested.
The pipe connections to the blowdown vessel shall be of the welded type
At least 3 spare nozzles provided with blind flanges shall be installed on the blowdown vessel
The vent pipe shall be adequately sized and routed to prevent:
Excessive noise. If the limits for sound pressure level specified elsewhere in this
document cannot be achieved with a blow-off pipe led directly into the atmosphere, a
silencer shall be installed.
Carry over of water drops. If necessary, a droplet separator shall be installed. The vent
pipe shall be routed to the HRSG top platform level to prevent the steam cloud from the
vent to cover parts of the HRSG.
Over-pressuring of the blow-down vessel in case of the HP drum emergency drain valve
opening at full pressure, resulting in steam being blown through the drain syphon into the
waste water system.
The blowdown vessel shall be provided with a drain valve
Page: 15
3.10.4 Continuous Blowdown Vessel

The continuous blow-down water shall be led to a separate pressurised blow-down flash vessel (at
least 3 m 3 capacity).
Design and construction of the continuous blowdown system and ancillaries shall be based on the
thermal shocks
of the incoming drain
Due attention shall be paid to the method of arranging the incoming drain and outgoing vent
and drain line.
The vessel shall be provided at least with an inspection hole, the size of which shall allow
inspections, cleaning of the vessel and minor work.
The pipe connections for all connected drains and vents shall be of the welded type
The blowdown vessel will be designed as a pressure vessel; design pressure as the feedwater
tank, and shall be equipped with a separate safety valve.
The vent shall be connected to the Feedwater Tank dome.
The drain shall be connected to the Intermittent Blowdown Vessel. The line shall have a
control valve suitable for level control of the Continuous Blowdown Vessel.

If the blowdown vessel is lower than the downstream wastewater system, the vessel shall be
equipped with 2x100% blowdown pumps.
The pump capacity shall be chosen such that the vessel does not overflow when the drum(s)
emergency drain valve opens at full drum pressure.
3.11 BOILER FIRING EQUIPMENT

3.11.1 General
The firing system of the Aux. Boiler shall be designed for its optimum when fired with Natural Gas
(NG) as main fuel, but continuous operation with Diesel Fuel Oil (DO) as back-up fuel must be
possible. This includes that the boiler shall be capable of firing in mixed fuel operation mode on
any proportion of NG & DO, and it includes automatic change over from NG to DO when the gas
pressure falls below the required level. The heating surfaces, burners and fuel system shall be
designed accordingly.
The system should include dual fuel low NO x burners, i.e. natural gas and diesel oil burners,
igniters and flame monitors, the fuel control valve stations including start-up pressure regulator,
valves, double shut-off i.e. quick closing valves for each burner for both fuels with automatic
venting in the gas lines, oil and gas piping and associated trace heating system, atomising steam
and compressed air piping, wind boxes, vanes and dampers. Each burner shall be equipped with
its own combustion control i.e. fuel and air control system. It shall be possible to operate the boiler
up to MCR in accordance with the load increase / decrease gradients as well as load steps
specified elsewhere in this specification with n-1 burners in service. With n-1 burners in service, it
Page: 16
shall still be possible to operate the boiler at the guaranteed load gradients and load steps up to
MCR.
The DO shall be taken from the fuel system and tanks. The fuel oil pump is in the scope of the fuel
oil system. However, the Aux. Boiler has to provide its own safety shut off valves and recirculation
lines, etc. as well as its constant pressure control valve station.
The NG is taken from the fuel gas system. The main pressure reducing station is in the scope of
the fuel gas system. However, the Aux. Boiler has to provide its own control valve station.
The analyses for NG as well as DO are stated in part G4.3.3 Fuel Data.
The requirements for fuel control systems and burner interlocking system described in part P2.27
Instrumentation and Control Systems shall be taken into consideration when designing the firing
system. The fuel gas and fuel oil flow control valves shall be provided dual redundant (2 x 100%)
for each Aux. Boiler unit. The same redundancy shall be provided for the pressure control system
of each fuel. Duty / standby selection facility shall be provided with automatic switchover to the
standby control valve upon failure of the duty valve in a smooth i.e. bumpless transfer. Each
control valve shall have upstream and downstream motorised isolating valves.
In order to keep the coefficient of excess air to a minimum, individual burner control shall be
adopted.
The most modern design of low NO x -burners and furnace shall be used to avoid pulsation and the
most up-to-date rules and regulations for safety and fire hazard shall be observed (e.g. NFPA,
TRD) for the firing equipment.
Measures to be taken to ensure that there will be no flame impingement under any operating
conditions.
The control system of the firing plant shall be laid out to permit start-up and shut-down from the
central control room and local panel.
When designing the boiler, the high temperature corrosion caused by vanadium, sodium and
potassium and the low temperature corrosion caused by sulfur shall be investigated for the DO and
all provisions shall be taken to eliminate these risks.
Air atomisers may be required for operation with DO, especially for cold start-up. The contractor
shall design the system taking into account the DO fuel data. The design shall be checked and
approved by the Engineer.
Each low NO x burner shall be provided with a purge system for cleaning with steam or compressed
air after shutdown.
The burner construction shall be such that the oil burner can be replaced safe from outside of the
boiler.
Drip trays must be installed below each burner and burner control station. The fuel oil collected in
these trays must be led to a common vessel.
It is required that each level of burners shall be compartmentised and shall include individual fuel
and air controls to allow each level to fire gas or oil with one fuel maintained on fixed flow and the
other on variable flow.
Burner tips shall be manufactured from erosion resistant materials suitable to withstand radiation
heat from other burners when a burner is out of service but left in position for periods of up to one
hour. Means shall be provided for steam purging of the oil burner guns whilst the burner is on
position in the register.
Page: 17
The burner registers and oil burner retraction shall be operated by service air actuated drives and a
suitable interlock shall be provided between the burners and register so as to prevent admittance
of oil or gas fuel to the burner when the register is closed. The air registers shall be so designed so
as to give the correct quantity of excess air when in operation and also to permit the lighting up of
the burner when the register is passing the full design airflow.
It shall also be possible to trip and start individual burners from the burner-operating panel to each
burner level and to the central control room.
A burner maintenance area with workbench and all necessary tools and equipment shall be
provided at each burner elevation.
The fuel piping shall be suitable for the fuels specified arid the layout of the burner front pipework,
valves and fittings shall give adequate space for the operators access and burner withdrawal.
The flexible hoses shall be of stainless steel construction, fire proof and attached to the associated
connections by welding and not brazing. Each hose shall be provided with a self-sealing coupling.
3.11.2 Flame Detectors

Flame detectors shall be of the UV type.
Each main burner shall be equipped with two flame detectors, which shall be mounted so as to
receive signals only from its particular gas or oil flame and shall be properly protected from
excessive heat, and the environment of the particular location. Flame detectors shall be readily
accessible for on-line cleaning and replacement and shall be firmly mounted so as not to be
inadvertently damaged. All leads to flame detectors shall be property connected, earthed and
protected against physical damage.
The pilot flames shall also be provided with redundant UV type flame detectors and flame
monitors.
The flame detector monitoring system shall incorporate a self-checking facility and shall be
arranged so that at the failure of the two detectors the relevant burner shall trip and initiate an
alarm in the control room. Flame loss shall be detected by the two detectors to trip the relevant
burner.
The requirements in respect of alarms, trips and indicators shall be in accordance with the Controls
and Instrumentation,
3.11.3 Ignition Equipment

The ignition system must be designed for the requirement of boiler start up with both NG or DO.
Normal ignition shall be on NG. Only if NG is not available, ignition shall be done with propane gas.
A propane gas ignition system dedicated for each Aux. Boiler shall be provided. Gas electric
ignition shall be provided. All burners shall be supplied with propane gas from an ignition gas
station (cylinder battery) for each boiler. The gas cylinder station shall have a capacity sufficient for
twenty-five (25) ignitions of the complete boiler i.e. 25 ignitions of all the burners installed per
boiler. All valves, pressure regulators, pipework connection shall be provided for both the NG and
the Propane gas station. Automatic selection with remote operation from the CCR shall be
provided.
3.11.4 Fuel Oil and Fuel Gas Pipes, Atomising Air Pipes, etc.
The scope of works shall include all pipes for diesel oil, atomising steam and atomising air, control
and service air.
Page: 18
3.12 AIR AND FLUE GAS SYSTEM

3.12.1 Boiler Enclosure
The combustion chamber, convection passes and economiser shall be completely enclosed so as
to form a completely gas tight enclosure. All necessary steelwork for supporting and strengthening
the boiler enclosure to withstand the maximum draught pressure fluctuations is to be included.
A gas tight membrane water-cooled wall method of construction shall be used throughout to
contain the combustion gases until they discharge to the boiler outlet.
The Contractor shall clearly indicate on his tender drawings those areas of the boiler where a gastight impervious wall construction is not possible with his design.
The Contractor shall include drawings with his tender showing how he proposes to ensure a gas
tight seal where tubes etc. penetrate the walls and where the roof, walls and floors of the
combustion chamber and gas passes are connected together.
The whole of the boiler pressure parts, combustion chamber, headers piping etc. shall be thermally
insulated and metal clad to meet the General Technical Requirements for Thermal Insulation, Part
G5.1.
3.12.2 Air and Flue Gas Ducts, Expansion Joints

All the necessary air and flue gas ducts (including insulation and cladding) shall be provided to
form the complete air and flue gas system. The material of the ductwork, expansion joints and all
other parts of the systems shall be suitable for the thermal cycling and continuous operation at high
temperatures pertaining to the maximum load of the Aux. Boiler at the highest ambient
temperature.
Openings for inspection/maintenance shall be provided.
All ducting shall be designed to reduce the resistance to the air/gas flow to a minimum.
Expansion joints shall be installed into the ductwork wherever required to prevent undue thermal
stresses and to prevent any undue transmission of forces and moments towards the connected
equipment.
For measuring the gas temperatures an adequate number of sampling and test points shall be
arranged in the ducts at suitable positions. The test and sampling points shall be equipped with
gas tight covers retained against loss by chaining.
The air and flue gas duct system shall be provided with access manholes on all positions of the
system where inspection and maintenance is required. The diameter of the manhole shall be
600 mm. Adequate davit or hinges shall be provided. At the location of the access manhole an
adequate landing platform shall be provided inside the exhaust system where there is no obvious
landing within 800 mm of the manhole itself.
The duct shall be designed so that rainwater falling on the cladding shall run off.
The air and flue gas duct system shall be designed to avoid drumming, vibration and any
resonance with the gas pulsation under all operating conditions.
The air and flue gas duct system shall be welded steel plate construction suitable stiffened. The air
distribution to the burners shall be designed in accordance with the requirements of the individual
burner control.
All ductwork surfaces made from carbon steel shall internally be corrosion protected in accordance
with Part G5.5 Corrosion Protection and Painting.
Page: 19
Expansion Joints
Fabric type with inner sleeves expansion joints shall be installed within the ductwork wherever
required, to prevent undue thermal stresses and shall be able to compensate full movement of the
ductwork.
They shall be of high temperature fabric, multi-layered and reinforced with stainless steel wires or
of metallic type. The fabric shall be protected internally by insulation and metal sleeves. External
protection shall be by stainless steel wire mesh. All metal parts in contact with the expansion joint
fabric shall have rounded edges
Generally the Contractor shall follow his standard design, but they shall however not be of sliding
type and shall be provided with flanges in order to be able to replace them without disturbing the
ductwork. Inside the ducts, all expansion joints shall be protected against ingress of dirt and debris.
Special attention is to be paid to prevent that the joint insulation soaks water or fuel oil from failed
GT starts or washing.
Adequate access shall be foreseen for removal of the joints.
Expansion joints shall be of a make and type approved by the Engineer. Adequately ventilated rain
shields shall be fitted to all expansion joints.
Gas flow induced vibrations
The Contractor shall include in his design all measures necessary to ensure that no part of the
boiler installation and ductings shall be subject to any vibrations which are induced by gas flow and
which may reduce the design lifetime of any part of the boiler and ductings, or create equipment
noise exceeding the limitations as per data sheets.
The design measures shall include, if necessary, provision for the installation of damping
equipment after the initial start-up of the boiler. Baffles shall preferably be installed in line with the
direction of gas flow.
The Contractor shall take particular care in the design to ensure that the frequencies of gas vortex
shedding from the tubes do not excite or resonate with the natural frequencies of the superheater,
evaporator and economizer tubes. In addition, such vortex shedding frequencies shall not excite or
resonate with the acoustic frequencies of the boiler casing or ductings. That is to say that standing
waves shall not be generated.
The Contractor shall state after contract award, the Strouhal numbers and the gas vortex shedding
frequencies for each tube bank, as well as the lower natural frequencies of the tubes, and the
acoustic frequencies of the boiler casings.
Ducting shall be designed with the minimum number of bends. It shall be gas-tight and smooth and
bends shall have rounded profiles and be fitted with guide vanes.
Ducting shall be sufficiently stiffened against mechanical vibration and distortion. Stiffening shall
not restrict the free expansion of the ducting in any direction.
Effective vibration isolation from the gas turbine is particularly required. It shall be possible to drain
all ducting. All ducting shall be designed such that the free cross-sectional area provide stable gas
flow and acceptable pressure loss.
Transition pieces between duct sections of different cross-sectional are shall be provided as
necessary. These shall be designed with the objective of preventing flow detachment from the duct
wall and providing the most economical pressure loss.
Duct supports shall be designed so as to remove all loads from the boiler casing. Sliding supports
shall be designed to allow lateral and axial expansion movements of the ducting.
Page: 20
Burner flames shall not impinge on duct walls or boiler tubes or any metal part during any
3.12.3 Dampers
All necessary control and isolating dampers shall be provided for safe and automatic operation and
remote control.
The position of all dampers shall be indicated with graduated scales.
The bearings of the dampers shall be located outside.
Every damper assembly and its operating linkage shall be designed to function smoothly and
easily over the range of operating temperatures and the maximum differential pressure produced
by the draught plant.
All damper assemblies shall be bolted into their respective locations. The flanged joints shall be
designed to be gas and air tight at 200% of the design draught pressure and no flange bolts shall
be less than 16mm in diameter.
Dampers for; combustion control. purposes shall be specifically designed to provide control over
the boiler operating range.
Except where otherwise agreed, dampers shall be of the balanced type and mounted in frames
and, wherever possible, shall be arranged with horizontal spindles. Dust and gas tight seats shall
be fitted wherever necessary.
The spindles and linkages shall be stiff enough to resist the maximum forces that may be applied
by the actuators, without damage or binding occurring. Spindle bearings and interconnecting
damper linkages for dampers in hot gas locations shall be arranged so that they are clear of the
damper frame, thus permitting thermal insulation to be applied. The bearings on air control
dampers may be of the grease lubricated roller type. Bearing capsules, sealed for life, may be
provided as an alternative, but these will be subject to the Engineers approval. Bearings that are
easily replaceable are preferred in all cases.
Bearings on flue gas systems and on other dampers may be of low friction, self-lubricating
material, the bearings and spindles throughout being of non-corrosive materials, so that damper
operation will not be impaired if they are used very infrequently.
All linkages and operating mechanisms shall be provided with guards for personnel protection.
Operating levers shall be positively secured to their respective spindles and the position of the
damper blades shall be marked on the ends of their spindles. All dampers are to be fitted with a
manual operating facility, which shall include damper blade position indicator. The arrangement of
the damper shall, be such as to permit locking of the damper blade(s) in any position from FULLY
OPEN to CLOSED.
Hand operating gear and damper automatic actuators shall be located so as to be readily
accessible for operation and maintenance. Access shall also be provided for maintenance of all
damper spindle bearings. Actuators for automatic control shall be supplied in accordance with the
Instrumentation and Controls specification. Complete damper assemblies and actuators shall,
conform to the requirements of Part G5 of this Specification.
3.12.4 Observation and access

The gas duct system shall be provided with access manholes on all positions of the exhaust
system where inspection and maintenance is required, on both sides of the boiler. The cross
section of the manhole shall not be less than 600 x 600 mm. At the location of the access manhole
adequate landing supports (made of round steel bar) shall be provided inside the exhaust system,
Page: 21
where there is no obvious landing within 1 meter of the manhole. All doors shall be perfectly tight
when closed.
The Contractor shall supply a suitable number of access lanes between the tube banks of the
economiser, boiler and superheater sections.
Where applicable, i.e. in the burner / furnace area, observation windows shall be provided and
shall afford an unrestricted view of all burners and flames. The windows shall also allow
observation of all surfaces.
Where necessary, air purging shall be provided to keep observation windows sealed, clean and
cool. The glass shall have external covers to prevent cracking and shall be protected on the hot
side by pivoting metal plates.
It shall be possible to renew the glass during operation, using barrier air or the above mentioned
pivoting metal plates.
There shall also be a sufficient number of access and inspection doors and access space for each
section or tube bank of the boiler.
Cleaning of the tube banks shall be possible when the boiler is out of operation.
The minimum distance for access between convective tube banks shall be 800 mm.
Access doors shall have a free opening at least 600 x 600 mm and shall be located on both sides
of access spaces. Hand-rails for a safe access shall be available.
3.12.5 Auxiliary Fans

Any other fans required, such as ignition-, cooling-, sealing air fans (if necessary), shall be
provided redundant with a capacity of 2 x 100 % of MCR each. Duty standby selection facility shall
be provided for each set of two fans with automatic start-up of the standby fan upon failure / trip of
the duty fan.
All fans shall be complete with electrical drive, base frames, anchoring bolts, suction silencers, flow
control devices, etc. Means shall be taken to prevent back flow through a fan when not in
operation.
3.12.6 Steam Heated Air Heater

To prevent the flue gas from cooling down to its dew point, when the ambient air temperature is
very low, at partial load and during start-up, a steam heated air heater shall be provided on the
discharge side of the forced draught fan. The required steam shall be tapped from the internal
auxiliary steam system.
The Contractor shall supply correction curves, showing the steam consumption of the steam
heated air heater in relationship to the ambient air temperature and the boiler load.
The supply shall include all necessary valves, fittings, steam traps, steam supply pipework and
condensate pipework.
If the bidders design can avoid any dew point corrosion without air heaters even at Auxiliary boiler
cold start-up, no air heaters need to be provided. The air pre-heaters will be provided as specified
if this cannot be achieved.
Page: 22
3.12.7 Regenerative Air Preheaters

If required by the design, considering the boiler efficiency, the fuel quality, the sulfur content in the
fuel and the dew point of the flue gas, the Aux. Boiler shall be equipped with one rotating
regenerative air preheater. The regenerative air preheater shall be the counter flow design.
The regenerative air preheaters must be of approved manufacturer and design in form and
material of the heat exchanging elements. The parts exposed to hot flue gas shall be temperatureproof material and the parts exposed to cold flue gas shall resist corrosion. Corten steel (or
equivalent; to be approved by the Engineer) shall be used for cold elements. Enamel coated
elements shall be offered alternatively and the expected lifetime difference between enamel coated
and corten elements shall be indicated in the offer. The elements of the cold-end layer shall be
grouped in boxes so that they can be easily assembled and dismantled through an opening in the
casing. Devices for easy removal of baskets shall be provided.
The casing shall be of gas-tight welded construction. The bearings shall be located outside the
casing so that they are not exposed to the influence of temperature and ash. Preference will be
given to a forced lubrication system, which shall be combined with the driving system and the
appertaining cooling system. Double lubricating pumps shall be provided (one stand-by DC
operated). The oil circuit shall be complete with oil tank, suction strainers, duplex filters, isolating
valves, pressure and flow switches, oil coolers, safety and relief valves, local instruments for
indication, remote facilities for operation and control.
The regenerative air preheater shall be equipped with two separate driving units of the electromotor driven or hydraulic type. One of them will be as stand-by. The seals installed to minimise the
air leakages at the air and flue gas side of the preheater shall be capable to adjust themselves to
the thermal deformations of the rotor.
The regenerative air preheaters shall be protected and interlocked against high flue gas
temperature inlet, low flue gas temperature outlet, heaters low speed, low lubrication failure, etc.
and such interlock shall be incorporated with the interlock system.
Speed monitoring devices shall be installed to monitor the heater for remote indication and alarm.
The regenerative air heater shall be equipped with air by-pass duct provided with necessary
control damper to adjust flue gas temperature outlet of air heaters at low loads and start up
conditions. At boiler partial loads while firing DO the flue gas temperature outlet of air preheater
should be adjusted to avoid corrosion of air heater cold ends, flue gas ducts and stacks due to
sulfur. The Contractors are requested to submit curves in their offer indicating the sulfur dew point
variation with load, excess air, etc. At all cases, the flue gas outlet temperature shall be kept higher
than the dew point. The air by-pass duct shall be sized to handle approx. 30 % of MCR air.
All required control dampers on the regenerative air heaters inlet and air by-pass ducts shall be
provided. All dampers either for control and/or for isolation shall be remotely operated from thermal
control room with provisions for local operation.
The regenerative air heaters shall be provided with soot blowing system, washing and drain
facilities including connecting pipe to the waste water system.
Fire extinguishing and alarm facilities shall be provided.
If the bidder s design can avoid any dew point corrosion without air heaters even at Auxiliary boiler
cold start-up, no air heaters need to be provided. The air pre-heaters will be provided as specified
if this can not be achieved.
Page: 23
3.13 FORCED-DRAUGHT FAN

3.13.1 Fan
The discharge of the total combustion air shall be effected by 2 x 60% centrifugal type fans. The
control of the combustion airflow shall be effected via adjustable inlet vanes. The fan characteristic
shall be steady at any load. Blades for centrifugal fans are to be shaped to give non-overloading
power characteristics.
The fan performance curves shall show the following characteristics: static head, shaft power input,
speed, efficiency and system resistance, plotted against volume.
The fan casing shall be constructed for easy maintenance and to avoid undue vibration.
Condensate drain nozzles shall be provided at the lowest part of the casing. Screens and filters
should be fitted at the inlet and the fan must be sound isolated. The fan casing shall be equipped
with an inspection door.
The impeller shall be stress relieved after welding and shall, after having been dynamically
balanced in the manufacturers works, run without undue vibration or noise.
Each fan-motor unit shall be provided with on-line vibration monitoring system including the
vibration detectors, analysers, be interfaced to the DCS for measurement indication and alarm.
High vibration trip of any fan-motor unit shall be as a result of 2-out-of-3 voting logic. Type and
design of the system is subject to the Engineer's / Employer approval.
The supply of the fan also includes the forced lube oil system as well as the foundation.
A complete draught plant operating on the pressurised furnace principle shall be supplied for each
boiler.
Two forced draught (FD) fans (2 x 60%) complete with drivers, isolating dampers, baseplates,
lubricating systems and cooling systems shall be supplied for each boiler.
The drive system shall be a fixed speed electric motor with inlet guide vanes.
Fans may be of the centrifugal or axial flow type but only fan designs with long in-service records
shall be supplied.
The FD fans are to be located at ground level. The FD fan suction shall be located at 5.0 m above
grade level; with a rain hood and a stainless steel mesh screen to prevent ingress of large foreign
matter.
Any other boiler auxiliary fans for sealing air, cooling air purposes, together with ancillary
equipment shall be supplied by the Contractor.
The Contractor is to include any additional equipment he considers necessary in order to achieve
the specified operating conditions and is to include a description of the system and its control
philosophy together with a schematic diagram in his Tender.
The complete fan systems shall also conform, where relevant, to the requirements of the General
Technical Requirements of the Specification.
The Contractor shall supply all drawings and data requested and shall complete the relevant
Tender Schedules.
3.13.2 Fan Capacities and Characteristics

The fan shall be designed with due regard to the output of the boilers, type of fuel, the draught loss
across the air heaters, burners, boilers, economiser, superheaters and ducts including air
measuring device.
Page: 24
Each fan shall be capable of providing 60% of Boiler MCR requirements with the excess air in the
furnace of about 10 - 15% when operating with diesel oil and the design plant ambient air
temperature as defined in part G4.
In addition to the total fan requirements, there shall be an added design margin tolerance of 10%
on volume and 21% on head based on a fan design temperature of 50 C. (The design fan volume
shall take account of the 50 C design temperature).
The Contractor shall include details of each fan characteristic, and shall also show the anticipated
pressure loss characteristics of the boiler draught or auxiliary system, fan efficiency and power
curves and shall complete the relevant Schedule, of Technical Particulars.
3.13.3 Materials and Construction

The FD fans to be provided for the boiler plant shall have operating speeds, which do not exceed
1500 rpm.
The critical speed shall be at least 20 percent in excess of the maximum continuous running
speed. The rotors shall be statically and dynamically balanced.
Fans shall run without undue noise or vibration, the vibration being limited to an effective root
mean square velocity of 1.8 mm/s or less. Zone A of the relevant ISO codes and standards shall
not be exceeded.
The layout and arrangement of the fans shall enable operating and maintenance requirements to
be easily and economically achieved.
Fan casings shall be arranged so that the fan runners can be easily removed without extensive
dismantling of ducts or damper assemblies. Lifting eyes shall be provided on the various sections
to facilitate lifting.
Joint flanges shall be designed for the maximum static pressure of the draught system and no bolts
shall be less than 16mm in diameter. All necessary access doors for cleaning and maintenance of
the fans shall be provided and these shall be positioned so as to provide easy access both from
the outside and inside. Satisfactory access to any inlet control valves or control dampers shall be
provided.
FD fan casings shall be constructed of mild steel plates with adequate thickness and stiffening ribs
to provide additional strength and minimise flow induced vibration. The casing thickness shall be
stated in the Schedule of Technical Particulars.
FD fans shall have bearings on either side of the impeller; overhung impeller may be provided for
auxiliary fans but it shall be subject to the Employer / Engineers approval.
Fan casing shaft seals shall effectively prevent the leakage of air and dust under all normal
operating draught and temperature conditions.
FD fans shall have bearings on either side of the impeller. Fan bearings shall be of the sleeve type
with tilting pad thrust bearing. Each fan shall be provided with a self-contained forced lubricating oil
system consisting of 2 x 100% oil pumps, filters and oil coolers. Should temporary storage oil be
provided in the lubricating oil system, this fact shall be clearly labelled. All bearing housings shall
be adequately sealed to prevent the ingress of dirt or water.
All, necessary facilities for cooling the bearings shall be provided. The Contractor shall include full
details of the lubrication system including the quantities and the pressure of the cooling water
required.
The design of the lubricating oil system shall permit easy cleaning of any oil cooler, cooling jackets
or coils. Water-cooled jackets on bearing housing or cooling coils in oil reservoirs may only be
Page: 25
employed on clean fresh water systems. All materials in the water cooling system shall be to the
Engineers approval.
Grease lubricated rolling bearings may be employed on auxiliary fans only.
All lubricating systems shall be simple and of a proven high reliability. Indications of oil systems
failure and excessive temperatures shall be in accordance with the requirements of Controls and
Instrumentation section of this specification.
The bearing housing of the FD fan shall be mounted on stools separate from the fan casings.
Bedplates shall be provided for bearing stools, couplings, gearboxes and driving units. Stools,
bedplates and fan casings shall be sufficiently rugged as to resist adequately all normal operating
forces and loads.
All necessary holding down bolts shall be supplied. The bearings of auxiliary fans may be mounted
on the fan casings subject to the approval of the Engineer. Provision for steel shims shall be made
between all machinery or bearing housing feet to facilitate alignment. Alternatively, the use of
castable resin grouting material is permitted subject to the Engineers approval.
Flexible couplings shall be of a well-proven design capable of operating throughout the specified
operating periods without the need for attention or lubrication.
Rigid couplings may be provided but their acceptance shall be subject to the Engineers approval.
Where flat surfaces occur within the fan casing the maximum allowable area without reinforcement
shall not exceed 0.25m 2. The direction of the rotation of fan and drive shall be clearly and
permanently marked.
3.13.4 Fan Driving Units

Electric motors shall be suitable for use on a 11kV, 3 phase 50 Hz system and must comply with
respective specification clause. Steel shims to a total thickness of 6 mm are to be provided
between the motor feet and the bed plate pads.
3.13.5 Lifting Equipment and Maintenance of Draught Fans

Access to the draught fans shall comply with the requirements of Clause of the General Technical
Requirements of this Specification.
Suitable lifting beams with electrical hoists and steelwork shall be provided to assist in lifting out
and replacing fan casing sections, and all rotating parts of the fan and drive systems. These shall
be in accordance with the General Technical Requirements of this Specification.
3.14 STACK
One carbon steel stack shall be provided. which shall meet the Dubai Municipality environment
requirements. It shall be at least as high as the bypass stack i.e. min. 60 m above ground level but
should preferably have the same height as the HRSG stack.
The stack shall be constructed from carbon steel. It shall be corrosion protected inside and outside
in accordance with Part 5.5 Corrosion Protection and Painting.
The stack shall be of self-supporting structure. At the upper part vortex breakers shall be installed,
and at the bottom an access gate to be provided.
Diameter shall be determined during the detail design based on the calculation carried out by the
Contractor. The respective detail calculations shall be submitted during detail design by Engineers
approval.
Page: 26
When designing the stack, the maximum wind speeds, earthquake factor, etc. as stated in part
G4.3 Reference Site Data shall be taken into consideration.
The stack shall be provided with an access door located conveniently in the base section. Further
access for maintenance and inspection according to relevant guidelines e.g. DIN and VGB must be
provided.
A continuous ladder with enclosing safety cage and intermediate platforms shall be provided in
accordance with DIN and VGB guidelines or equivalent. The access ladder shall be extended to
the top of the stack for inspection purposes. At the top level a platform shall be provided around
the full circumference.
Lightning rods shall be provided as well as aircraft warning / position lighting, which may extend
over the specified height, which shall be designed in accordance with the regulations of the
International Civil Aviation Organisation (ICAO) and to be approved by the Dubai Civil Aviation
Authority, Dubai Airport. The exhaust stacks shall be painted red and white as per above
mentioned international and national regulations, respectively as decided by the Employer.
Eyes of corrosion resistant material shall be provided externally at the top to allow fastening of
pulley blocks for inspection and maintenance.
The bottom of the exhaust gas duct system shall be sloped towards a drain collection point. The
drain point shall be provided with sufficient drain pipes (size 80 mm) and plugs which shall be
arranged for easy access.
In case the Stack is insulated, the insulation shall be in compliance with the Part G5.1 General
Requirements for Mechanical Equipment - Insulation. Personnel protection shall be provided up to
about 4 m above the ground level and at all other relevant areas if the chimney will not be
insulated.
At the mouth of the stack, a deflector ring of stainless steel of adequate external diameter shall be
arranged to prevent down-flow of gases on the outside of the stack at extreme low loads.
Lugs of corrosion resistant material shall be provided externally at the top to allow fastening of
pulley blocks, for inspection and maintenance.
Earthing shall be in accordance with the requirements of part G5.2 General Technical
Requirements Electrical Equipment and P2.26 Technical Specification Electrical Equipment.
3.15 THERMAL INSULATION AND REFRACTORY MATERIALS

The thermal insulation of the Aux. Boiler, hot air and flue gas ducts and pipes shall be carried out
in accordance with the VGB-directives and the provision in part G5.1 General Technical
Requirements Mechanical Equipment and Piping
The cladding of the thermal insulation shall be made of seawater proof marine grade aluminium
sheets of 1.2 1.5 mm thickness depending on the application.
The use of refractory material in the Aux. Boiler unit and flue ducting shall be reduced to an
absolute minimum.
Refractory materials shall be applied for inspection and access openings, burner openings, etc.
Details of refractories & insulation shall be submitted for Engineers approval.
3.16 LIFTING APPLIANCE

Sufficient lifting appliances shall be provided for easy maintenance and repair.
Page: 27
Girders for fixing temporary lifting appliances shall be installed above all components having a
weight of heavier than 50 kg for maintenance and overhaul.
As a minimum 1 (one) permanent motorised hoist (500kg capacity) shall be installed on the top
platform. Landings and access platforms shall be provided at each main platform (from the ground
floor to the top platform.
Further requirements are stated in part P2.21 Cranes and Hoists.
3.17 PRESERVATION SYSTEM

The boiler shall be equipped with a nitrogen capping and dry lay-up system.
sections of the boiler (capping) with necessary piping and valves. The N2 bottles shall be stored
on ground level under a shaded roof.
3.18 PRE-SERVICE CLEANING AND BLOWING-OUT

Before the first start-up of the Aux. Boiler, the following items shall be chemically cleaned:
The Aux. Boiler and its associated internal steam and feedwater pipework.
Main steam lines from the Aux. Boiler up to the common HP steam header.
Main feedwater pipework and related auxiliary pipework.
The proposed process shall be fully described.

The obligation to perform an acid pickling can be waived if the Contractor can positively
demonstrate that all water and steam pipes, tube bundles and/or harps, etc., are in good condition
before installation, with only minor amounts of mill scale and rust. To ensure this, the Contractor
shall properly protect all equipment against corrosion during manufacturing, shipment and on-site
storage. The proposed process shall be clearly described in the offer. If all these conditions are
met, the acid cleaning can be replaced by a soft alkaline flush or boil out.
The cleaning processes shall be designed to ensure that the maximum amount of organic matter,
silica, mill scale, rust and other deposits are first detached from the metal surfaces to be cleaned
and are subsequently removed. Particular attention is drawn to non-drainable sections of the plant
to be cleaned, and special measures shall be taken to ensure adequate flushing to obviate
chemical damage.
All chemicals required like acid, inhibitors, etc., shall be provided including temporary valves,
pipework, pumping equipment, etc.
Provisions shall be made for "blowing-out" of the complete new steam pipework with steam.
Temporary pipework and supports that may become necessary, disconnecting and re-making of
joints shall be included.
Further details for cleaning of piping are stated in part G5.1 General Technical Requirements
Mechanical Equipment and Piping.
3.19 STEEL STRUCTURE

The requirements under Part G5.4.12 General Technical Requirements Civil apply. In addition,
the design of the steel structure for the Aux. Boiler shall meet the following requirements:
Page: 28
The Aux. Boiler shall be arranged with the total pressure parts comprising steam drum,
superheaters, evaporator, economiser, headers, integral pipework, spray attemperators, firing
equipment, air preheaters, etc., in the form of a self-contained unit supported by its own steel
structure. This structure is to be quite independent of any building.
In the extent of this item, the following shall be included at least:
Aux. Boiler main columns, girders and cross connections.
Supporting structure for platforms, stairs and galleries.
Supporting structure for flues and ducts and equipment located in those flues and ducts.
Buckstays, buckstay supports, tie bars.
Pipe racks for pipes located in Aux. Boiler area.
Access platforms and galleries for maintenance and operation for all equipment installed
(drum man-holes, water columns, gauge glasses and their shut off valves, safety valves, all
other valves associated with operation of the unit, access doors, inspection ports, entrance
doors for entire unit including furnace economiser, evaporator, superheaters, ducts, steam
temperature control devices, and burners). All valves and instruments shall be accessible from
fixed installed platforms where ever it is possible. Mobile facilities will not be accepted.
Girders for fixing the lifting appliances required for dismantling and mounting during
maintenance and overhaul shall be installed over all components having a weight heavier than
50 kg.
One set of full height stairs from grade to top of unit shall be furnished and installed for the
Aux. Boiler.
All steel structure shall be delivered complete with base plates, anchoring bolts, embedded
items etc.
All parts of steelwork and foundation bolts, which are required to be built into foundations or are
necessary for the support of the plant shall be first priority of delivery.
The design of the Aux. Boiler steel structure shall meet the following requirements:
The supporting structure shall be designed considering the internal forces and expansions, as
well as considering the forces from wind, earthquake and sun radiation. The design conditions
are stated in part G4.1 and G4.2 of the General Requirements.
Consideration shall be made that the steel structure can take over also forces of the pipes,
flues and ducts which will be eventually supported by the Aux. Boiler main columns.
In addition to this, the steel structure must be able to resist the forces resulting from water
filling of the Aux. Boiler and pipes during the hydraulic test, or from other loads during erection.
Special care shall be given to the design of pipe racks for steam pipes, which must be able to
support these pipes during water filling (hydraulic test or fluoric acid cleaning). In order to
avoid over stressing of the pipe racks and the appertaining foundations, the most critical
loading condition shall be considered.
Stairs and platforms shall be supported so that no forces shall be introduced into the Aux.
Boiler body itself.
All nuts, bolts and washers must be hot dip galvanised and properly protected against
corrosion before installation.
Page: 29
3.20 THERMAL INSULATION

In general, all exposed parts of the boiler and its auxiliaries with an operating temperature of more
than 60 C shall be thermally insulated. Personnel protection shall be provided at areas with higher
temperatures where insulation is not required.
The instrumentation herein shall meet part G5.3 General Technical Requirements Instrumentation and Control Systems.
A sufficient number of field sensors and local/remote indicators are to be provided to secure a
reliable and safe operation, monitoring and protection of the Aux. Boiler unit.
Wherever possible, field signal distributors, local indicators and transmitters shall be mounted in
groups to allow an easy operation, monitoring and maintenance.
All instrument tapping required for efficiency and performance tests and all provisions for the
installation of flow measuring devices shall be provided.
The control system requirements are described in part P2.27 Instrumentation and Control
Systems - Package P and shall be taken into consideration when designing the systems.
Analogue Controls
The control loops shall be optimized according to the ITAE criteria.
The accuracy of the control system shall be guaranteed for the following cases and control loops:
Controlled variable
load variation:
Conditions / Allowable control variations

= 1%/min
= 5 %/min
continuous continuous
range of the rated load:
40-100 %
40-100 %
10%
load steps
20%
load steps
40-100 %
40-100 %
Full Load
Rejection by
ST and/or
Desal. units
HP Steam Pressure
1.0 bar
2.0 bar
3.0 bar
5.0 bar
6.0 bar
HP Steam Temperature
(above 60% rated load)
1.0 %
2.0 %
3.0 %
5.0 %
5.0 %
Drum Level (in the % of the

drum internal diameter)
2.0 %
4.0 %
8.0 %
12.0 %
12.0 %
Excess Air (O2)
+ 2.0 %
- 0.5 %
+ 2.5 %
- 0.5 %
+ 3.5 %
- 0.5 %
+ 5.0 %
- 0.5 %
+ 5.0 %
- 0.5 %
The Contractor shall design the control equipment on such a way, that the above guarantee figures
can be reached.
The boiler shall not trip in case of a fan trip but the boiler load shall automatically be reduced to the
max. allowable load (which will be somewhat higher than 60%).
In case of load rejection caused by the backpressure steam turbine and/or the distiller unit(s) the
Aux. Boiler shall also not trip but reduce the boiler load automatically. The start-up valve could be
used to keep the boiler pressure below the set pressure of the safety valves. The control of the
boiler shall capable to avoid opening of any boiler safety valve upon a load rejection.
Page: 30
The requirements as stated in part G5.5 General Technical Requirements Corrosion Protection
and Painting shall be taken into consideration.
WEATHER PROTECTION CANOPY
An overhead corrugated sheet canopy of materials shall be provided to protect operating and
maintenance personnel from sun and rain. The contractor shall provide an efficient and
architecturally acceptable protective canopy over the boiler area.
All canopy sheeting shall be arranged to be supported from the boiler supporting steelwork and all
necessary steelwork, supporting purlins, shall be supplied under this contract. The canopy shall be
self-drainig and provided with adequate drain gulleys and downcomers to ground level.
The arrangement of the weather protection canopy shall be to the approval of the Employer /
Engineer.
The actual firing floor platforms are also to be provided with a ventilated enclosure to minimise the
ingress of dust and to protect the operators.
INSPECTION AND TESTING
The Aux. Boiler with all components shall be tested according to the relevant provisions of the
design codes and with the provisions stated in part G5.6 Inspection & Testing.
CNE/015/2002
P2.4
Fuel Oil Storage

and
Supply System for GTs and Boilers
WORKING DOCUMENT
Part P2.4 Fuel Oil Storage and Supply System for GT's and Boilers Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
PAGE
GENERAL ..................................................................................................................................... 1
DESCRIPTION.............................................................................................................................. 1
DO - DELIVERING FOR JEBEL ALI COMPLEX........................................................................ 1
DO - SUPPLY FOR STAT ION L, PHASE I.............................................................................. 1
DO DELIVERING FOR JEBEL ALI COMPLEX.............................................................................. 2

3.1
GENERAL ......................................................................................................................... 2
3.2
SCOPE OF WORKS......................................................................................................... 2
3.2.1
Unloading Facilities ..................................................................................... 2
3.2.2
New Pipe Line ............................................................................................... 2
3.3
DESCRIPTION OF THE PIPE ROUTING ........................................................................ 3

3.3.1
General .......................................................................................................... 3
3.3.2
PORT Area..................................................................................................... 3
3.3.3
DUGAS Area.................................................................................................. 3
3.3.4
DUBAL Area.................................................................................................. 3
3.3.5
Jebel Ali Power and Desalination Complex.............................................. 4
3.4
DESIGN / CONSTRUCTION REQUIREMENTS.............................................................. 4
3.5
CATHODIC CORROSION PROTECTION....................................................................... 6

3.5.1
Scope of Works ............................................................................................ 6
3.5.2
Design Requirements and Data.................................................................. 6
DO - SUPPLY FOR STAT ION L, PHASE I..................................................................................... 7

4.1
LAYOUT ............................................................................................................................ 7
4.2
SCOPE OF WORKS......................................................................................................... 8
4.3

4.3.1
General .......................................................................................................... 9
4.3.2
Diesel Fuel Oil Storage Tanks with Floating Suction ........................... 10
4.3.3
Diesel Fuel Oil Forwarding System for GTs.......................................... 10
4.3.4
Diesel Fuel Oil Forwarding System for Auxiliary Boilers..................... 11
4.3.5
Diesel Fuel Oil Return System.................................................................. 11
4.3.6
Transfer System......................................................................................... 11
4.3.7
Drain System............................................................................................... 11
4.3.8
Diesel Fuel Oil Pumps................................................................................ 12
4.3.9
Strainers and Filters................................................................................... 13
4.3.10
Piping and Valves....................................................................................... 13
4.4
INSTRUMENTATION AND CONTROL ......................................................................... 14
4.5
INSPECTION AND TESTING......................................................................................... 14
4.6
FIRE FIGHTING AND FIRE DETECTION ..................................................................... 14
P2_04fuel_oil_Working_Doc.doc
Page: 1
GENERAL
This specification describes the technical requirements for the diesel fuel oil (DO) system as backup fuel for the gas turbines and the auxiliary boilers and covers the minimum requirements for the
design, engineering, manufacture, erection and inspection, commissioning and testing.
This specification describes further the technical requirements for the DO - pipeline from the Jebel
Ali Port / Fuel Suppliers Terminal to Jebel Ali Power and Desalination Station Complex to ensure
the DO delivering for the existing and the future Stations.
2
2.1
DESCRIPTION
DO - DELIVERING FOR JEBEL ALI COMPLEX
At present DO is delivered by road tankers and unloaded at Stations D and E to the storage
tanks at Station D and at Station E respectively. The storage tanks at Station G are filled from
the Station E using their transfer pumps.
DO as back-up fuel not only will be needed for Station L, Phase I, but for all the other existing
stations and those to be built in future in case that natural gas is not available.
To ensure the reliability of DO supply for the whole Jebel Ali Power and Desalination Station
Complex a new pipe line shall be built, starting from the Jebel Ali Port / Fuel Suppliers Terminal,
running in principle parallel to the existing medium fuel oil pipe line till to the boundary of
Dugas/Dubal, turning to east till eastern boundary of Dubal. From there it shall run northwards
along the perimeter fence of Dubal and Jebel Ali Power and Desalination Station Complex.
In Jebel Ali Complex the new pipe line shall be connected to the filling header of storage tanks for
Station L, Phase I and Phase II and to the existing DO storage tanks at Stations D, G and E.
Connection facilities shall be provided for the future DO tanks.
2.2
DO - SUPPLY FOR STATION L, PHASE I
DO system supplies the following consumers in Station L, Phase I:
The Gas Turbines
The Auxiliary Boilers
The Black Start and Emergency Diesel Generators
Diesel engine driven fire fighting pump.
For Station L, Phase I and Phase II six (6) DO storage tanks are planned in total, each with a net
capacity of approximately 8,500 m 3.
Four (4) tanks shall be built within the scope of Station L, Phase I and two (2) tanks within the
scope of Station L, Phase II.
The tanks and all DO facilities for Phase I shall be designed and supplied considering the
extension in future and connection possibilities for Phase II. Adequate land space shall be
provided for the addition of the two (2) DO storage tanks, fuel oil forwarding skids, etc. for Station
L, Phase II. All headers for pipes, such as fill lines, suction and return lines shall be designed and
supplied for all six (6) tanks. All relevant headers shall be equipped with isolating valves with blind
flanges in order to be connected with the two (2) tanks and piping systems for Phase II in future.
Page: 2
All common equipment of the tank farm like sump oil tank, fire fighting equipment, etc., shall be
designed and supplied for the whole demand of Phase I and Phase II, i.e. for all six (6) DO tanks.
3
3.1
DO DELIVERING FOR JEBEL ALI COMPLEX

GENERAL
Diesel fuel oil will be delivered by ship tankers and unloaded at the tanker berths in Jebel Ali Port.
It is expected that at the area of berth No. 5 and berth No. 7 is adequate space on the concrete
platform to extend the existing unloading capacities with supplementary unloading arms and
accessory facilities. However, any necessary civil work shall be provided by the Contractor.
A new pipe line, starting from the Jebel Ali Port / Fuel Suppliers Terminal shall connect the tanker
berth No. 5 / berth No. 7 to the Jebel Ali Power and Desalination Station Complex.
The proposed scope is shown on the following drawings:
Principle Diesel Fuel Oil Supply Line, Drawing No. CNE/015/2002-W-00-G-D-00015
Principle Pipe Line Route, Drawing No. CNE/015/2002-W-00-G-D-00016, not valid for the
portion west and north of Dubal area
Drawing No. MP/0429- Proposed Route for 24 dia. Fuel Oil Pipe Line for the portion south
and east of Dubal and other drawings showing the pipe route underground services of DUBAL
are attached to this Addendum 1.
3.2
SCOPE OF WORKS
3.2.1 Unloading Facilities

The unloading station shall include, but shall not be limited to the following main equipment:
Two (2) marine unloading arms
One (1) pig launcher including the provision of N2 gas supply connection for pig launching
required for maintenance. If no DO has been inside the lines, compressed air may be used to
perform pig launching for mechanical completion.
Two (2) x 100% DO booster pumps, if required
N2 cylinder battery for flushing the unloading arm
Piping, fittings, expansion joints, valves, non-return valves, valves and piping for drains and
vents, thermal relief valves, etc.
All necessary instrumentation and control works
All necessary electrical works
3.2.2 New Pipe Line

The new pipe line shall include, but shall not be limited to the following main equipment:
One (1) Pipeline 16 to 24, length appr.13,000 m,
Three (3) x 50% flow meters
One (1) pig receiving station
Page: 3
Drain and vent stations as required
Road crossings, pipe crossings (gas-, fuel-, water lines), crossings of channels, crossings of
water outlet and inlet, etc. as required
One (1) Tee-off 16 with isolating valve and connection to the filling header at Station L
One (1) Tee-off 16 with isolating valve and connection to the road tanker unloading header at
Station D
One (1) Tee-off 16 with isolating valve and connection to the road tanker unloading header at
Station E
One (1) Tee-off 16 with isolating valve and connection to the existing DO header at Station
G
Three (3) Tee-offs 16 with isolating valves and blind flanges for future connections
Piping, fittings, expansion joints, valves, non-return valves, valves and piping for drains and
vents, thermal relief valves, etc.
3.3
DESCRIPTION OF THE PIPE ROUTING
3.3.1 General
The 24 DO pipeline shall connect a new marine unloading arms at the Jebel Ali Port (Berth No. 5,
No. 7) with the existing and new Stations in Jebel Ali Power and Desalination Complex.
The pipeline shall in principle be buried with the exception of the crossing over restrictions, if
required.
The routing of the pipeline should be mostly parallel to the existing 24 Medium Fuel Oil (MFO)
pipeline described hereunder.
This specification does not enumerate or describe all the restrictions and crossing points to be
considered and all the services to be performed. All materials and equipment shall be provided as
are required to make a complete, safe and properly functioning installation for the pipeline.
The restrictions listed below correspond to a minimum to be considered. The completeness shall
be verified by the Contractor. It is the Contractors responsibility to obtain all necessary Non
Objection Certificates from the concerned Companies and Authorities as the case may be.
3.3.2 PORT Area

The routing for the new pipe will be stipulated by the Jebel Ali Free Zone Authorities.
3.3.3 DUGAS Area

The routing in the DUGAS area should be in principle parallel to the existing pipelines (24 gas,
24 MFO and 2 x 36 water pipelines). Sufficient space is available on the shore to bury the new
pipe without observable restrictions except the three crossing points with DUGAS lines (2 x 16
feed lines and 1 x 12 fuel gas line).
3.3.4 DUBAL Area

At the southern boundary of Dubal, the line turns eastwards and run in the piping corridor along the
south boundary fence of Dubals future expansion site. At the eastern tip the route turns to the
Page: 4
north and run outside of Dubals fence. At the roundabout it crosses H.P. gas line and follows this
line at the west side into DEWAs land and there runs inside the fence till to the Jebel Ali Power
Station Complex, under crossing one culvert and one planned road at the southern boundary of
DEWAs land.
Attached to this Addendum is also the drawing of Dubal marking related buried services. The
accuracy of these drawings is not guaranteed however, and confirmation of the existence of
services should be obtained by trial excavations.
3.3.5 Jebel Ali Power and Desalination Complex

3.3.5.1 Existing Pipelines in the Area
The following pipelines are buried or haunched in the area of Jebel Ali Power and Desalination
Complex and to be considered by the routing for the new pipeline.
24 gas pipeline
24 MFO pipeline
2 x 28 water lines
2 x 36 water lines.
The haunched 48 gas pipeline is located outside of the old fence and will not be a restriction for
the routing of the new pipeline.
3.3.5.2 Between the fence to DUBAL and Station G

An isolating valve and an oil metering station shall be supplied directly after entering the DEWA
Area.
From the fence the pipeline shall be routed towards the Station L and after crossing the existing
water lines (2 x 28) parallel to the existing haunched pipelines.
In the area of the DO storage tanks for Station L, Phase I and II, the pipeline shall be connected
with a 16 tee-off to the filling header of the tanks. Further on 3 x 16 tee-offs including isolating
valves and blind flanges shall be supplied for future connections.
3.3.5.3 Between Station G and Station D

At the present time the fuel oil is pumped from the storage tanks in station E to the storage tanks
in station G. The transfer lines (1 x line for DO and 2 x lines for HFO) are located between the
haunched lines mentioned above and other facilities of the existing stations so that there is
insufficient space available to bury the new pipeline up this connection point.
In this area the new pipeline must run on sleepers or on pipe rack.
The DO storage tanks in Station G and the unloading station E shall be connected to the new
pipeline with 16 tee-offs and isolating valves.
3.3.5.4 Area Station D

The new pig receiving station shall be located at the end of the pipeline near to the existing MFO
pig receiving station. Connection line shall be provided from the new pig receiving station to the
existing unloading station D.
3.4
DESIGN / CONSTRUCTION REQUIREMENTS
The new pipe line and the unloading facilities, valves, flow meters, etc. shall be designed for the
following design conditions:
Design Pressure
16 bar
Mass Flow
2,400 m 3/h
Pipe Line
16 to 24
Minimum Earth Cover for the Pipe Line
1.0 m
Page: 5
The pipe shall be designed with the size between 16 to 24 and shall be in carbon steel and be
principally buried.
The buried pipework shall be protected from corrosion by polyethylene-coating (PE) and cathodic
protection appropriate to the requirements of this specification.
The minimum of the thickness for polyethylene-coating shall be 3.0 mm. The piping and fittings to
be coated shall be properly prepared at the pipe manufacturers works. The pipe ends shall be
stripped of the coating and shall be oiled for temporary corrosion protection.
All pipe ends shall be supplementary coated after welding by wrapping with tape or by similar
measurements. All welds shall be allowed to cool below 55C before application of primer and
tape. The temporary corrosion protection shall be removed after welding. The wrapping shall be
applied spirally with overlap of 50%, that is, all parts of the stripped area shall be at least double
wound. The tape shall extend 75 mm each side of the coating.
The coated pipelines shall be handled in such a manner that it is installed in the bottom of the
trench without damage to the coating. The coated pipe shall not be moved by means of cables or
chains, or by prizing with skids or bars, but shall be handled only by side booms, tractors or cranes
equipped with wide belt slings, specifically designed for lifting pipelines of the size and weight of
the pipe being handled without damage to the wrapping.
The underground pipework shall be designed in order to withstand the loading from covering soil
as well as from traffic as applicable.
The underground pipe route shall be indicated by above ground markers.
In the area of Jebel Ali Power and Desalination Station Complex the pipeline shall be connected to
the filling header of the storage tanks for unit L, Phase I and Phase II
the road tanker unloading headers at Station D and Station E
the existing DO header for Station G.
Furthermore connection facilities, such as isolating valves with blind flanges shall be provided for
the future stations.
The pig receiving station shall be located at the end of the pipe line, i.e. in the area of Station D.
The received DO shall be measured by a metering station consisting of 3 parallel operating meter
runs (two duty, the third standby). Each meter run shall be designed for the 50% of the ultimate
flow rate and shall be equipped with local display and electronic counter, pick-up, strainer and gas
separator. The flow meters shall be accurate to within 1 % overall. Flow transmitters shall be
provided to transmit the flow signal to the DCS. Flow integrator shall be built in the software of
DCS as well as the local integrator.
Page: 6
3.5
CATHODIC CORROSION PROTECTION
3.5.1 Scope of Works

The scope of works shall include all studies, design, supply, installation and commissioning, etc. of
a cathodic corrosion protection system of the impressed current type to protect all steel and steel
structures, which are buried. This shall include:
Co-ordination with other metallic parts, e.g. the earthing system, etc., buried into the soil
All material and works required for the implementation of the cathodic protection system.
3.5.2 Design Requirements and Data

3.5.2.1 General
Cathodic protection, either by a sacrificial system or by an impressed current system shall be used
as required to ensure long term corrosion protection. The system design shall consider the
following:
Soil resistivity prevailing at the Site
Ten years minimum service life of anodes for impressed current cathodic protection
Five years minimum service life of anodes for sacrificial cathodic protection
The impressed current protection system shall automatically maintain a voltage level as required
by the design of the system and the anodes utilised. However, in the event that alterations to the
voltage may be desirable when reviewing actual protection performance, the equipment shall be
capable of being readjusted to new figures.
The criteria for protection shall be in accordance with the applied standards and code of practice
as to be proposed by the Contractor for approval.
3.5.2.2 Sacrificial Cathodic Protection

In plant areas where the risk for fire and/ or explosion hazards is inherent due to materials handled
in such area, sacrificial anodes shall be provided.
3.5.2.3 Impressed Current Cathodic Protection

In plant areas where sacrificial cathodic protection is not mandatory, protection by impressed
current shall preferably be provided.
3.5.2.4 Design Particulars

The design and the selection of material and methods shall consider that beside steel structures
and pipes other metallic parts as cables, earthing conductors, etc., shall be buried into the ground.
That equipment shall not be affected by the cathodic protection system.
The AC and DC systems, as well as control and monitoring devices shall be designed in
compliance with the relevant electrical and I&C Specifications of this specification.
Ground anodes for buried structures shall be suitable for the intended environment including the
prevailing soil and ground water conditions.
Sacrificial anodes shall preferably be of zinc or aluminium alloy.
Impressed current anodes shall preferably be copper cored titanium, continuously plated with
platinum. Anodes shall be protected against physical damage in service.
Page: 7
Reference electrodes shall preferably be of high purity zinc or aluminium.

The reference electrodes shall have adequate surface to prevent the polarisation.
Sensing electrodes shall be incorporated to provide a feedback to the automatic voltage regulation
equipment.
Reference electrodes shall be provided for all areas under protection.
Adjustable, automatic control of impressed current protection shall be provided to allow the level to
be set to match developing Site conditions.
The anodes shall be spaced sufficiently far from the structures to prevent crud build-up and high
local current flow. In addition, an extra thickness of protective coating shall be incorporated
between the adjacent parent metal and the anode.
The control equipment shall be so arranged that each group of equipment shall be controlled
independently of other equipment.
The supply and distribution cubicles shall be located in relation to the equipment being protected.
Monitoring of the individual distribution cubicle supply and anode voltages as well as alarm
facilities shall be provided.
Failure of individual anode system, of distribution cubicle supply and of protection coating shall be
monitored individually locally and groupwise in the CCR.
Link boxes shall be provided to enable testing of the galvanic current.
All buried steel pipework to be protected shall be provided with electrically isolating flanges where
it emerges from the ground and no connections between the buried pipework and the electrical
earthing grid shall be made unless required through polarisation cells, to maintain safe potential
gradient control.
Protective coatings, i.e. polyethylene coating, shall be employed on buried pipes to minimise
protection current requirements. All pipe joints shall have protective coatings applied.
Excavations for pipe runs shall be lined with sand or fine grit and the backfill shall be suitably
graded and applied to minimise damage to the pipe coating.
Each pipe run shall be supplied with a cable cad-welded in place for subsequent connection of the
cathodic protection system.
4
4.1
DO - SUPPLY FOR STATION L, PHASE I

LAYOUT
The proposed layout of Station L, Phase I is shown on the following drawings:
General Layout, Drawing No. CNE/015/2002-X-01-G-D-00025
Principle Diesel Fuel Oil Diagram, Drawing No. CNE/015/2002-W-00-G-D-00002, not valid for
the portion west and north of Dubal area
Drawing No. MP/0429- Proposed Route for 24 dia. Fuel Oil Pipe Line for the portion south
and east of Dubal (attached to this Addendum 1)
The four (4) DO storage tanks for Station L, Phase I shall be located as shown in the General
Layout. Adequate land space shall be reserved for the addition of the two (2) DO storage tanks for
Station L, Phase II.
Page: 8
The fuel oil forwarding skids for GTs and Auxiliary Boilers (pumps, strainers, gauge and control
panel etc.) shall be arranged on the concrete platform, under a proper sun shed in a fenced
structure, located near the diesel fuel oil storage tanks. Adequate land space shall be provided for
the addition of the fuel oil forwarding skids for the Station L, Phase II.
The transfer pumps to transfer DO from one tank to the other tank and to pump DO to the Day tank
shall also be provided in this area.
4.2
SCOPE OF WORKS
The scope of provide and services shall comprise the respective components of the diesel fuel oil
system as specified including all the equipment which is necessary for the safe and efficient
operation of the plant.
The necessary controls, interlocks, firefighting equipment and installations, earthing facilities, etc.
shall be provided to ensure safe operation of the system.
Thermal relief valves, drains and vents shall be provided as required.
The specification does not enumerate or describe all the materials and services to be performed.
All materials, equipment and services shall be provided as are required to make a complete,
properly functioning installation and shall confirm to the highest standards of engineering design
and workmanship.
All applicable international and national codes and standards shall be adhered to.
The scope of work to be provided shall mainly consist of but shall not be limited to:
Four (4) DO storage tanks with a capacity of 8,500 m 3 (net) each, including the tank
equipment such as valves, instrumentation and control equipment, floating suction, etc.
Headers for the filling, suction, transfer and return lines designed and supplied for all six (6)
DO storage tanks, connected to the tanks and the pumps for Phase I and equipped with
connecting facilities for Phase II respectively
One (1) Day tank with a capacity of 12 hours for full load of emergency generators as well as
black start diesel generators, complete with tank equipment e.g. valves, instrumentation and
control equipment
DO supply system complete from the storage tanks to the gas turbines, including mainly:
Two (2) x 100% DO forwarding pumps for each GT
Two (2) x 100% duplex suction strainers for each GT
Two (2) x 100% duplex filter coalescer units complete for each GT
DO supply system complete from the storage tanks to the Auxiliary Boilers, including mainly:
Two (2) x 100% DO forwarding pumps
Two (2) x 100% duplex suction strainers
Two (2) x 100% duplex filter coalescer units complete
One (1) x 100% flow meter for each Auxiliary Boiler
Two (2) x 100% DO bulk transfer pumps, including one (1) duplex suction strainer each
One (1) x 100% DO transfer pump, including one duplex suction strainer to Day tank
Page: 9
Two (2) x 100% drain pumps with one (1) x 100% duplex filter coalescer units each
One (1) Slope oil tank, at least 5 m 3, complete with tank
One (1) Sump oil tank, at least 1 m 3 with all facilities to discharge in a sludge vehicle
Pipework, fittings, expansion joints, valves, non-return valves, relief valves, strainers, filters,
flow meters, etc. for mainly:
Filling system from the header to the tanks
Forwarding system from the tanks to the GTs, the Auxiliary Boilers and the Day tank
Return system from the GTs and Auxiliary Boilers to the tanks
Transfer system from tank to tank
Forwarding and return system from/to Day tank to/from emergency diesel generator, black
start facility
Drain system complete
Accumulators (if required)
Service and instrument air system (is required)
Control valves including actuators, positioners, limit switches, solenoid valves, air set and
other associated control equipment
Local panel
Control and monitoring
Local instrumentation
Cathodic protection for the pipes below ground
Oily water separator with all requirements
Thermal relief valves and piping
4.3
4.3.1 General
The design of the DO System shall enable the gas turbines to start, generate up to full load and
shut-down on either gas or diesel fuel. In addition, it shall be possible to change automatically and
manually from gas to diesel fuel oil whilst on load on sensing a falling gas pressure or manually
from diesel fuel oil to gas whilst on load.
The DO supply system shall be equipped with headers , which allow
to fill each tank separately from the header,
to transfer DO from each tank to other tank,
to take DO from each tank,
to fill the Day tank.
It shall be possible to run the DO supply system while one tank is under maintenance.
Page: 10
The pump station shall be provided with a bridge crane for maintenance purposes for all pumps to
be installed for Phase I and Phase II.
Part G4 General Project Requirements and Part G5 General Technical Requirements of this
specification shall be adhered to.
4.3.2 Diesel Fuel Oil Storage Tanks with Floating Suction

Each tank shall have a separate concrete catching basin dimensioned to contain the volume of the
tank and plus water of 30 cm height.
The tanks shall be of the vertical straight cylindrical type constructed of carbon steel plates.
Design, engineering, manufacture, erection and inspection, commissioning and testing shall be
carried out according to the General Technical Requirements Mechanical Equipment and
Piping as specified under Part G5.1
Corrosion Protection and Painting shall be carried out according to the General Technical
Requirements Corrosion Protection and Painting as specified under Part G5.5
4.3.3 Diesel Fuel Oil Forwarding System for GTs

Each gas turbine shall be provided with a separate pipework from the suction header containing
mainly
Two (2) x 100% duplex filter coalescer units.
One pump shall serve as standby or maintenance and shall switched on automatically if pressure
is under a certain limit.
The DO forwarding pumps shall provide a constant suction pressure for the gas turbines. The
transient period of the pump shall be tolerated without a pressure collapse and without causing a
trip, a shutdown or a load fluctuation in the GT whilst running fully on oil over the whole range from
0 to 100 %.
Local and remote operation/control indication shall be provided. Pressure relief valves shall be
provided on the discharge lines to provide a return flow at part load condition, or to work as
minimum flow protection. A trip of the pump should not cause a successive trip of the gas turbine.
The discharge lines shall have sufficient volume - or shall be provided with an accumulator - to
ensure buffer capacity during the automatic switch over to the standby pump. The buffer capacity
shall be selected to compensate the missing pump capacity during the switch over time.
There shall be an automatic fire safe ball valve on each GT fuel oil supply line. This valve shall be
located on skid with flow meter and filter coalescers just outside the GT hall and shall be tripped by
GT fire detection system.
it shall be the responsibility of the Contractor to provide additionally equipment or to design the DO
system in such a way that vapours/air ingress inside the fuel system are inhibited or eliminated by
other means rather than closing the fire shut off valve without fire detection actuating during
shutdown or outage of GT.
Page: 11
4.3.4 Diesel Fuel Oil Forwarding System for Auxiliary Boilers

The Auxiliary Boilers shall be provided with a common fuel oil supply line with
Two (2) x 100% duplex filter coalescer units.
Downstream of the filters the supply line shall be separated. The separate line to each Auxiliary
Boiler shall be equipped with a flowmeter.
4.3.5 Diesel Fuel Oil Return System

Diesel fuel oil not consumed by the GTs and/or the Auxiliary Boilers shall be collected via return
lines in the return header. From the return header DO shall be distributed to the storage tanks.
4.3.6 Transfer System

The DO supply system shall be provided with two (2) x 100% DO forwarding pumps, each
equipped with a 100% duplex suction strainer to
transfer DO from tank to tank
transfer DO to the Day tank with one (1) x 100% forwarding pump equipped with one suction
strainer.
Each pump shall have the capacity to transfer the whole volume of a full tank to the other tanks
within 8 hours.
4.3.7 Drain System

Tank area
All waters of the tank area as well as the tank dewatering drains shall be collected in a concrete
sump basin with suitable oil-prove coating and a sufficient capacity to collect the rain water. The
sump basin shall be provided with 2 x 100% sump pumps, level switches for alarm and pump's
protection, manual pump operation and low and high level alarms. The collected fluid in the sump
basin shall be transferred to the oil interceptor basin. .
The oil interceptor basin shall be made of concrete with suitable oil-prove coating comprising one
chamber for water-oil separation and a second chamber for retention of the separated water
phase. The oil interceptor basin shall be equipped with level switches and remote maximum level
alarm. Suitable oil and oily sludge transfer pumps (2 x 100%) shall be provided to transfer the oil
and sludge to a sludge vehicle for final disposal. The water from the oil interceptor basin shall be
directed to a soak-away pit by (2 x 100%) water transfer pumps.
DO supply area
All fuel oil drains and vents of filters, pumps, relieve valves, etc. of the DO supply system shall be
collected in a drain tank made of carbon steel of at least 5,0 m 3. The tank to be provided shall be
installed in a concrete pit. The concrete pit shall be provided with a sump and suitable oil-prove
coating. Collected fluids from this pit shall be removed by a portable submersible sump pump to
the sump basin of the tank area.
Page: 12
Two (2) x 100% drain pumps, shall transfer the fuel oil back to the storage tanks. Level switches
for automatic pump operation, protections and alarm shall be provided.
4.3.8 Diesel Fuel Oil Pumps

The pumps shall be designed to allow satisfactory and safe operation during all possible operating
conditions, including cold and hot start up.
Each pump shall be provided with necessary relief valves, combined minimum flow and non-return
valves and isolating valves and all devices necessary for safe and efficient operation and
maintenance.
Diesel fuel oil pumps shall be horizontal, centrifugal pumps, self venting, with declining Q-P curve
and shall be designed in accordance with requirements of API 610.
The pumping units shall be free from harmful vibrations under all load conditions.
Sound pressure level shall be rated and measured according to the ISO standards Noise
assessment with respect to annoyance. Precision sound level meters shall be used for measuring
sound pressure levels. When the whole system is in operation at full load, the maximum
acceptable level shall not exceed 85 dB(A) at 1 m distance. The acoustic measurements shall be
carried out in accordance with ISO 3744.
The pump casing shall be made of cast/forged steel. The shaft and impeller shall be of stainless
steel. The pump shafts shall be fitted with renewable sleeves of stainless steel or other approved
material. Renewable wearing rings shall be fitted at points of running clearance. All bearings shall
be arranged to facilitate inspection and repair.
The combined shaft system shall be designed such that any critical speed is at least 20 % above
the running speed.
Each pump shall be designed to permit removal of the rotating parts such that the casings can
remain connected to the suction and discharge pipework.
The pump set shall be supplied complete with centrifugal pump, drive motor, flexible coupling,
mechanical seal, flushing system with piping and common base plate for pump & motor with drip
tray.
The selected impeller diameter shall be smaller than the maximum impeller diameter that can be
accommodated by the pump such that a 10% head increase can be achieved by replacing only
with the maximum diameter impeller. Spare wearing rings shall be undersized in bore so that they
be machined to suit any reduction in diameter of the impeller neck due to wear.
Pumps selected shall have stable performance curves with head continuously rising up to shut off.
Pumps shall be provided with pressure gauges at least on the suction and discharge branches.
Gauge boards shall be provided for the mounting of pressure gauges adjacent to the equipment to
which they refer. Pressure gauges shall be provided with suitable isolating valves to enable them
to be removed at any time without shutting down any part of the system. The range of pressure
gauges shall be approximately twice the normal working pressure. Additionally pump suction and
discharge pressure transmitters shall be provided and connected to the DCS. The function of each
instrument shall be clearly indicated on the face of each instrument dial.
Grease lubrication anti-friction bearings shall be provided for the pumps. Anti-friction guide
bearings shall be ball bearings designed for the rated life of the unit under the design operating
conditions. Anti-friction thrust bearings shall be sized for 175 % of the required thrust load.
The pumps shall be equipped with a spacer coupling; the spacer length shall permit the removal of
the coupling, bearings, seal and/or rotor without disturbing the suction and discharge lines.
Page: 13
Pumps shall be equipped with mechanical seals.

Drainage facilities shall be provided on the pump casing and/or adjacent pipework to facilitate
dismantling of the pumps.
All the equipment, including instruments shall be from an approved manufacturer. Equipment shall
be robust design and dustproof construction. It shall be possible to service the equipment with a
minimum of dismantling.
Control and instrumentation shall be integrated in DCS.
4.3.9 Strainers and Filters

4.3.9.1 Duplex suction strainer
The duplex suction strainer with manual change over facilities shall be located on the suction side
of the DO forwarding pumps and shall be complete with all necessary fittings. The strainer screens
shall be of stainless steel. Strainer change over shall not interrupt the supply of fuel and it shall be
possible to clean or renew the stand-by filter element whilst the system is running.
4.3.9.2 Duplex filter coalescer

Duplex filter coalescer unit complete with on load change over valve shall be supplied for each DO
forwarding pump. Each unit shall be capable of passing the full flow of fuel oil for the GT. The
coalescer shall ensure that the water in the fuel is below ten parts per million. The filter coalescer
shall be positioned in such a manner that cleaning and maintenance can be carried out without the
necessity of isolating the other full lines. If the filter cover can not be lifted and positioned easily by
one person the integral lifting equipment shall be provided.
Automatic operation to dispose coalesced water to oily drains system shall be provided.
The strainer and filter shall be equipped with differential pressure gauges and transmitters
connected to DCS.
4.3.10 Piping and Valves

All pipework and valves shall comply with in the Part G5 General Technical Requirements of this
specification.
Pipes outside the buildings shall be above ground and/or on pipe racks. Only the pipes between
the tank area (area L, Phase II) and the pipe racks on the area of L, Phase I shall be buried.
Polyethylene coating and cathodic corrosion protection shall be provided for the buried pipe.
All piping shall be designed, constructed and tested in accordance with ANSI B31.1 or ANSI B31.3
as appropriate.
The pipes shall be anchored, supported and guided in such a way to prevent excessive thrust of
stress due to the combination of internal pressure, thermal expansion and weight of the connected
items. With the exception of those items, which require flange joints to facilitate removal, all
interconnection piping shall be butt welded. Pipework design within the dike area shall make due
allowance for any tank settlement which may take place.
All the inlet and outlet equipment and pipework terminal connections shall be flanged in
accordance with ANSI B 16.5. The discharge flange ratings shall be adequate to withstand the
maximum discharge pressure of the pump. The minimum pressure rating for flanged connections
shall be class 150.
All nuts and bolts shall fulfil the requirements specified in Part G5 General Technical
Requirements. The gaskets shall be of fuel oil resistant type.
Page: 14
Provisions shall be made to neutralise all possible static electric charges arise on fuel oil system,
e.g. see NFPA Standard 15/77.
In consideration to the tank to tank transfer operation, the relevant suction and pressure pipe work
shall be sized according to the increased capacities, considering the maximum fuel flow for GTUnit operation and the tank to tank transfer capacity simultaneously.
Suction pipes from the tanks to the headers shall be routed passing through the dike wall. The
sealing of the opening around the piping in the dike wall, which shall be made of stainless steel,
shall prevent any leakage from both directions and shall be subject to approval by the Engineer.
The diesel fuel oil pumps shall be designed to empty the storage tank considering this requirement.
All valves shall have cast steel or forged bodies.
All pipe sections between valves shall be equipped with pressure relief valves.
To allow proper venting and draining of all pipe sections, all necessary vents and drains required
must be provided, at each section. Sufficient slope to each vent and drain must be provided. All
vents and drains shall be piped to the relevant drain.
4.4
Instrumentation and Control shall be carried out according to the General Technical
Requirements as specified under Part G5.
The number and installation of diesel fuel oil flow meters shall be such that a complete mass
balance per gas turbine is possible. They shall be capable of passing the full load designed fuel oil
flow without restriction. The flow meters shall be accurate to within 1 % overall. Flow transmitters
shall be provided to transmit the flow signal to the DCS. Flow integrator shall be built in the
software of DCS as well as the local integrator.
Control, monitoring, interlock and protection system has to be provided as far as required for safe
and satisfactory operation and supervision of DO system mainly operated from the CCR.
4.5
Inspection and testing shall be carried out according to the General Technical Requirements as
specified under Part G5.6.
4.6
FIRE FIGHTING AND FIRE DETECTION
Fire fighting and fire detection system shall in accordance to the requirements specified in Part G5
General Technical Requirements and Part P2.23 Particular Technical Specifications Station
Fire Fighting and Fire Detection Systems.
CNE/015/2002
P2.5
Gas Systems for GTs and Boilers
WORKING DOCUMENT
Part P2.5 Gas Systems for Gas Turbines and Boilers Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
PAGE
GENERAL ..................................................................................................................................... 1
CONNECTION TO SUPPLIER PIPE LINES................................................................................ 2
LAYOUT ........................................................................................................................................ 2
SCOPE OF WORKS..................................................................................................................... 3
4.1
GAS PRESSURE REDUCING STATIONS...................................................................... 3
4.2
GAS BOOSTING COMPRESSOR STATION.................................................................. 4
4.3
FURTHER FACILITIES .................................................................................................... 4
DESIGN / CONSTRUCTION REQUIREMENTS.......................................................................... 6

5.1
GENERAL ......................................................................................................................... 6
5.2
EMERGENCY SHUT-DOWN (ESD) VALVES................................................................. 7
5.3
FUEL GAS SCRUBBING / FILTERING SYSTEM........................................................... 7
5.4
CONDENSATE TANK...................................................................................................... 8
5.5
FUEL GAS HEATING SYSTEM....................................................................................... 8
5.6
GAS PRESSURE REDUCING SYSTEM ......................................................................... 9
5.7
GAS CONSUMPTION METERING ................................................................................ 10
5.8
GAS BOOSTING COMPRESSOR STATION................................................................ 10
5.9
EXPANSION VESSELS / SURGE VESSELS ............................................................... 11
5.10
FINAL GAS CONDITIONING......................................................................................... 11
5.11
PIPEWORK AND VALVES ............................................................................................ 12
5.12
DRAINS AND VENTS..................................................................................................... 12
5.13
INERT GAS SYSTEM ..................................................................................................... 12
5.14
GAS CHROMATOGRAPH ............................................................................................. 13
5.15
GROUND FLARE CUM-INCINERATION SYSTEM ...................................................... 13
ELECTRICAL .............................................................................................................................. 13
INSTRUMENTATION AND CONTROL ..................................................................................... 13
INSPECTION AND TESTING..................................................................................................... 14
P2_05gas_systems_Working_Doc.doc
Page: 1
GENERAL
Station L shall be operated with dual fuel:
Natural Gas (NG) as primary and Diesel Oil (DO) as back-up fuel for GT operation,
NG as primary and Diesel Oil (DO) as back-up fuel for Auxiliary Boiler operation and
NG for supplementary firing for Waste Heat Recovery Boilers (HRSG).
The Natural Gas System (NGS) serves to receive the natural gas from the supplier and transfer it
to the consumers on site.
Within NGS the natural gas shall be filtered, condensate shall be removed and the pressure shall
be controlled. All imaginable fuel gas mass flows shall be covered keeping at the same time the
pressure fluctuations downstream of the control valve / boosting compressor within the permissible
limits of the gas turbine manufacturer.
The NGS shall be able to supply sufficient quantity of natural gas under all plant conditions and
under consideration of the lowest lower heating value of the natural gas to the customers.
Gas pressure at terminal point will be minimum 21 bar(a), maximum 50 bar(a) normal supply
pressure 23 25 bar(a). Under normal operation conditions, the natural gas will be received at a
temperature of about 18 C to 32 oC. However, when the complete power plant is out of service the
gas temperature may fall below the lowest ambient temperature of 2.8C, i.e. this lowest
temperature shall also be considered in the design. The NGS shall be designed corresponding to
the natural gas consumption of the offered GTs under all possible operating conditions,
considering the supplementary firing for the HRSGs and/or the consumption of the Auxiliary Boilers
respectively.
Gas Heaters shall be provided in order to prevent the gas temperature from dropping below the
dew point of the gas and to keep the gas temperature between the limits given by the gas turbine
manufacturer.
The design of the gas fuel supply system shall enable the gas turbines to start, generate up to full
load and shut-down. In addition, it shall be possible to change automatically and manually from gas
to diesel oil whilst on load on sensing a falling gas pressure or manually from diesel oil to gas
whilst on load. Pipe dimensions downstream the reducing station shall consider adequate storage
capacity for a trouble free change over from gas to diesel oil at all load ranges up to full load in the
event of sudden closing of either Emergency Shutdown valve (ESD) and or Slam Shut Off valves
without load reduction.
Each GT shall be provided with a complete separate Pressure Reducing/Boosting Train, consisting
of emergency shut-down valves, filters/separators, heaters, gas pressure reducing stations,
metering and gas compressors.
It must be ensured that each of these Pressure Reducing/Boosting Trains can be taken out of
service for repair and/or maintenance and that in this case all three (3) GTs with the HRSGs - or
the two (2) Auxiliary Boilers respectively - can be supplied with NG by the remaining two (2)
Pressure Reducing/Boosting Trains. For this purpose all the three (3). Pressure Reducing/Boosting
Trains shall be connected with each other via cross connection pipes, manual isolating valves,
non-return valves, etc.
The cross connections shall not be used to control the normal operation of the GTs / HRSGs.
Each GT / HRSG shall be operated unit-wise.
The design flow rate of each Pressure Reducing/Boosting Train shall be at least 1.5 times 100 %
of the maximum demand. When designing the system the Contractor shall ensure that a single
Page: 2
failure in any gas supply train together with the receiving station does not lead to a gas turbine load
reduction or even a gas turbine trip. This requirement includes also a gas compressor trip and gas
compressor change over.
CONNECTION TO SUPPLIER PIPE LINES
Natural Gas will be delivered to Jebel Ali Power and Desalination Complex through the following
pipe lines:
1 x 48 Natural Gas pipe line of DUSUP.
2 x 24 Natural Gas pipe lines from DUGAS.
All of the above mentioned pipelines are connected with each other.
The 48 pipe line is already equipped with:
Two (2) x 16 Tee-off branch with isolating valves for L Station (one for Phase I and one for
Phase II)
Two (2) x 20 Tee-off branches with isolating valves for the future Stations
Further one of the 24 pipe lines is equipped with a 24 tee-off branch with an isolation valve
located near the G Station through which DEWA has plans to built a Header under a separate
contract between Station G and K. An isolation flange will be made available at G Station tapoff area for connection to Station L Phase I.
The piping which connects the 1 x 16 tee-off branch valve provided on the 48 line for Station L
Phase I shall form a suitable header to feed Station L Phase I. Isolating valves with blind flange
shall be provided on both ends of the above header for the connection to the future Stations (Refer
drawing no.: CNE/015/2002-W-00-G-D-00001).
The connection from the supplier lines to the header shall adequately match the maximum NG
demand of the Station even in case that the gas supply is interrupted from one line. In case that
the gas supply is from the 24 line is interrupted, gas will be taken from the 48 line via the 1 x 16
valve and from DEWAs new header in case of interruption of gas supply from the 48 line. The
Contractor shall verify for both cases that these connections will be sufficient even at an ambient
temperature of 2.8oC when the GTs and HRSGs are at full load and at the most unfavourable gas
conditions mentioned above. Hot taps on the 48 gas line for further connections shall be provided,
if required.
LAYOUT
The proposed layout of unit L, Phase I is shown on the following drawing:
General Layout, drawing No. CNE/015/2002-X-00-GD-G-D-00025.
The Natural Gas Supply System shown in the Diagram No. CNE/015/2002-W-00-G-000001 is
amended to reflect the text of Clause 2. Refer also to Annex 1
The Gas Pressure Reducing Station shall be located near to the plant fence and to the existing gas
pipelines. All equipment of the Gas Pressure Reducing Station shall be installed outdoors in a
fenced and concrete compound covered by a sunshade and furnished with cranes and hoists as
required. The fence shall be provided with lockable gates and proper lighting. Fire fighting
equipment shall be installed as described in Part P2.23 Station Fire Fighting and Fire Detection
Systems.
The new Ground Flare-cum-Incinerator Stack shall be located near to the Gas Pressure Reducing
Station.
Page: 3
The Gas Boosting Compressor Station shall be located between the Gas Pressure Reducing
Station and the Gas Turbines. Thus, the piping volume between the gas compressors and the gas
turbines can serve as a buffer to avoid inpermissible pressure fluctuations / oscillations at the gas
turbines during fuel change over. Supplementary surge vessels respectively expansion vessels
shall be provided, if required.
SCOPE OF WORKS
The intent of this specification is to define the minimum technical requirements of the natural gas
system for the combined cycle power plant without excluding other necessary components and
services not specifically mentioned herein.
The Contractor shall be responsible for the design, engineering, selection, manufacture,
procurement, installation, commissioning and testing of the complete system.
The specification does not enumerate or describe all the materials and services to be performed.
All materials, equipment and services shall be provided as are required to make a complete,
properly functioning installation and shall confirm to the highest standards of engineering design
and workmanship.
The system shall be complete in every respect including any ancillary work for a safe, reliable and
proper operation of the plant including any civil, mechanical, electrical and I & C works. All
applicable International and National Codes and Standards as well as the requirements of the local
gas supplier together with the local rules and regulations and the gas turbine manufacturer shall be
adhered to.
4.1
GAS PRESSURE REDUCING STATIONS
Gas Pressure Reducing Stations serves to:
Supply of natural gas in the quantity and quality required to the gas turbines at all operation
conditions;
Supply of natural gas for the supplementary firing of the HRSGs
Supply of natural gas for the firing of the Auxiliary Boilers
Shave off the high pressure gradients during normal plant operation
Isolate of the natural gas supply system from the gas turbine in abnormal operation conditions;
Inertisation of the natural gas system for inspection and maintenance.
Each GT / HRSG will be provided with one (1) separate Gas Reducing System including mainly:
(100 % means NG consumption of one (1) GT on base load operation and low ambient
temperature and one (1) HRSG on maximum demand)
Emergency Shut Down Valves
4 x 100 % per GT
Fuel Gas Scrubbing / Filtering System
2 x 100 % per GT
Fuel Gas Heating System
2 x 100 % per GT
Fuel Gas Pressure Reducing Valves
3x
50 % per GT
Fuel Gas Combined Monitor Control / Slam Shut Off Valve
3x
50 % per GT
Fuel Gas Slam Shut Off Valve
3x
50 % per GT
Page: 4
Fuel Gas Pressure Reducing Valves for start-up or no-load

operation with a Combined Monitor Control / Slam Shut Off
Valve and a Slam Shut Off Valve (if required)
1x
Fuel Gas Metering System
1 x 100 % + 1 x 50 %
per GT
Gas chromatograph for fuel gas quality monitoring
1 x 100 % for all GTs
An inert gas system for purging the NG system will be

provided. Nitrogen will be used as inert gas and will be
provided in refillable bottles
One (1) common condensate tank, including condensate

collection system and pumps
Safety Valves, On-Off Valves,
4.2
10 % per GT
GAS BOOSTING COMPRESSOR STATION
In case that the gas pressure is below the required pressure of the gas turbine manufacturer, gas
compressors shall be provided to boost the pressure.
Compressor bypass lines shall also be provided in order to be able to bypass the gas compressors
if the gas pressure at the Gas Pressure Reducing Station is high enough for the gas turbines
operation. The gas compressors shall start and stop automatically with pre-warning alarm in the
CCR.
Each Gas Turbine shall be provided with one (1) separate Gas Boosting System including mainly:
Gas Boosting Compressors
3 x 65% per GT
Gas Coolers
Separate for each

compressor
Pressure Control valves
Safety Valves, On-Off Valves, Shut-off Valves
All associated pipework, valves, no return valves and

accessories,
Silencers and sound insulation
4.3
FURTHER FACILITIES
The natural gas system shall also be provided with:
Expansion / surge vessel(s) and gas storage system,
Ground Flare cum-incineration System including the flare

stack
Additionally Second Fuel Gas Pressure Reducing Valves,

Combined Monitor Control / Slam Shut Off Valve and
Metering devices as required
if required
2 x 100 % per HRSG
Page: 5
Additionally Second Fuel Gas Pressure Reducing Stations

with constant pressure control valves, Combined Monitor
Control / Slam Shut Off Valve and Metering devices as
required
2 x 100 % per Aux. Boiler
Fuel Gas Pressure Reducing Valves, Combined Monitor

Control / Slam Shut Off Valve for start-up
1 x 100% per Aux. Boiler
Final Gas Conditioning consisting of a final filter device, final

metering device (2 x100%) and a final high speed shut-off
valve
2 x 100% per GT
All associated pipework, valves and accessories, root valves

for tapping points, isolating flanges for cathodic protection (if
applicable)
Drains and vents, orifices, strainers, filters, pumps, safety

valves
Fire detection and CO2 fire fighting system
Platforms, walkways and stairs, whenever required
All required electrical works
All necessary field instrumentation and sensors, transmitters,

etc.
Actuators for all control valves
Instrument and Service Air System
Impressed current cathodic protection and monitoring system

(if applicable)
Closing of all wall openings in buildings for the piping
Consumables such as first fill of lubrications and greases
Tie-in with existing facilities
All standard equipment and accessories which are normally

included in the supply schedule but not separately
mentioned here
Page: 6
5.1
GENERAL
The NGS shall be designed in accordance with the relevant international standards, e.g. for sour
gas service in accordance with National Association of Corrosion Engineers standard MR -01-7590.
The NGS shall be designed in accordance with General Technical Requirements specified in Part
G5 and the General Project Requirements specified in Part G4.
The Gas Pressure Reducing Station and Gas Boosting Compressor Station shall fulfil the
requirements of the manufacturer of the gas turbines. For capacity calculations the Lower Heating
Value together with the lowest ambient temperature shall be taken into consideration.
The Contractor shall collect gas samples in order to produce proper fuel gas composition and shall
satisfy himself fully in this regard. A natural gas analysis is included in the Contractors scope of
supply.
The NGS shall be capable of supplying natural gas under all possible operating conditions of the
plant in a proper way including but not be limited to:
Base load operation:
Each GT and each HRSG supplementary firing are operating at peak load
Each GT are operating at peak load, HRSG without supplementary firing
Combined load operation e.g.:
One (1) GT and one (1) HRSG at base load + two (2) Auxiliary Boilers are operating
Two (2) GTs and two (2) HRSGs at base load + one (1) Auxiliary Boiler is operating
No GT and two (2) Auxiliary Boilers with BPSTs in service
During start-up, shutdown
Part load operation / load gradients
Only one GT with HRSG supplementary firing is in operation
Two GTs with HRSGs are in operation
Load rejections
The NGS shall be designed to meet the near field and far field emission standards.
The natural gas system shall be provided with all the necessary drains, vents and inert gas
connections.
Pipework from the Gas Pressure Reducing Station to the Gas Boosting Compressor Station as
well as the pipes from the Gas Boosting Compressor Station to the final filters and gas pressure
reducing trains of the boilers shall be installed on pipe racks. The connection-pipes between the
supplier pipelines and the Gas Pressure Reducing Station shall be installed above ground.
All equipment, instruments and valves shall have easy access from fixed platforms for repair and
maintenance.
The NGS shall be electrically isolated from the main supply system with an insulating flange.
Page: 7
Sound pressure level shall be rated and measured according to the ISO standards Noise
assessment with respect to annoyance. Precision sound level meters shall be used for measuring
sound pressure levels. When the whole system is in operation at full load, the maximum
acceptable level shall not exceed 85 dB(A) at 1 m distance. The acoustic measurements shall be
carried out in accordance with ISO 3744.
5.2
EMERGENCY SHUT-DOWN (ESD) VALVES
Each GT- Gas Pressure Reducing/Boosting Train shall be equipped with 2 x 100% lines including
each 2 x 100% emergency shut-down valves (ESD), depressurising valves and relief valves
located downstream the tie-in point. In the event of an emergency the ESD valves shall isolate the
Gas Pressure Reducing Station from the supplier pipes.
All ESD and depressurising valves shall be of double cylinder type and shall have fail to remain in
position mode.
Each train shall be provided with a dedicated LCP (local control panel) for the operation of the ESD
and depressurising valves.
Each ESD and depressurising valve shall have its own hardwired emergency pushbutton (EPB) at
the LCP and in the CCR on the Power Control Desk. Each LPC EPB shall have 4 contacts, 3 of
them for trip with 2 out of 3 relay logic in each LCP and one contact for to the DCS for indication.
The connection to the EPB in the CCR shall be directly hard wired and shall use 3 channels with 2
out of 3 selection. a fourth contact shall be connected to the DCS process station of the pertaining
train.
The ESD valves shall be capable of being operated either from the control room or locally without
using a selector switch.
Opening/releasing of the ESD valves shall only be possible locally by hand. For resetting a
compensating line shall be installed across the ESD valves for pressure balance. The
compensating line shall be provided with a block ball valve.
Open/Close position of the ESD and depressurising valve shall be indicated at the LCP and on the
DCS operator workstations.
At the ESD valves manual depressurising valves shall be provided for maintenance of ESD valves.
The depressurising valve shall be sized in accordance with the requirements of API RP 521.
The ESD valves shall not be associated with any interlocks.
Hardwired interlock shall be provided to prevent the depressurising valve from opening before the
ESD valve is closed.
The ESD valves shall be fire safe in accordance with API-607 or BS-5146 and of anti-static
design in accordance with BS-5351.
5.3
FUEL GAS SCRUBBING / FILTERING SYSTEM
Each GT shall be equipped with 2 x 100 % Fuel Gas Scrubbing / Filtering System.
The combined cyclone/filter unit shall be foreseen to separate liquids and dust/particulate matters
from the gas.
The dust-liquid separators shall be vertically orientated and shall be designed to meet the
requirements of the latest technology. They shall be particularly suitable for filtering solid particles
and separating liquids from the gas. The liquid separator shall be designed taking as a minimum a
0.1% liquid content under normal operation condition into consideration. Under abnormal operation
condition i.e. when the gas line was out of service for some time and the gas temperature has
Page: 8
dropped to or below the lowest ambient temperature a flood of liquid may enter into the liquid
separators. Thus, the system shall be sized to avoid positively any deleterious operation condition
and damage to the plants equipment like e.g. gas compressors and / or the gas turbines.
The filter separator elements shall be designed for the maximum flow of clean gas of the gas
turbine such that the differential pressure across the filters shall not be greater than 0.1 bar. The
elements shall also withstand a differential pressure of 2.0 bar without rupture.
A solids and liquid collection unit including a coalescer filter, capable to remove particles down to
1 m shall be provided.
The filters shall be of automatic self cleaning type.
A condensate draining device for the scrubber/filtering unit shall enable automatic and manual
operation. The condensate draining lines shall be installed as stainless steel pipes and valves.
Filter separators and vessels containing filter elements, demister pads or other equipment shall be
provided with a differential pressure indicator and high differential pressure alarms to indicate when
cleaning is not operating properly.
The filter separator shall be equipped with level gauges and level switch high level alarms to
indicate if liquids have accumulated in the filter, drain valves, a lockable vent valve connection
leading to the vent system, a pressure safety valve and a vessel purge connection. The discharge
of the safety relief valve shall be connected to the flare system.
5.4
CONDENSATE TANK
One (1) common condensate tank shall be provided for the whole NGS.
The drain shall be provided with two series connected ball valves for isolation, control valves,
2 x 100 % pumps and connecting pipework to the flare for incineration. The tank shall be equipped
with level gauges and level switch high level alarms. The control valves in the drain lines shall
open automatically whenever the condensate level in the tank exceeds a preset value.
The condensate tank shall be equipped with a blow off line on the top including two ball valves, a
safety relief valve with block ball valve and a pressurising line with a block ball valve branched on
the main line and needle valve on the tank. The blow off and the discharge of the safety relief valve
shall be connected to the flare system.
The condensate tank shall have a minimum 4 weeks storage capacity to store slurry and
condensate but not less than 4 m 3. 2 x 100% pumps with necessary protection including piping and
valves shall be provided to pump the condensate to the flare-cum-incineration system.
To facilitate regular cleaning of the tank a manhole of 600 mm diameter shall be suitably located.
5.5
FUEL GAS HEATING SYSTEM
Each GT shall be equipped with 2 x 100 % gas heaters.

The gas heaters shall be fired with natural gas and be equipped with mainly:
one (1) pressure control valve
one (1) combined monitor control / slam shut off valve
one (1) slam shut off valve
on-off valves, safety valves.
Page: 9
The gas heaters shall be provided upstream of the pressure reducing train, in order to prevent the
gas temperature from dropping below the dew point of the gas and to keep the gas temperature
between the limits given by the gas turbine manufacturer. They gas temperature shall be at least
kept so that no water shall condense from the atmosphere on the external surfaces of the gas line.
The gas heaters shall have stainless steel tube bundles and tube sheets.
The tapping point for gas extraction shall be downstream of the Gas Consumption Metering.
5.6
GAS PRESSURE REDUCING SYSTEM
Each GT shall be equipped with 3 x lines for 50 % load and 1 x line for 10 % load (start-up, partial
load, no-load operation, etc.).
Each line shall be equipped with
one (1) pressure control valve
one (1) monitor control valve
one (1) slam shut off valve
on-off valves, safety valves.
The valves shall be operated by the flow medium.

The gas pressure at the set value shall be regulated by the pressure control valve. In case of
failure of the pressure control valve, the monitor control valve shall take over the gas delivery
pressure at the required value. Failure mode of the pressure control valve in both stages shall be
open fully. Loss of instrument air or electric control signal shall cause the pressure control valve to
open fully. The monitor control valve shall be open fully when the pressure control valve is in
normal operation. Failure mode of the monitor valve is to close fully. The pressure sensing for
each control valve actuation shall be from independent tapping points after pressure control valve.
The pressure control valve actuation shall be done by different DCS modules for independent
equipment and by different DCS stations for each GT-train.
The monitor control valves shall be highly reliable self-operated valves, with a pilot actuator
controlled by the flow medium. The gas supply line to the pilot actuator shall be taken from a
dedicated tapping point for each valve located ahead of the slam shut off valve.
It shall be possible to select any one at the three 50% streams per GT as a duty stream, a stand-by
stream or a back-up stream. In the stand-by stream the pressure control valve shall be fully closed
in automatic mode and shall be ready to come into service automatically whenever the pressure
drops down below a preset value, the monitor control valve shall be fully open and shall only come
into service automatically whenever the controlled pressure shoots up to a preset value. In the
back-up stream the same concept of the standby stream shall be followed with a pressure setting
of the active valve lower than the standby stream setting.
Changeover from the 10% stream to the duty selected 50% stream and vice versa shall be
automatic. Staggered pressure settings shall be used for the pressure controllers of the active
control valves. Flow controllers shall also be used as flow limiters to ensure that the opening of the
active control valves under the pressure controllers will not exceed the flow capacity of each
stream. The whole control logic is subject to the Engineer's / Employers approval.
All control valves and monitor control valves shall be taken in operation at regular intervals of
approximately 4 weeks. An alarm system shall be installed to manually change over the 50%
streams from one mode to another mode by exceeding this time period.
Page: 10
The slam shut-off valve shall close when both the control valves fail and the outlet pressure
exceeds a preset value. The slam shut-off valves shall be equipped with gas/pneumatic pilot
operated actuators. They shall be provided with latching mechanism and manual release handle.
Each line shall be provided with a safety relief valve, an inlet and outlet hand operated isolating
valves to isolate the line from the system and a hand operated valve to relieve the pressure of a
line in case of maintenance. Non return valves shall be provided before each outlet hand operated
valve.
5.7
GAS CONSUMPTION METERING
Actual consumption metering shall be carried out with 1 x 100 % and additionally 1 x 50% flow
meter per GT train. The design of the flow meter, number of flow meter runs and size of each
stream shall be based on the range of gas flow rates envisaged and shall be to the approval of the
Engineer/Employer.
Whether the gas flow metering system shall be placed on LP side downstream of GPRS or on HP
side upstream of all other equipment shall be subject to Tender clarification.
Each line metering shall have independent pressure and temperature measuring tapping. The
measured gas flow shall be corrected to standard temperature and pressure conditions by a flow
computer. The flow meters shall not be used for control of any plant operations.
The flow meters shall be provided with isolating valves.
The flow meters shall have tariff metering accuracy ( less than 1 % accuracy in the whole range
from minimum to maximum gas flow rates) and shall comply with API Chapter 14, Section 3 (AGA
Report #3, Gas producers association 8185-90) specification.
It must be possible to bypass the flow meters via a by pass line. The by pass line shall be
equipped with double block valves with a centre bleed valve to verify that the block are holding.
Flow transmitters shall be provided to transmit the flow signal to the DCS to be displayed on the
VDUs in the CCR. Also necessary RTUs and accessories for transmitting the flow signals to
Dubai Supply Authorities (DUSUP) Gas Control Station at Jebel Ali shall be provided. Details of
which will be furnished during Project execution.
Flow computers shall be provided separately for each train and shall be installed in an air
conditioned electronic room of the pertaining train. The flow computers shall be interfaced to the
DCS. Model, type, number configuration and interface type of the flow computers is subject to the
Engineer's / Employer's approval.
5.8
GAS BOOSTING COMPRESSOR STATION
The gas pressure at the Gas Pressure Reducing Station may always or only sometimes not be
sufficient to operate the plant in a reliable manner. Thus, a natural gas compressor station shall be
provided.
The gas compressors shall be of oil-free centrifugal type and it shall be ensured that sufficient lube
oil is also supplied during a total power failure. The Contractor shall provide a DC lube oil pump if
required. 2 x 100% lube oil pumps, filters, oil coolers, etc. shall be provided for each compressor.
The bypass gas coolers shall have sufficient spare capacity that cooling of gas is still ensured even
in case of a failure of one compartment / module, as applicable.
The natural gas boosting compressor station shall increase the gas pressure in order to be able to
operate the plant at full load at the lowest ambient temperature as well as to allow the operation at
any partial load. For this purpose 3 x 65 % gas compressors shall be provided for each GT. A
separate line shall enable to bypass the gas compressors if the gas pressure after the reducing
valves meets the requirements of the gas turbine.
Page: 11
The system shall be designed in such a way that bumpless switching on and off of any compressor
is possible without exceeding the maximum permissible pressure variations and / or oscillations.
The gas pressure at the GT skid shall not fall under the minimum pressure given by the gas turbine
manufacturer for full load when switching off and/or tripping of one compressor and switching on
the other compressor. This requirement is also applicable during the start-up time of the stand-by
compressor. The Contractor shall particularly ensure and consequently shall provide all measures
that no load reduction of the GT will occur upon a gas compressor change over or a gas
compressor trip. It shall also be ensured that the gas pressure at the inlet of the GT will not drop
down to the setting of fuel changeover.
Depending on his own optimisation to realise the above requirement, the Contractor is free to offer
additionally other solutions such as provisions of accumulators, suitable storage facilities, etc. for
the gas compressors (3 x 65 % each) or other measures not specified here.
The compressor station shall be designed to meet the near field noise emissions of max. 85 dB(A)
as well as far field emission standards at the fence of the Power Plant. Noise attenuation hoods
shall be provided in case the noise levels cannot be kept below these values.
The compressors shall be equipped with vibration dampers if required.
The compressors shall be designed according to API-standard 618.
The drive motors and all other E-motors shall be of explosion proof design.
The lubricating pumps shall be of spindle type and provided with separate driver motors.
The compressor coolers shall be preferably of the air cooler type.
Load control shall be achieved by a bypass system leading the compressed gas back to the inlet of
the compressors. In this case, gas coolers shall be provided. The gas coolers shall be of gas to air
type. The gas coolers design shall at least foresee a spare capacity of 15% or the failure of one
fan.
Control and supervision of the compressor station shall be done by the Plant DCS system. It must
be ensured that the compressors switch automatically on in case of the pressure is below the
minimum skid pressure given by the GT manufacturer. An alarm shall be provided in case the
capacities of the compressors in service exceed the capacity required by the plant.
5.9
EXPANSION VESSELS / SURGE VESSELS
The requirements of pressure variations and pressure oscillations at the fuel skid of gas turbines
shall be strictly adhered to. The system shall be designed in such a way that bumpless switching
on and off of any compressor including trip of a compressor is possible without exceeding the max.
permissible pressure variations and or pressure oscillations. The Contractor shall ensure that
upon a compressor trip the gas turbine does not reduce its load or even trip.
Thus, surge vessels respectively expansion vessels shall be provided if necessary, in order to
ensure full compliance with the above.
5.10 FINAL GAS CONDITIONING

Upstream of the fuel gas skid of the gas turbine, a final filter device, a final metering device and a
final high speed shut-off valve shall be supplied.
The final-chance filter shall be provided to remove corrosion products from the system as well as
any moisture entrained in the event of damage to the gas heater.
Page: 12
5.11 PIPEWORK AND VALVES

All the equipment shall be fitted with isolating valves and also with depressurising valves to permit
repair and maintenance without interrupting the gas supply. Non-return valves shall be provided
before each inlet of hand operated valve.
The piping downstream of the final filter device up to inlet skid of GT shall be in stainless steel.
The velocities in the main gas piping shall not exceed the values specified in Part G5.1 General
Technical Requirements Mechanical Equipment and Piping
Flanges in fuel gas pipework shall be kept to a minimum.
All isolating valves shall be ball type and be furnished with double block and bleed. All isolating
valves shall be designed to withstand the differential pressure across them when closed.
All gas vessel nozzles shall be flanged.
The internal surface of all pipes in this system shall be cleaned and dried after hydraulic testing.
All the gas pipes shall be designed, constructed and tested in accordance with BS or ANSI B31.1
or ANSI B31.8 Gas Transmission and Distribution Piping System, as appropriate.
Insulation flanges shall be foreseen to disconnect the above ground system from the below ground
system. Flanges shall be electrically bridged over for grounding.
Whenever there is a risk of pressure above design point safety relief valves shall be provided.
5.12 DRAINS AND VENTS

All the gas lines shall be sloped to drain to a series of drain valves located at suitable points.
These drain valves shall be lockable.
The drains from each filter separator and other liquid drainage points shall be fitted with a nonreturn valve and manual isolating valve. The drains shall be grouped and connected to a common
drain header leading to the condensate tank.
Vents and discharge lines of the safety relief valves shall be connected to the common vent/flare
system with the exception of the vent before GT connection. The shut of valves in the vent line
from the safety valves shall be locked open by an approved master key system.
5.13 INERT GAS SYSTEM

Nitrogen shall be used as inert and purge gas.
The capacity of the N2 cylinder battery to be provided shall be sufficient to purge the NGS
completely.
Only one type of refillable nitrogen bottles shall be used with a volume of 50 litre and an initial
nitrogen pressure of 200 bar.
The N2-battery station shall be furnished with the necessary instruments and valves for proper
handling as well as a convenient number of hoses with connections with a length of not less than
7 m shall be provided.
Sufficient permanent valved connections and vents for purging shall be foreseen. The fuel gas
supply system shall be equipped with isolating valves so that isolating and purging shall be
possible without the need for complete shutdown. However, sectionwise system isolation and
purging shall be possible without need of systems shut-down.
Page: 13
5.14 GAS CHROMATOGRAPH

One (1) gas chromatograph is foreseen for all the gas turbines to monitor H2S content, specific
gravity, higher and lower calorific value and gas analysis for all individual gases corresponding to
the typical gas analysis data sheets in Part G4 of this specification. The calorific value is to be
computed based on the composition of individual constituent of the gas.
Any gases needed for the calibration of the equipment shall be provided until the end of the
Defects Liability Period.
5.15 GROUND FLARE CUM-INCINERATION SYSTEM

Flare System shall be Ground (low) level flare and capable of burning gas condensate.
All vents required for normal operation shall be piped to a new flare system on the shortest
possible way.
Burners, stand by burners and all necessary equipment for the flare system including a new flare
stack shall be provided. All burners shall be capable of burning Gas Condensate.
ELECTRICAL
All the electrical equipment shall be designed to comply with the hazardous area requirements of
IEC 79 where the source of hazard is defined in IEC 79. Where the zone si designated, the
electrical equipment located within a sphere of 7.5 m radius from the source of a zone one hazard
must be suitable for one zone. A sphere of radius 5 m is applicable to zone two hazards.
All the equipment shall be grounded.
The control system shall be supplied as a fully assembled and functionally prewired, programmed
and tested system.
All necessary control, monitoring, interlocking and protecting functions of the NGS shall be in
accordance to the stipulations in Part G5 General Technical Requirements and Part P2.27
Particular technical Specifications I&C Systems.
The remote control and supervision of the system shall be done from the CCR. All signals for
remote tasks shall be cabled to the DCS system.
In order to guarantee the maximum possible availability of the control system, for each train
separate DCS process stations with fail-safe feature shall be provided and installed in separate air
conditioned local electronic rooms of each train. The remote functions of redundant components
shall be done by separate and physically independent modules.
A sufficient number of instruments for local and remote supervision and control shall be provided
for reliable plant operation.
All the required tappings for temperature, level, pressure, etc. connections shall be provided.
Three times redundant pressure transmitters shall be provided and dedicated to the control and
protection functions. Double redundant pressure transmitters shall be provided and dedicated for
indication and pre- alarms, e.g. upstream to each of the Gas Pressure Reducing Stations.
Pressure measurement before ESD skid to measure the supply pressure in each train and any
measurement causing switch over to other fuel shall be three times redundant and shall be done
with transmitters.
Temperature measurements shall be provided in local and in the CCR.
Page: 14
The change over from gas to oil firing shall be initiated in case the operation pressure falls lower
than the minimum set point on the supply pressure to the GT. The signal shall be initiated by a 2 of
3 pressure measurement.
The GT will be changed over to oil firing:
When pressure (measured in two (2) out of three pressure measurements) is lower then the
minimum supply pressure
In case of failure of two (2) measurements even when the pressure is higher than the
minimum supply pressure. In case of failure of one (1) measurement only an alarm is
announced.
The return from oil firing to gas firing will be done manually from the central control room.
Gas Chromatograph
The gas chromatograph provided for the Gas supply system shall have manual selection possibility
of any of the gas supply trains. The scope includes also the sampling and all necessary sampling
devices like filters, pressure and temperature regulators; instrument air supply with filters and
catalytic purifier, etc. as required for the proper operation of the system.
The chromatograph shall be installed in the local electronic room and shall be connected to the
DCS by bus communication (standard Ethernet). The measured values shall be displayed in the
CCR on the operator workstations using a separate view directly accessible departing from the
Gas system views.
The following minimum features are required from the gas chromatograph.
Operation
full automatic
Sensitivity
0.5 % of full scale
Linearity
2 % of full scale
Repeatability
1 % of full scale for the range 0.05%-2%
Ambient temperature effect
None (in the allowed temperature limits)
Calibration
Automatic
Zero calibration
Automatic
Two (2) pcs. of configuring/diagnostic devices shall be provided as Special Equipment / Tool (e.g.
laptop) if the necessary tasks are not available via built-in keyboard/display of the device itself.
See Part G5.6 Inspection and Testing
CNE/015/2002
P2.6
Steam Turbine Units

and
Auxiliaries
WORKING DOCUMENT
Part P2.6 Steam Turbine Units and Auxiliaries Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
PAGE
GENERAL ..................................................................................................................................... 1
SCOPE OF WORKS..................................................................................................................... 1
LAYOUT ........................................................................................................................................ 3
4.1
GENERAL DESIGN REQUIREMENTS ........................................................................... 3

4.1.1
Overspeed..................................................................................................... 4
4.1.2
Vibration Intensity ........................................................................................ 4
4.1.3
Balancing....................................................................................................... 4
4.1.4
Stresses and Natural Frequencies............................................................. 5
4.1.5
Noise Level.................................................................................................... 5
4.1.6
Swallowing Capacity.................................................................................... 5
4.1.7
Steam Tables and Charts ............................................................................ 5
4.1.8
Deviations from the Rated Steam Parameters.......................................... 5
4.2
TURBINE CASINGS......................................................................................................... 5
4.3
TURBINE ROTORS.......................................................................................................... 7
4.4
TURBINE BLADING......................................................................................................... 7
4.5
BEARINGS........................................................................................................................ 8
4.6
SHAFT GLANDS .............................................................................................................. 9
4.7
GLAND STEAM SEALING SYSTEM............................................................................... 9
4.8
HP EMERGENCY STOP VALVES, HP CONTROL VAL VES ...................................... 10
4.9
IP EMERGENCY STOP VALVES, IP CONTROL VAL VES.......................................... 11
4.10
EXHAUST STEAM LINES.............................................................................................. 11
4.11
HP/LP BYPASS STEAM REDUCING STATIONS........................................................ 12
4.12
GOVERNOR EQUIPMENT............................................................................................. 12
4.13
TURNING GEAR ............................................................................................................. 13
4.14
OIL SYSTEM................................................................................................................... 14
4.14.1
General ........................................................................................................ 14
4.14.2
Hydraulic Oil System ................................................................................. 15
4.14.3
Oil Pumps .................................................................................................... 15
4.14.4
Oil Coolers................................................................................................... 16
4.14.5
Oil Tanks...................................................................................................... 17
4.14.6
Clean and Dirty Oil System....................................................................... 17
4.14.7
Oil Filters and Strainers............................................................................. 18
4.14.8
Oil Purification Plant.................................................................................. 18
4.15
WARM-UP / DRAINING.................................................................................................. 18
4.16
STANDSTILL POSITIVE VENTILATION....................................................................... 19
P2_06steam_turbine_Working_Doc.doc
Page: ii
4.17
TURBINE HEAT AND SOUND INSULATION ...............................................................19
4.18
TURBINE CLADDING.....................................................................................................20
4.19
UNIT FOUNDATION .......................................................................................................20
4.20
COUPLINGS....................................................................................................................20
4.21
FIRE PROTECTION EQUIPMENT .................................................................................21
4.22
OTHER TURBINE EQUIPMENT ....................................................................................21
4.23
STEAM TURBINE CONTROL........................................................................................21

4.23.1
General.........................................................................................................21
4.23.2
Low Live Steam Pressure Control............................................................22
4.23.3
Back Pressure Control (BPC)....................................................................22
4.23.4
Partial Arc Admission Control ..................................................................22

5.1
STEAM/METAL ...............................................................................................................23
5.2
LUBE OIL/CONTROL OIL..............................................................................................23
5.3
SPECIAL MEASUREMENTS .........................................................................................24
TESTS AND INSPECTIONS.......................................................................................................24
SPARE PARTS...........................................................................................................................24
SPECIAL TOOLS AND EQUIPMENT ........................................................................................24
Page: 1
GENERAL
This part of the specification covers the design, manufacturing, assembly and inspection in the
Contractors workshops, supply, delivery, unloading, erection, aligning, painting, commissioning,
trial operation, acceptance and performance tests of two (2) controlled extraction back pressure
steam turbine generator sets complete with all of its auxiliary equipment without excluding other
components and services not mentioned.
The steam turbines shall be designed in accordance with General Technical Requirements
specified in Part G5 and the Performance and Design Criteria specified in Part P4. Part G4
General Project Requirements shall be adhered to whenever applicable. The BPST shall be
capable to deliver safe and reliably sufficient steam to the IP and LP headers in order to ensure the
production of 70 MIGD of distillate i.e. it shall not be necessary to provide additional steam via the
bypass stations to ensure the required water production.
SCOPE OF WORKS
The scope of works shall comprise the respective components of each steam turbine including all
the equipment necessary for the safe and reliable operation of the unit, and shall mainly consist of,
but not be limited to the following items:
Two (2) Extraction Back Pressure Steam Turbines (BPST) directly coupled to the generator, each
set complete with
Generator and electrical auxiliaries, described in Part P2.26
HP/LP bypass steam reducing stations, described in Part P2.7
HP emergency stop valves and control valves complete, including piping and the necessary
chemical cleaning and blow-out provisions
Steam strainer for installation in the emergency stop valve or including housing for installation
in the live steam line as well as additional steam strainers for the commissioning
Complete IP controlled steam extraction system including stop valves, control valves and pipe
work
Hydraulically operated emergency shut-off valve(s) and check valve(s) installed in series for
each bleed or extraction
Motorised stop valve(s) for each bleed or extraction
Spray attemperators in the exhaust steam line complete
Safety valves in the exhaust steam line and bleed or extraction lines
Gland steam and sealing system complete with gland steam condenser
One (1) turbine oil plant, complete, containing at least:
One (1) oil tank including oil strainers
One (1) main oil pump (100%) direct driven, gear shaft driven or with AC motor drive
One (1) auxiliary oil pump (100%) with AC motor drive
One (1) emergency oil pump with DC motor drive
Page: 2
Two (2) control oil pumps (each 100%) with AC motor drive
Two (2) oil vapour fans (each 100%) with AC motor drive with oil separation in the piping
Two (2) oil coolers (each 100%)
One (1) double oil filter (fine filter) for lube oil flow
One (1) double oil filter for oil flow
Dedicated stationary centrifugal oil purification plant for each turbine
Complete high-pressure hydraulic system separate from the lube oil system. It shall include
hydraulic oil power unit with 2 x 100% hydraulic oil pumps, tank, double oil filters, coolers,
accumulators, sufficient instrumentation and control devices etc.
Motorised or hydraulic operated turning gear equipment complete
Manual turning equipment
Complete turbine enclosure
BPST unit foundation
All required ventilation or air conditioning equipment for safe operation of mechanical and
electrical equipment
Complete draining system
Complete heat and sound insulation
Necessary noise abatements measures
Painting and corrosion protection
Fire protection equipment
Electrical earthing of the equipment
Necessary supporting steelworks, access walkways, ladders, service platforms for the
complete steam turbine generators area, together with all auxiliary equipment
All required steel parts embedded in concrete
All necessary base frames, base plates, anchor bolts, etc.
Downtime ventilation plant with air dryers complete
Flush cleaning system, complete
Turbine governing and control equipment, complete, containing at least:
Electro-hydraulic turbine governing complete
Electronic run-up controller
Turbine safe load computer
Automatic controls
Supervisory system
Page: 3
Fail-safe protection system
Automatic turbine start-up, warming and draining equipment
Automatic shutdown
All necessary control, governing, measuring and monitoring equipment as well as additional
instrumentation necessary to match particular design arrangements of the apparatus and units
Thermal Stress Evaluator (TSE)
All piping, thermal insulation, expansion joints, flanges including sealing and screws, valves,
safety devices, mountings, fittings, fastenings etc.
Complete detailed labelling of all installations
Special lifting tackles and special tools as required for maintenance, inspection and repair
Electrically heated equipment for loosing the turbine casing bolts (if applicable)
Initial spare parts for the complete commissioning and trial operation
All consumables for commissioning and trial operation
Standard equipment and accessories which are normally included in the supply schedule but
which are not separately listed
Static and dynamic calculation of the turbine foundation, design of foundation
LAYOUT
The proposed layout is shown on the following drawing:
General Layout, drawing No. CNE/015/2002-X-00-G-D-00024
Water / Steam Cycle Flow Diagram, drawing No. CNE/015/2002-W-00-G-D-00003
4.1
GENERAL DESIGN REQUIREMENTS
The BPSTs shall be designed in compliance with International Codes and Standards, such as IEC
and ISO. In a few cases, explicitly mentioned in these Bid Documents, more stringent
internationally acknowledged national standards would have to be applied. National standards,
such as ASME, BS, JIS, VDI or DIN, may be considered provided their requirements are equal or
higher than the standards specified here.
The BPSTs shall be of proven standard design and of the single flow, single casing type. Only
BPSTs and components of well-proven design with sufficient capacity margin shall be provided.
References and operating hours of BPSTs and main components of equal rating design and type
shall be submitted with the Bid Documents.
The BPSTs and all of its components shall be of robust design and shall be suitable for a safe and
reliable service. Reliability, availability and simplicity of design and operation are of utmost
importance. The design of each BPST unit shall be such that easy and safe access is provided to
all parts, which require adjustment or inspection during operation. Access to all parts requiring
disassembly for maintenance and overhaul shall be without undue difficulty.
Page: 4
Each BPST shall be designed to generate the rated electric power and additionally to supply the
total LP steam required to produce 100% MCR of the total water production from the desalination
plant operating at high temperature mode.
The BPSTs shall preferably be operated at fixed inlet pressure over the load range. The droop of
the governor shall be adjustable between approx. 2 to 8% it shall however, also be possible to use
the units for support of frequency control.
The BPSTs shall be equipped with high pressure bypass steam reducing station as required
dumping steam into the back pressure header in case of a turbine, generator or electrical system
trip.
The BPSTs shall be of indoor design, i.e. within ventilated turbine building. Noise enclosure if any
shall be easy one step removal type.
Spray water attemperators shall be provided to cool the steam to the temperatures required at the
desalination plant.
The BPSTs and the respective associated equipment shall be able to be operated without any
restrictions and any limitation in time at each load between no-load and maximum load.
Grey cast iron will not be accepted. If there should be grey cast iron contained in a series
manufactured small part, which is under consideration, the written approval of the Engineer is
necessary.
Stub pipes on the casings and larger constructional parts must have a minimum wall thickness of
5 mm whilst the minimum nominal bore is 20 mm. If flanges are provided, there are to be at least of
nominal pressure 25 bar.
The control valves are to be operated in each case with auxiliary energy. Direct acting control
valves will not be accepted. In order to be able to repair the automatic control equipment, the
necessary stop valves are to be installed.
The BPSTs must be able to sustain load jumps of at least 20% referred to maximum continuous
rating as often as required and at any load condition without danger to the machine, provided the
necessary holding time is observed. Furthermore, they must be able to sustain load changes as
often as required with a load change speed of at least 6 % per minute.
The steam condition design shall be such that at no point in the steam path the steam conditions
reaches a state which can cause water particle erosion to the turbine components.
4.1.1
Overspeed
The maximum overspeed shall be limited by two independent electronic overspeed trip devices
with back-up by an additional mechanical overspeed protection in order to prevent any harmful
vibration and/or distortion of any part of the equipment. The capability to withstand this overspeed
shall be proven in a workshop test performed at 120% of the nominal speed at least for 3 minutes
on the fully bladed BPST rotor.
4.1.2
Vibration Intensity
The permissible vibration intensity of flexural shaft vibration amplitudes of the BPST rotor shall not
exceed the vibration range as stated in the ISO 7919, Zone A.
4.1.3
Balancing
When balancing the rotor of the BPST, weight adjustments shall preferably be made by inserting
dovetail weights in at least two special grooves of the rotor (see Assessment Criteria for the
Precision of Balancing Rotating Non-Yielding Components, Class Q 2.5, VDI No. 2060).
4.1.4
Page: 5
Stresses and Natural Frequencies
The BPST shall be designed to withstand all stresses resulting from a generator short-circuit
without taking any permanent metal distortions. Sliding of plates relative to others will be tolerated.
Low modes of natural frequencies of the blading shall not resonate with harmonics of the rated
speed. A range of 20 % below to 20 % above the nominal speed shall be free from blade
resonances for undampened blades.
No more than one critical speed is allowed within the range 0 90 % speed. It is required that no
critical flexural nor torsional frequency of the coupled rotor assembly of the BPST unit will be within
10 % of the rated speed, nor any critical speed of each individual rotor - with regard to proper
balancing - will lie within this speed range.
4.1.5
Noise Level
The sound pressure level inside the BPST building shall not exceed 85 dB(A) when all equipment
is running at MCR. This level will be measured in one (1) meter distance from any point of the
equipment. For the reducing and turbine bypass station in the case of only briefly occurring
maximum operation, a sound pressure level shall not exceed 100 dB(A) on the turbine hall floor
and 110 dB(A) in the region of turbine steam inlet.
4.1.6
Swallowing Capacity
The BPST shall be capable of supplying the full rated output at deviations from the rated steam
conditions (e .g. as per IEC Recommendations Publication 45) without encountering any risk.
The swallowing capacity shall be 107 % at a minimum referred to load case G MNCR thus,
consequently the whole steam turbine generator sets shall be capable to produce the respective
power for an unlimited time period.
4.1.7
Steam Tables and Charts
The 'Properties of Water and Steam in SI Units latest issue as prepared by E. Schmidt in cooperation with ASME and other engineering societies, or equivalent and acknowledged steam
tables and Mollier charts, subject to the Engineer's approval, shall be used for computation and
Guarantee tests.
4.1.8
Deviations from the Rated Steam Parameters
Deviations from the rated steam parameters shall be in accordance with IEC Publication 45,
Clause 19.
4.2
TURBINE CASINGS
The BPSTs should be of single casing type.

A Steam turbine design without inner casing is accepted due to the standard type of the offered
turbine and the submitted reference list.
All casings shall have complete centre line supports to ensure proper radial clearances under all
transient conditions. This includes inner casings, bearings, diaphragms, glands, etc.
Provision shall be made to allow the BPST casing to expand freely without inducing heavy forces
and consequent distortion and misalignment. Sliding keys maintaining alignment shall not give rise
to lubrication problems.
In the BPST casings gradual changes in shape and in wall thickness shall ensure moderate
temperature gradients in order to minimise thermal stresses. The BPST casings shall be stressrelieved after rough machining in accordance with the manufacturer's experience.
Page: 6
Supervisory thermocouples shall be provided at suitable points on the cylinder casings to indicate
metal and steam temperatures and to enable thermal stress levels to be evaluated and considered
during start-up and load-change procedures.
For even temperature distribution along the circumference, inlet and exhaust branches shall as far
as possible be symmetrically arranged. For steam admission to the BPST, a minimum of two
steam branches - one in the upper and one in the lower casing half - shall be provided. The nozzle
casing block, balance piston casing, shaft sealing casings and other internals shall be flexibly
accommodated in the BPST casing to allow for thermal expansion.
The BPST casing and associated inserts subjected to steam temperatures in excess of 400C
shall be constructed of suitable cast alloy steel whereas cast steel shall be used for steam
temperatures of more than 230C.
Particular attention shall be paid to the design of all bolts subject to high temperature, such as at
the BPST casing and steam valves, to ensure that they have adequate creep resistance under all
normal operating conditions.
The BPST exhaust casing may be integral with the HP casing, or separate and of welded design.
The BPST exhaust shall be equipped with a series of water injection nozzles to cool the steam
leaving the last LP stages in the event of extended low-load operation including idle load.
Inspection of highly stressed and back end BPST stages must be possible through adequate
endoscope openings without opening the casing.
The BPST casings shall have adequate remotely controlled drainage facilities with remote
indicators for the start-up and shuttingdown procedures.
All casings shall have openings through which dry air may be blown for preservation during
standstill periods, and also release the air.
Cast iron material is not acceptable for any turbine component
The nozzle ducts must be supported separately in the casing, Integrally cast nozzle ducts will not
be accepted.
In order that rapid assembly and dismantling of the turbine will be possible, the turbine casings
shall be preferably split on the horizontal centerline and the joint shall be metal to metal design .
Suitable lifting gear and slings shall be supplied for raising and lowering the upper portions of the
BPST casing and rotor clear of the blading. Guide rods for preventing damage to the blading shall
be provided. Furthermore, jack screws, lifting lugs, eyebolts and guide rods shall be foreseen to
facilitate alignment, disassembly and reassembly.
Separate casing flange heating is not acceptable because of the complication of the system.
If heating is necessary for the tightening and loosening of the turbine casing bolts, this must be
allowed for in the design and appropriate electrical heating equipment supplied.
All casing joints shall be designed to minimise distortion and remain steam tight for a minimum of
30,000 running hours without the need for bolt re-tightening. The Contractor shall give details of all
such joints and confirm the criteria for steam tightness upon which the design is based.
All pipe connections wherever practicable are to be connected to the bottom half of the casing to
facilitate the removal of the top half of the casing for maintenance and overhaul with minimum
dismantlement.
4.3
Page: 7
TURBINE ROTORS
The BPST rotors and discs shall be integrally forged from high quality steel.
incorporating shrunkon discs are not acceptable.
Rotor designs
The rotors shall have thermal stability within the whole operating range. The rotors shall be
stressrelieved after machining, in accordance with the manufacturer's experience.
Stress concentrations in the rotor shall be avoided by adequate design. In the design of the rotor,
all notches, sharp inner edges or excessively small radii are to be avoided so that fatigue failure is
excluded. All internal radii are to be provided with a high surface finish.
As already specified in this chapter, no critical flexural or torsional frequency of the coupled rotors
assembly of the BPSTs shall be within 10% of the rated speed. When determining the critical
speed of the rotors by calculation, such factors as bearing stiffness, oil film elasticity, elastic
properties of supporting structures, vibration excitation by glands, steam nozzles, partial admission
of steam, extraction tappings, effects of rotor key-ways, spacers, sleeves, etc. shall be considered.
The coupled critical speeds of the turbine and generator rotors must lie outside the range from
80 % to 125 % of the nominal speed. The rotors are to be statically and dynamically balanced in
the factory so that the maximum effective vibration magnitudes do not exceed the recommended
values under steady running conditions at all loads according to ISO 7919, Zone A.
The fixed parts of the steam turbine must be free of any resonance, which might disturb the
operation.
It must be possible to re-balance the rotors on site without particular difficulty. Each rotor shall
have slots or threaded holes or similar features at each end within the BPST casing to which
balancing weights could be fixed if that should becomes necessary. The required openings in the
BPST casings shall be provided.
4.4
TURBINE BLADING
Only blade profiles of approved type, which have been in satisfactory commercial operation for at
least five years shall be accepted.
The rotating blades may be either forged or machined from solid. Stationary blading and
associated nozzle chambers, diaphragms and carrier rings shall be designed for minimum
deflection under maximum steam load conditions adequate to the clearances in the BPST.
The blading material shall have good creep and fatigue strength properties, as necessary, with
small elongation at fracture and resistance to cracking, scaling and erosion at the operating
conditions.
The composition, heat treatment and surface treatment of the blade material shall give maximum
resonant strength. In addition, the material shall be resistant to pitting, corrosion and erosion. The
material shall be inspected for chemical and physical properties.
At least all critical areas of the blades shall be polished or otherwise surface treated as per the
manufacturer's practice. After machining, at least 25% of the blades shall be subjected to a
magnaflux test. If more than 5% of the checked blades are found to have failures, all of the blades
shall be tested.
Stress concentrations are to be avoided as far as possible by using suitable fillets, by obtaining
gradual changes in sections, smoothing sharp edges, particularly at the junction of blade profile to
blade root section and by avoiding flutter.
The level of the principal stress centrifugal stress and steam bending stress shall be
conservative. By changing the frequency of response as necessary, low modes of natural blade
Page: 8
frequencies (tangential, axial, torsional and combined) shall not come into resonance with low
harmonics of the rotational speed.
The blading shall be designed to minimise blade end leakage. Full details of the blading design
shall be submitted with the Bid Documents, including details such as blade root fixing and
shrouding attachment for each blade row as well as details of stationary blades.
The nozzles shall only generate exit edge wakes of low magnitude or the wake stimulus shall, if
necessary, be reduced by increasing the axial clearance of the stationary and rotating blades.
The nozzles and the rotating blades with their end plates of the control stage shall be machined
from solid. End plates or sharpened tips shall be provided at the subsequent blade rows.
At the extraction point of the BPST reinforced blade profiles shall be used, since the possibility of
the formation of vortex flow and accumulation of deposits at these points cannot be excluded.
All roots and fixing of the BPST blading shall be of highest quality and proven in tests as well as in
such a manner that the blades may be easily removed in case of repair, without disturbing other
blade rows.
The blading shall preferably be assembled without the use of lacing wires or brazing.
The Contractor shall submit full details of blade vibration characteristics and operational
experience of the last row of blades being offered. The blade vibration characteristics should be in
the form of a Campbell diagram.
The turbine stages operating in the wet steam region are to be provided with sufficient water
drains. Such wet steam conditions shall not cause erosion damages to turbine components. The
life expectancy of the last stage blades with respect to the rate of erosion shall be stated in the
Tender.
The design and construction of turbine blading shall be suitable for continuous operation at
maximum output capacity with turbine speed ranging from 6% below to 4% above rated speed to
prevent the possibility of damage from vibration due to natural frequency of blading, etc..
4.5
BEARINGS
All journal bearings of the BPST unit shall be of the pressure oil lubricated, horizontally split and
preferably self-aligning type (ball type support of the bearing body) and shall allow easy removal of
the bearing sleeves with only minimum lifting of the BPST rotor and without dismantling the BPST
casing.
The bearing design shall suppress hydrodynamic instabilities, such as oil whip or "oil film
unpriming", so that the rotor runs stable at all operating conditions. In addition, sufficient damping
shall be provided to limit shaft vibrations.
The rotor train shall be equipped with a thrust bearing of the Mitchell, Kingsbury or other reliable
multi-pad type. It shall act bilaterally carrying thrust in both directions. The thrust pads shall be
suspended elastically (tilting design). In the event of high shaft speeds the thrust bearing shall be
separate from the journal bearings.
Means shall be provided to check and to indicate the wear and tear of the thrust bearing pads
during normal operation including alarm and trip. The device shall be of electronic type backed up
by a hydraulic type to ensure full reliability.
Special attention shall be paid to the sealing of the bearings to avoid any oil loss at the bearing and
a contamination of oil by penetration of steam or water into the bearings.
The maximum vibration velocities shall not exceed the requirements of ISO 10816-1 for Zone A.
Page: 9
Two holes shall be provided in each of the journal bearing for installing two thermocouples. Each
thermocouple shall be provided with triplex elements and triplex output signals. 2 of 3 voting logic
shall be provided for the triplex signals from each thermocouple for protection. If any one
thermocouple becomes faulty, the signals from the faulty thermocouple shall be excluded from the
2 of 3 voting logic and thus shall not cause a trip to the turbine. Alarm shall be initiated in case of
fault. Alarm shall be initiated in case of actual temperature becomes high reaching a pre-set value.
Further increase in the temperature to the pre-set value shall cause a trip as a result of 2 of 3
voting. Thrust bearing pads shall be provided with the same arrangement.
Provisions shall also be made for visible indications of the oil discharge flow from each bearing.
The temperature of the oil leaving the bearings shall not exceed 75C at maximum cooling water
temperature and maximum load occurring at the same time. An alarm device shall be provided.
Suitable means of earthing shall be installed to prevent any damage to bearings, oil pump drives,
etc., by any shaft currents, which may be produced. Bearings and any associated pipes shall be
insulated from the ground and earthing brushes shall be provided.
4.6
SHAFT GLANDS
The BPST shaft glands, interstage diaphragm packing in impulse type BPSTs and the glands at
balance pistons shall be of the labyrinth type of well proven design. Gland sealing permitting
examination and replacement without lifting the cylinder casings shall be provided.
The sealing strips may either be installed in the rotor or in the rotor and the associated casing.
Sealing strips in the rotor shall be caulked into the shaft in order to allow easy replacement in the
event of damage. If fins are employed, the material shall be soft and the fins shall be very thin at
their ends where accidental rubbing may occur.
When using stepped labyrinths, special attention shall be paid to the axial differential expansions
between the rotor and the casing.
4.7
GLAND STEAM SEALING SYSTEM
The steam sealing system shall service the BPST shaft glands as well as the live steam stop and
control valves.
The injection cooler necessary for reducing the sealing steam temperature shall be supplied with
condensate from the main condensate pumps.
The system shall operate fully automatic between 20% of MCR up to the maximum live steam
parameters and shall be complete in every respect, including but not be limited to the following
main components:
Automatic sealing steam pressure regulator with all pertaining accessories.
Hand-operated bypass valves for the event of emergency and repair of the above regulator.
Motor-operated isolating valves for remote start-up and shutdown of the system. For start-up
the sealing steam may be taken from the live steam header.
Gland steam condenser with stainless steel tubing, water side characteristics according to the
values of the main condensate, with two full-duty exhauster fans, automatic draining to the
feedwater tank by a pump and automatic venting to an outdoor location subject to the
Engineer's approval.
When the gland steam condenser is under maintenance, the two exhauster fans shall be
capable of maintaining operation of the gland steam sealing system.
Page: 10
Desuperheater for gland steam supply to the LP shaft glands, if needed, including features to
prevent water reaching the shaft glands in the event of a malfunction of the desuperheater
spray water control system.
All necessary supply pipework with appropriate strainers preventing any foreign matter
damaging the shaft glands, droplet traps as necessary, valves, venting and draining
equipment and pipework.
4.8
HP EMERGENCY STOP VALVES, HP CONTROL VALVES
Generally, the HP/ST shall be equipped with two independent closing devices operated by the
safety system of the BPST to positively avoid overspeeding the BPST. At least two (2) HP
emergency stop valves and a minimum of two (2) HP control valves shall be provided per BPST.
Conforming to the fail-safe principle, the valves shall be closed by springs upon loss of auxiliary
power. The stop valves shall close instantaneously, the control valves following within less than
one second. The steam flow shall assist the valve closing action. The valves shall be designed for
fast opening.
The HP emergency stop valve shall be provided with an internal pilot valve, as necessary, enabling
the main valve to be opened against full steam pressure and allowing sufficiently fine control for
starting up the unit.
The HP emergency stop and control valves shall be designed for the maximum live steam
pressure, i.e. boiler safety valves in their fully open position.
Emergency stop valves and control valves may be in single or combined casing designed but shall
be equipped with individual hydraulic actuators and closing spring sets.
The actuators of the control valves shall be of the double acting type or single action type with
strong closing spring to ensure close control and to avoid sticking of the valve spindles. Actuators
mounted directly on the valve casings, thus avoiding any connection levers, shall be provided.
Each emergency stop valve shall be equipped with contact assemblies to indicate the fully open
and fully closed position, whereas the control valves shall have additional position transmitters to
signalise the spindle travel of each valve.
The valves shall be made of steel or cast steel and shall be well accessible. Those subjected to
wear shall be easily removable.
The emergency stop and control valves shall have renewable seat inserts and the annular faces of
valve seats and cones shall be hardened or stellite armoured. The spindle seals shall be of the
labyrinth design equipped with an adequate number of tappings to be connected to the gland
steam sealing system of the BPST. Facilities for back-seating shall preferably be provided for both
the stop and control valves.
In their closed positions emergency stop valves shall be steam tight. Minor steam leakage through
the closed control valves is tolerable.
The specified noise level of the BPST unit shall be taken into account when selecting the steam
velocities in the valves.
The design of the stop valves shall allow:
Pressure testing of the connected pipework with 1.5 times maximum possible operating
pressure.
Easy connection of blowout pipes for steam-blowing operation of connected pipework prior to
first start-up.
Page: 11
Acid pickling of ready connected pipework with any modern chemical agent and easy
connection of temporary pipework needed for this process.
On-load testing of the functioning of each stop valve of the BPST unit at a partial valve stroke.
If special protection covers are deemed necessary for acid pickling and/or blowout, they are to be
included in the scope of supply for each valve.
Particular attention shall be paid to the mechanical stiffness of the stop valves, which shall have
ample tolerance for forces and moments exerted by the connected pipework. Selection of the
valve shape and variation in wall thickness as well as the surface finish shall be such that undue
stress concentration and thermal fatigue are positively avoided.
The steam pipework between the control valves and the HP/ST cylinder shall have fully welded
connections except for suitable dismantling joints.
For each emergency stop valve one permanent coarse-mesh, removable, corrosion-resistant
steam strainer shall be provided upstream of the valve or at the valve inlet and one additional
fine-mesh steam strainer - mesh size smaller than 1.6 mm - shall be fitted for protection during the
commissioning period. The finemesh strainer shall be removable after initial operation, without
disturbing the inlet piping. Warm-up and drainpipes connected to the strainer casing shall be
provided.
If steam strainers are arranged in a separate strainer casing or body, then the complete strainer
including casing and related drain arrangements shall be included in the scope of supply.
All HP steam valve bodies shall be thermally insulated to ensure a cooling rate, which is similar to
that of the related BPST casings.
Satisfactory access for operational and maintenance purposes by means of permanent platforms
and walkways shall be provided to all valves, unless they are arranged on the operating level of the
BPST unit.
In order to facilitate the safe and reliable shut-down of the machine, the emergency stop valves
and control valves must be arranged with easy access as near as possible to the appropriate
turbine casings. In so far as flange connections are provided on the live steam side, these are to
be executed as high quality designs.
Each emergency stop valve, control valve, shall be provided with facilities to prove the movement
with the set operating and without the necessity of unloading the turbine.
All control valves shall be designed to eliminate hunting and provide smooth operation over the
entire speed and load range of the turbine.
The position transmitters of each control valve shall be provided dual redundant if they are used for
control.
4.9
IP EMERGENCY STOP VALVES, IP CONTROL VALVES
At least two (2) IP emergency stop valves and a minimum of two (2) IP control valves shall be
provided per BPST.
The construction requirements given above for the HP emergency stop valves and HP control
valves are to be considered respectively.
4.10
EXHAUST STEAM LINES
The exhaust steam lines shall be equipped with spray attemperators to reduce the exhaust steam
temperature and pressure to the required conditions of the desalination plant.
Page: 12
Safety valves shall be provided in the exhaust steam lines.
4.11
HP/LP BYPASS STEAM REDUCING STATIONS
The BPSTs shall be equipped with high pressure bypass steam reducing station as required
dumping steam into the back pressure header in case of a turbine, generator or electrical system
trip. The HP/LP Bypass Steam Reducing Stations are described in Part P2.7 Steam Systems.
4.12
GOVERNOR EQUIPMENT
The BPST Governor shall be provided with high-pressure hydraulic fast response servo-valves and
control valves actuators. The governor equipment shall be complete in all aspects. The governor
shall be capable to carry out the following regulation tasks:
Speed regulation
Electrical power regulation
Exhaust Steam Back Pressure regulation
Live Steam Pressure Limitation.
The turbine control system shall be capable to control the LP steam header pressure in Back
Pressure Control mode under all conditions of steam load changes including desalination units trip.
The description below contains the regulation tasks and a framework proposal for the solution of
these tasks.
The Contractor is required to supply the range of equipment, which makes possible the safe
fulfilment of the tasks as outlined, and the maintenance of the necessary regulation accuracy and
the fully automatic operation of the turbine.
In addition, the regulation circuits must guarantee stable turboset operation at all load points.
All features of the governing system shall be demonstrated during commissioning.
An electro-hydraulic turbine governor system is preferably to be employed with the hydraulic part
capable by itself of providing safe operation of the turbine. Using the electro-hydraulic regulation,
precise frequency-power characteristic should be possible with a high response sensitivity and fine
adjustability of the frequency-power characteristic even during operation. Furthermore, control of
load shedding is to be ensured while avoiding running up on the static characteristic. In addition,
the governor equipment must meet the following requirements:
Speed increase, on the sudden shedding of load from maximum continuous power to no load
running, is not to exceed 8% even transiently, referred to the nominal speed, and thus the
possibility of over-speed trip operation during load shedding is excluded.
It must be possible to set the proportional band within the limits 2 - 8.0 %.
It is also required that the governor must operate over the full regulation range without hunting.
Between 100 rpm and the nominal speed, it must be possible to set the speed to any desired
value and the speed variations, particularly during starting, must not be greater than 1%.
In isolated operation, the speed governor system must be capable of maintaining the nominal
frequency of 50 Hz with deviations of max. +0.5 Hz. The response sensitivity, the setting
range of the proportional band of the speed regulator and the arrangement of the speed
regulation of the turboset must correspond to this requirement.
Page: 13
As regards the extraction pressure control, the pressure in the bleed steam piping is to be kept
constant independent of the electrical power produced i.e. above the minimum load required.
The Contractor shall inform about the minimum load required in order to be able to fulfil the
steam extraction requirements.
The exhaust pressure control system must be able to maintain the required value set with
maximum deviations of +2 %.
It must be possible at any time to adjust remotely the set point for exhaust steam pressure
from the control room. The supply pressure limitation must ensure that no more steam is taken
from the live steam header that can be produced by the available boilers. The possibility of
running with lower live steam pressures at part load must be provided. The supply pressure
limitation must also for this reason be capable of being remotely adjusted from the control
room.
Duplicate overspeed protections, one electronic and one mechanical shall be provided to
operate and cut off live steam, by closing the turbine inlet valves, when the turbine speed rises
to a predetermined level which shall not exceed the nominal speed by more than 10 % / 12 %.
The devices are to be readily accessible for adjustment purpose and on load testing of each
overspeed protection system shall be possible when the unit is operating at rated speed and at
any load without tripping the unit.
The generator voltage regulation has the task of maintaining the voltage supplied by the
generator at the required value by adjustment of the exciter. It must ensure that even with
rapid changes in load or possibly load shedding the voltage does not vary beyond the
permitted tolerance.
The generator regulation must be designed to ensure successful parallel operation with
differing load points for the individual units within the framework of the voltage and frequency
tolerances.
4.13
TURNING GEAR
Hydraulic turning gear shall be provided. The equipment shall be complete and fully automatic,
engaging automatically before the BPST shaft comes to a standstill and disengaging as soon as
the BPST speed exceeds the turning gear speed during start-up.
The hydraulic turning gear shall be operated by the hydraulic oil system, which is to be supplied
separate from the lube oil system.
The turning gear shall be capable of starting the rotor train from standstill and driving it
continuously during outage periods. It shall be interlocked with the lube oil system as a part of the
interlock logic to be implemented in the Sub Group Control (SGC).
In case the manufacturer provides a low speed turning gear, the oil pumps shall be started and
remain in operation during the whole turning period.
In addition, provision shall be made for the manual (hand) operation of the BPST rotor.
The turning speed is to be so chosen that the formation of a good lubricating film is ensured.
A higher turning speed is preferred because of the better temperature balance between the upper
and lower casing parts due to the fan effect. In any event, two oil pumps are to be supplied; their
employment during starting of the turning device avoids mixed frictional effects in the bearings.
In the event of a turbine trip or shutdown with a loss of AC power supplies for indefinite period, the
turbine shall run down without damage. The Contractor shall detail any particular procedures to be
observed on subsequent restarting with the turbine in hot, warm or cold condition.
Page: 14
4.14
OIL SYSTEM
4.14.1
General
The oil system shall be designed for the lubrication of the BPST and generator bearings, the
generator sealing system. A separate fire-resistant hydraulic fluid system shall be provided to
energise the hydraulic steam valve actuators of the BPST.
The lubricating oil used shall be identical to that of the GT lube oil.
As general guidelines for design and construction of the oil system, the following rules shall be
considered:
Oil tank, pumps, filters, coolers, etc., shall be so arranged that they can effectively be
protected against fire. The BPST hall crane shall be used for handling the equipment.
Only seamless piping with a pressure rating of not less than PN 10 (and accordingly higher for
the hydraulic oil piping) shall be applied. The use of flanged connections shall be avoided.
All oil piping shall be installed in a covered trench on one side of the BPST unit pedestal table.
Steam conducting piping and electrical cables must not be led through this trench.
At the bearings, the oil piping has to be insulated to avoid its contact with any shaft currents.
No thermal insulation shall be applied in the oil system.
The lubricating and hydraulic oil systems serve to supply the lubrication points and the control
equipment of the complete turbine generator.
The temperature rise of the bearing oil in the bearings must not exceed 30 K and the oil drain
temperature of the bearings must not exceed 75C.
Oil vapour suction fans and oil separators are to be provided. The possibility of unacceptable
concentration of the oil vapour must not exist at any point of the oil system. The oil vapour fans are
to be provided with explosion proof motors.
All oil carrying parts must be separated from equipment subjected to hot steam so that premature
aging of the turbine oil and the danger of fire is excluded. The oil pipes must be run in separate
covered oil ducts away from the cables. The oil ducts must lead into the separate turbine oil room.
The lube oil pipes shall material shall not be inferior to stainless steel SA 304 and connections
between oil carrying parts must not be made with compression ring joints and must be secured
against unintentional loosening. Flange connections of the oil pipes outside oil ducts and turbine oil
room must be encapsulated. The fastening of the oil pipes must be such that excessive vibration is
largely excluded. Oil drain points are to be equipped with double stop valves. It must be possible to
shut off the control oil circuit separately.
If positive displacment pumps are employed, pressure relief valves must be provided in each case
for the full flow quantity. To the extent necessary and to avoid an unacceptable drop in pressure
during starting of the auxiliary oil pumps, a pressure accumulator is to be installed in the oil system.
The fine oil filter equipment can be installed in a by pass flow. It must be sufficiently generously
dimensioned so that continuous cleaning of the oil can be attained safely even under increased
conditions of dirt. It must be possible to change the filter elements during operation.
Filters in the lubricating oil main circuit or in the hydraulic oil circuit are to be arranged as duplex
filters which can be switched over without interruption.
Page: 15
At high hydraulic oil pressures the standard of oil purity to be achieved must meet increased
requirements.
The different oil systems are to be made easily distinguishable by a clear arrangement and
different coloring.
The oil pipes shall be pickled and, on commissioning, flushed with alternatively cold or heated oil.
All the facilities necessary for commisioning are to be provided.
In the choice of materials for the oil systems, account must be taken of the envisaged 30 year
operation.
4.14.2
Hydraulic Oil System
Separate high-pressure hydraulic oil system shall be provided for actuation of the control valves,
stop valves, turning gear and safety equipment. The hydraulic system shall be complete in all
aspects. The oil tubes material shall not be inferior to stainless steel 316L.
It shall include as a minimum but not limited to the following:
Hydraulic Power Unit, complete unit including the tank, hydraulic elements and devices.
2 x 100 % high pressure hydraulic pumps
2 x 100 % coolers
2 x 100 % filters
2 x 100 % accumulators
Sufficient instrumentation to the satisfaction of the Engineer
Any instruments to be used for protection shall be configured in 2 of 3 voting logic
Any other equipment/devices deemed necessary for the completeness, safe and reliable
operation of the system.
4.14.3
Oil Pumps
4.14.3.1 General
All oil pumps shall be of sufficient capacity to maintain an adequate rate of oil supply under all
operating conditions. In particular, they shall be capable, if necessary, of meeting any exceptional
demands required by relay control gear and the generator sealing system. All pumps shall be
supplied with local discharge pressure gauges, which shall be duplicated near the turbine front
pedestal and in the control room.
4.14.3.2 Main Oil Pump

One BPST shaft, gear shaft-driven or AC motor-driven full capacity main oil pump shall be
provided for the BPST and generator requirements.
4.14.3.3 Auxiliary Oil Pump

One AC motor-driven auxiliary oil pump of full main oil pump capacity (1 x 100%) shall be provided.
It shall start automatically in case of excessive pressure drop in the oil system.
Page: 16
4.14.3.4 Emergency DC Oil Pump

One DC motor-driven bearing oil pump shall be provided to feed the bearing oil circuit in case of a
power failure or power station black-out. The pump shall start automatically.
4.14.3.5 Hydraulic Oil Pump

2 x 100% AC motor-driven HP hydraulic oil pumps shall be provided in the separate hydraulic oil
system.
4.14.4
Oil Coolers
All heat exchangers shall be designed in accordance with the relevant standards, codes and
recommendations of ASME, TEMA, HEI, DIN or VDEW (Association of German Public Utility
Companies) or equivalent standards agreed upon.
Full capacity twin oil coolers shall be provided. They shall be equipped with the interconnecting
piping and associated valves to allow change-over during normal operation without interrupting the
oil flow. Two three-way valves are to be provided including all necessary equipment required for
change-over. Sight glasses to observe proper filling after maintenance shall also be supplied.
The oil shall be cooled by cooling water from CCW system. The oil pressure shall be higher than
that of the water.
To facilitate cleaning, the oil coolers shall have straight tubes. The tube bundle must be fully
removable from the cooler casing.
The tubes shall be made of CuZn28Sn (equivalent to admiralty metal, ASTM B 111-80 alloy No.
C 44300) or similar copper base alloys. The tubes shall preferably be expanded into the tube
plates. The tube plates of the oil coolers shall have the same as or better material than the tubes.
The water boxes made of cast steel shall be protected by an adequate coating. They shall be
bolted to the oil cooler body. Oil cooler shell and baffles shall be of carbon steel. The cooling
water velocity in the tubes shall not exceed 1.9 m/s under any possible operating conditions.
The design of the exchange surface shall be based on a cleanliness factor in the order of 0.85.
The oil side of the cooler shall be provided with a small continuous venting pipe of 1 arranged at
the highest elevation and connected to the oil tank, including a sight glass.
A temperature control of the oil leaving the oil coolers and employing an oil bypass around the
coolers shall be provided. The temperature control shall not be effected on the water side. The
temperature control shall be of automatic type with local control facility.
One set of ten brushes for cleaning the oil cooler tubes shall be included in the scope of supply for
each BPST.
4.14.5
Oil Tanks
The lube oil system shall be provided with a main oil tank. The hydraulic oil system shall be
provided with a separate oil tank.
Oil tanks with an oil level sight glass installed on the suction side of the tank, alarm switches to
signal high and low oil levels and an oil vapour extraction fans including a vacuum pressure
indicator shall be provided.
The tank capacity and the duty of the main oil pump in the lube oil system shall be such that the
number of circulations per hour does not exceed eight (8).
The interior of the tanks shall have baffles for deaeration and foam separation. A set of removable
strainers of fine-mesh size (mesh No. 50-100 per cm2) shall be fitted for filtering the returning oil
Page: 17
drains. The tanks shall be provided with the necessary drains and holes for inspection and
cleaning purposes. Easy access is required.
The discharge line of the oil vapour extractor fans should initially be run with a slope to a low point
for automatic separation of oil and vapour and then be led to a suitable point outdoors subject to
the Engineer's approval.
A tank drain valve shall be provided at the lowest point of the tank to allow sludge and water
removal and tank draining.
The oil tanks, coolers, pumps and purification plant as well as all associated equipment shall be
arranged in an elevated separate room for fire protection. The oil pipes running through the walls
or bottom of this compartment shall be equipped with fire proof wall penetration sleeves. The
partition shall have a minimum of 30 minutes of fire resistance.
The tanks shall be of welded steel construction with bolted and jacketed access and inspection
covers. The inner tank surface shall be coated with a proven oil- and heatresistant rustpreventing material subject to the Engineer's approval.
Oil tank levels shall be monitored within DCS in CCR.
Oil tank levels measurement initiating BPST trip shall be carried out according to 2 of 3 principle.
4.14.6
Clean and Dirty Oil System
In case if the same oil type is foreseen for the hydraulic oil system as for the lube oil system, a
common clean and dirty oil system shall be supplied to provide for the exchange of the service oil.
Both the clean and the dirty oil tanks shall have a capacity for the entire oil filling quantity of the
BPST unit. The tanks shall be located outside of the BPST building.
One mobile electrical drain pump shall be provided for the power station equipped with flexible
hoses and couplings for connection to the BPST service tanks.
One stationary clean oil pump with a capacity to fill the main oil tank within six hours shall be
located outside of the BPST building.
The system shall be complete with pipework, isolating valves, flexible hoses, local instrumentation
and accessories. Necessary fire protection and fire fighting measures shall be provided.
By varying oil type for the hydraulic oil system and for the lube oil system, separate clean and dirty
oil systems shall be provided.
4.14.7
Oil Filters and Strainers
One strainer shall be installed in the suction line of each oil pump. A removable fine-mesh oil
strainer shall be installed in the oil tank to clean the drain oil. Twin oil filters are to be provided in
the common discharge line of the pumps.
The oil flow used for control and safety equipment shall be led through a separate twin oil filter with
100 % capacity of each section.
All filters are to be provided with the necessary change-over valves including a connection gear to
permit simple on-load cleaning.
Filters and strainers shall be equipped with differential pressure gauges with alarm contact for the
control of filter fouling.
Each filter section shall have removable cartridge type filter elements.
A level sight glass shall be provided across the filter in the oil tank to allow observation of the oil
levels on both sides of the filter.
Page: 18
4.14.8
Oil Purification Plant
Each BPST unit shall be equipped with one dedicated stationary centrifugal-type oil purification
and clarification plant connected to the oil tank.
The plant shall be complete with integrated inlet and discharge pumps, each with a bypass for flow
adjustment, electric heaters, strainers upstream of each pump, safety valves, flow indicators,
monitors as well as any other parts required for a complete and fully automatic purification unit. A
common alarm shall be given to the control room in case of any fault.
A centrifugal type oil separator with its auxiliary equipment is to be provided in the by-pass flow for
at least 10 % of the circulating oil flow. The separator shall be capable of being used in operation
and when the turbine is at rest. Thos parts of the oil separator in contact with the fluid are to be
manufactured from the stainless material. The oil separator is to be equipped with automatic
heating. Dirt and all solid particles greater than 5 microns are to be removed in the oil separator.
Oil additives of any type, however, should not be removed from the oil. If necessary, oil vapour
extraction shall be provided for this equipment. The oil separator delivered shall be a self-cleaning
design.
4.15
WARM-UP / DRAINING
The turbine must be equipped with an automatic warm-up system and automatic draining
equipment complete with drain tanks, pumps, piping, etc.
All drains shall be fully automatic and equipped with a hand-operated bypass arrangement. Those
drains to be used for repair and maintenance purposes only may be hand-operated. Also, drains
only actuated once before start-up as a preparatory measure may be hand-operated.
Generally, any clean drainage shall be recovered and returned to the condensate system via a
valve assembly and flash vessel of adequate size. This valve assembly shall preferably consist of
power-assisted throttling and isolating valves with a hand-operated bypass arrangement. Valve
assemblies shall be arranged in groups according to the origin of the drain and the operating
pressure, also with regard to easy checking and maintenance.
Drain valves and drain traps shall be of a proven type. The use of drain traps shall be kept to a
minimum.
Drain piping shall be properly insulated as protection against accidental contact by the personnel
wherever needed.
The pipes entering the flash vessel shall be so dimensioned that velocity at the vessel inlet shall
not exceed the maximum noise level requirements. If necessary, throttle orifices shall be provided
in the inlet headers.
The flash vessel is described in Part P2.8 Condensate and Feedwater Systems
specification.
4.16
of this
STANDSTILL POSITIVE VENTILATION
In order to protect the BPST from corrosion during standstill periods, one mobile package type
dehumidification unit shall be provided. This dry preservation unit will blow dry air through predetermined openings to various sections of the BPST. The escape facilities for the moist air such
as manholes or special vent openings shall be arranged in the BPST such that all sec tions and
parts will be dried effectively. The openings shall be of ample size to ensure a sufficient flow of air
through the BPST.
The drying unit shall have adequate performance to reduce the moisture content of the BPST hall
suction air by about 30 - 40 %. Automatic control by a hydrostat shall be provided. The unit is to
be easily connected to the BPST through flexible hoses and couplings.
Page: 19
The equipment shall mainly consist of the following components mounted on a common console
and shall be fully piped and wired:
Electric motor driven fans for dried air, regeneration air, with condenser, as necessary
Air filter with removable inserts on the suction side of the unit
Electric air heater for regeneration air, as needed
Switchbox for fan and heater
Dry air hoses of adequate lengths, with hose couplings
All other necessary equipment, such as dry air hydrostat, regeneration air thermostat, etc.
Flexible power cable for plug connection.
The output of the equipment shall be adequate to keep the air discharging from the BPST at a
temperature of 3 K above ambient temperature, under steady state conditions.
The air guidance within the unit to be protected is to be arranged so that all parts experience a
sufficient flow.
The ingress of seepage steam into the turbine is to be prevented. The ventilation equipment is to
be designed for at least two air changes per hour referred to the volume to be ventilated.
4.17
TURBINE HEAT AND SOUND INSULATION
The BPST insulation shall be designed for outdoor operation.

All components of the BPST unit attaining a temperature in excess of 50 oC during normal
continuous operation shall be heat-insulated, except the oil system.
Prefabricated formed lagging, each finally clad with sheet metal, may be employed. The lagging
material must be asbestos free, fireproof and free from corrosive action on metal.
Alternatively, plastic composition material may be used with slip joints for easy removal where
joints may have to be broken. This material may be installed by spray application requiring
suitable metal fixings such as tack welded nuts to accept screwed rods. Spray insulation shall be
adequately tamped and reinforced by wire mesh layers. However, preference would be given to
the prefabricated formed lagging specified at the beginning.
Special attention shall be paid while lagging the lower half of the BPST casing with a view to
obtaining a uniform cooling and heating rate of both casing halves and to reduce severe
temperature gradients and distortions of the casings.
In order to avoid a possible penetration of oil, insulation with an oil-tight hard cover is to be
provided. Damaging heat radiation on to the foundations must be avoided.
Hot sections which cannot be insulated, such as for example observation openings, are to be
provided with a corresponding contact protection. Otherwise the general insulation requirements
shall apply.
For insulation layers exceeding a thickness of 60 mm, internal supports shall be applied to ensure
and maintain equal thickness of the insulation along the surface. Particular attention shall be taken
to adequate tightness of the sheet metal surface to minimise the fire hazard due to penetrating oil.
The insulation around flanges, joints and steam piping welds - in case periodical examination is
required - shall be easily removable. Measuring studs shall be surrounded by sheet metal cones
to allow better accessibility.
Page: 20
The Bid Documents shall include details of the high temperature insulation material proposed,
including its properties, recommended method of application and experience with its use at high
temperatures.
The local instrumentation shall be arranged outside the insulation as far as applicable.
4.18
TURBINE CLADDING
The turbine cladding is to be designed as a sheet metal cladding and provided with sufficient
corrosion protection and acoustic properties to reduce the noise to the specified levels. It is to
cover the complete turbine area including the turbine outer bearings. Heat build-up within the
turbine cladding is to be avoided by appropriate devices. The turbine cladding is to be provided
with doors. It must be easy to dismantle. Particular importance will be attached to good
appearance of the turbine generator with the turbine cladding. It shall be of neat and proper
appearance and shall be properly painted. Cooling air fans and adequate lighting shall be
provided. The sound attenuation insulation shall be robust in structure and shall be properly fixed
to the inside of the sheet metal enclosure, so that it will also withstand the removal of enclosure
sections without deterioration.
The steam turbine noise enclosure shall be easy one step removal type.
4.19
UNIT FOUNDATION
The BPST floor shall be adequately elevated above the ground floor to provide for the exhaust
steam pipe to be connected to the lower BPST casing half. In addition, this will allow the
accommodation of the generator auxiliaries beneath the generator. If columns are used, springs
and viscous dampers shall be provided at their tops.
All mechanical structures, supports and parts to be embedded in the concrete foundation as well
as the performance of static and dynamic calculations and the erection supervision of turbine
foundation belong to the scope of supply and services of the BPST supplier.
4.20
COUPLINGS
Couplings between the BPST shaft, as applicable and the generator shall be of the rigid type.
If toothed couplings are employed, these are to be provided with forced oil. All parts of toothed
couplings are to be fully machined. Coupling hubs and sleeves are to be individually balanced,
statically and dynamically, at a speed corresponding to the operating speed. For the short circuit
shock, at least 8 times the nominal torque on the drive coupling is to be applied with at least
100 times frequency. If necessary, this value is to be corrected upwards after the torsional critical
speed calculations for the total plant and the actual generator short circuit torque are known.
4.21
FIRE PROTECTION EQUIPMENT
The fire protection equipment shall be provided as far as applicable similar to the gas turbine
generator.
The lubrication and hydraulic oil areas shall be provided with:
Automatic fire detection and alarm system utilising flame and heat detectors.
The system supplied shall be complete in all respects and shall be integrated in the fire protection
and fighting system specified in Part P2.23 Station Fire Fighting and Fire Detection Systems.
4.22
OTHER TURBINE EQUIPMENT
Connections for turbine washing / cleaning equipment shall be provided on the turbine. One
complete turbine washing / cleaning system is to be provided for all steam turbines.
Page: 21
Turbine bleeds are to be provided in each case with a bleed steam emergency shut-off valve and
non-return valve. In addition to these, motorised stop valves are to be provided in order to make
possible repair and maintenance work on turbines during downtime.
4.23
STEAM TURBINE CONTROL
4.23.1
General
The start-up of the turbine from standstill condition to nominal speed under cold/warm/hot start-up
conditions, synchronising the generator to the grid and loading the turbine to any pre-set load shall
be fully automatic. Provision shall be made for the operator in the main control room to take
control for manual operation of the turbine start-up, synchronisation and loading.
The shut-down of the turbine from full load to standstill condition shall be fully automatic. Start/stop
of any auxiliary system such as the lube oil system, turning gear, drain system, etc. during the
start-up/shut-down of the turbine shall be fully automatic. The start-up sequence shall include
automatic testing programme for the equipment such as the emergency lube oil pump.
The start-up/shut-down sequences of the turbine and its auxiliary systems shall be configured in a
hierarchy system of Functional Group Control (FGC), Sub-Group Control (SGC) and Sub-Loop
Control (SLC) in a co-ordinated manner.
The start-up/shutdown sequences of the steam turbine shall be initiated by the operator from the
DCS operator station in CCR at the turbine screen graphic display or from the Plant Master
Sequence (PMS).
A Thermal Stress Evaluator (TSE) shall be provided. It shall analyse, monitor, display and control
the thermal stress levels of the turbine. It shall automatically co-ordinate with the auto-run-up
programme and loading programme in order to ensure that the permissible turbine stress levels
are never exceeded. In case the allowable safe thermal stress margin is exceeded during runup/loading the TSE shall automatically halt the speed/load in position until the thermal stress has
come down within the allowable margin, which shall then release the halt of the speed/load, and
the run-up/loading programme shall then re-start automatically. If the stress margin is exceeded
during the run-up programme at the critical speed, the TSE shall then reduce the speed to a safe
value below the critical speed and halt on it until the stress becomes normal and the run-up
programme shall then re-start automatically. The safe value below the critical speed shall be well
defined as it will not be allowed to keep reducing the speed down through the whole range.
On-load testing facility shall be provided for the following equipment/systems:
Mechanical Over Speed Bolt
HP Steam Stop Valves partial stroke
Protection System Channels.
The test shall not cause a trip to the turbine. The test shall be conducted in an automatic sequence
through all the above equipment/systems and the result of each test shall be indicated. Any test
failure shall be indicated with alarm message. The test programme shall either be initiated
manually by the operator from the DCS operator station or automatically at pre-set intervals.
The control system shall monitor the live steam conditions, back pressure and extraction steam
pressure status of turbine generator auxiliaries and turbine thermal stresses and shall provide the
plant monitoring system with all data necessary for turbine performance calculations.
The control system shall be capable of shutting down the turbine generator and its auxiliaries in a
safe and controlled manner automatically from any load.
Page: 22
The control system shall have maximum and minimum adjustable load limits and a rate of change
load limit.
The control system shall have the capability of automatically controlling the turbine speed to
prevent the unit from reaching the overspeed tripping point in the event of an instantaneous
change in load from full load to not load or to maintain the grid frequency during normal operation.
Provision shall be made for on-line testing of all stop valves.
4.23.2
Low Live Steam Pressure Control
In case of lack of steam, the live steam pressure decreases. The BPST control shall be switched
over automatically and bumplessly to steam pressure control, in order to keep the live steam
pressure constant at a minimum value to be co-ordinated with the GT/boiler.
The operation of the limiter for the low live steam pressure shall be annunciated with alarm
message to be displayed in the DCS monitors.
4.23.3
Back Pressure Control (BPC)
A Back Pressure Control (BPC) shall be provided. The BPC shall control the pressure of the LP
steam header. In normal operation the BPST shall be in BPC mode and the HP/LP bypass valves
shall be closed in a standby mode. Proper interlock logic shall be provided to ensure that the BPST
control will not switch over from the BPC to the load controller unless the LP steam header
pressure control is switched over from the BPC to the HP/LP bypass valve. This requires proper
co-ordination with the Plant Master Controller (PMC).
4.23.4
Partial Arc Admission Control
The facility of partial arc admission control shall be provided for part load operation, which
guarantees high efficiency.
The stipulations in the General Requirements and Particular Technical Specification for
Instrumentation and Control Systems shall be considered.
The system shall be remotely controlled by the DCS full automatically. Remote supervision and
manual interaction, when required shall be done from the CCR operator workstations.
A sufficient number of field sensors and local/remote indicators are to be provided to secure a
reliable and safe operation, monitoring and protection of the BPST and its auxiliaries. Wherever
possible, field signal distributors and local indicators and transmitters shall be mounted in groups to
allow an easy operation, monitoring and maintenance.
The scope of supply shall be in accordance with the flow and control diagrams, indication, alarm,
trip specifications and other I&C documents. The scope of control and instrumentation indicated on
the drawings and specified hereunder and in Part P2.27.1 Instrumentation and Control only
comprises the minimum requirements for a safe, reliable and efficient operation of the power plant,
an appropriate execution of the functional and performance tests and an aid for a thorough
analytical fault detection in the event of failure or breakdown.
The Engineer's proposal shall be checked, modified and completed by the Contractor accounting
for the special features and design particulars of his equipment as well as his experience as to
operational safety, efficiency of control and ease of supervision of the BPST unit.
Measuring points not shown on the respective flow diagrams for reasons of clearness on the
drawing are listed separately hereafter. Each sensor shall have its own tapping point.
5.1
Page: 23
STEAM/METAL
HP BPST casing flange metal temperature inside/outside
HP BPST casing metal temperature lower/upper half
Other relevant absolute and/or differential values of the HP BPST casing and/or rotor metal
temperature
Position of the valve cone of each control valve (live steam, HP bypass steam reducing
station)
End position of each stop valve (bracket see above) and of the extraction steam control and
shut-off valves.
All temperatures measurements required for the Thermal Stress Evaluator (TSE).
5.2
LUBE OIL/CONTROL OIL
Lube oil tank level high/low
Lube oil temperature before and after coolers
Lube oil outlet temperature of each journal bearing
Lube oil pressure after coolers, switches at various pressure levels
Sleeve metal temperature of each journal bearing, lower segment(s)
Pad metal temperature of thrust bearing
Lube oil outlet temperature of thrust bearing, front/ rear side
Lube oil drain flow of each bearing
Differential pressure on lube oil, power/control oil filters
Pressures in control and safety system
5.3
SPECIAL MEASUREMENTS
Absolute axial displacement of BPST casing(s)
Differential expansion of BPST shaft versus casing(s)
Turbine shaft position at thrust bearing
Loading of thrust bearing (load gauge)
Bearing and/or shaft vibrations (2 pick-ups at each bearing)
Also subject of the Contractor's scope of supply are all additional measuring points, sensors and
other local measuring equipment required for:
Final acceptance and guarantee tests at Site
Controls and interlocking of individual auxiliary systems
Remote alarms - possibly combined with the initiation of a BPST trip -, should the controlled
variables of any BPST auxiliary system (e.g., the gland steam sealing system) reach a
predetermined limit
Page: 24
Actuation of functional group sequence controls
If deemed necessary, additional instrumentation can be recommended by the Engineer during

project follow-up.
TESTS AND INSPECTIONS
Tests and inspections shall be carried out in accordance with Part G5.6 Inspection and Testing.
SPARE PARTS
All required spare parts as described in the G4.6 "General Project Requirements - Spare Parts,
Special Tools and Consumables" are included in the scope of works.
SPECIAL TOOLS AND EQUIPMENT
All required special tools and equipment as described in the G4.6 "General Project Requirements Spare Parts, Special Tools and Consumables" shall be included in the scope of works.
CNE/015/2002
P2.7
Steam Systems
WORKING DOCUMENT
Part P2.7 Steam Systems Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
PAGE
GENERAL ..................................................................................................................................... 1
HP STEAM SYSTEM .................................................................................................................... 2
IP STEAM SYSTEM ..................................................................................................................... 2
LP STEAM SYSTEM .................................................................................................................... 3
SCOPE OF WORKS..................................................................................................................... 3
LAYOUT ........................................................................................................................................ 4
7.1
GENERAL DESIGN REQUIREMENTS ........................................................................... 4
7.2
PIPING SYSTEMS............................................................................................................ 5
7.3
PRESSURE REDUCING AN D DESUPERHEATING STATIONS .................................. 6
7.3.1
HP/LP Pressure Reducing and Desuperheating Stations....................... 6
7.3.2
HP/IP Pressure Reducing and Desuperheating Stations ........................ 7
7.3.3
Stop Valves................................................................................................... 8
7.3.4
Strainer .......................................................................................................... 8
7.3.5
Noise level..................................................................................................... 9
7.4
START-UP BYPASS STATION....................................................................................... 9
7.5
STEAM SUPPLY FOR GLAND STEAM SYSTEM.......................................................... 9
7.6
INSTRUMENTATION AND CONTROL ........................................................................... 9
7.6.1
Control of HP Steam Header ..................................................................... 10
7.6.2
Control of IP Steam Header....................................................................... 10
7.6.3
Control of LP Steam Header ..................................................................... 10
7.6.4
General Control Concept of the Steam Systems .................................... 11
P2_07steam_systems_Working_Doc.doc
Page: 1
GENERAL
Steam is generated
In three (3) heat recovery steam generators (HRSGs) and/or
in two (2) auxiliary boilers or in combination
and delivered
to two (2) back pressure steam turbines (BPSTs)
to five (5) or more MSF units.
The plant comprises generally the following three (3) steam systems
High Pressure Steam System (HP Steam)
Generated in the HRSGs and/or Auxiliary Boilers.
Used for the BPSTs.
Used for the HP/IP steam pressure reducing and desuperheating stations.
Used for the HP/LP steam pressure reducing and desuperheating stations.
Intermediate Pressure Steam System (IP Steam)
Supplied from steam extraction of the BPSTs as first priority.
Supplied from the HRSGs / Auxiliary Boilers through the HP/IP steam pressure reducing
and desuperheating station as second priority.
Used for the MSF air ejectors.
Low Pressure Steam System (LP Steam)
Supplied from the exhaust of BPSTs as first priority.
Supplied from the HRSGs / Auxiliary Boilers through HP/LP steam pressure reducing and
desuperheating stations as second priority.
Used for the MSF brine heaters.
Each steam system shall be designed as header type configuration.

The HP steam parameters may be adjusted according to the required output of the steam turbines.
This means that the main steam pressure can be selected between approximately 35 bar up to
100 bar, steam temperature accordingly in the range of 410 C and 560 C.
The auxiliary boilers shall be designed with the same steam parameters as the HP steam from the
HRSGs.
Drain systems shall be provided in the different steam systems and shall be connected to a clean
drain flash vessel. Proper warm up systems shall be provided to avoid deleterious thermal stress
and/or thermal shocks of the different steam lines. The drain lines shall also be used to warm up
the steam lines. They shall meet the design conditions of the main lines regarding to pressure,
temperature and material.
Page: 2
HP STEAM SYSTEM
All HRSGs shall feed common HP steam header from which the live steam shall be distributed to
the BPSTs.
In case of shutdown or trip of any of the HRSG the HP steam shall be supplied by the Auxiliary
Boiler.
The steam lines from each HRSG and Auxiliary Boiler shall be separately led to the BPST building
and shall be connected to common HP header. The common HP steam header shall be located
close to the BPSTs and have equivalent distance to both BPSTs.
The HP steam header shall be provided with a pressure relief valve to vent the steam to
atmosphere in case the pressure in the header exceeds a predetermined value. The relief valve
shall have sufficient capacity to avoid operation of any of the boilers' safety valves in case of BPST
load rejection and/or a desalination unit trip. When designing the capacity of this relief valve other
means for controlling the steam pressure like reducing or tripping of the supplementary firing, etc.
shall also be taken into consideration. Double isolating valves shall be provided upstream the relief
valve and a silencer shall be provided in the discharge line.
From the HP steam header separate steam lines shall run to:
Two (2) BPSTs
Two (2) HP/IP steam pressure reducing and desuperheating stations
Two (2) HP/LP steam pressure reducing and desuperheating stations
Based on his own economic optimization the Contractor is, however, free to offer a solution with
more steam reducing and desuperheating stations with smaller capacity in order to limit the
diameters of each pipe and of the valves. The offered capacity in total must be equal or greater
than the specified values.
Each of the steam lines to be connected to the BPST the HP/IP stations as well as the HP/LP
stations shall be provided with motorised stop valve, a small-motorised bypass valve to be used
during BPST start-up, if required. A flow meter, a manual shut off valve, if needed for maintenance
purposes of any reducing station or turbine when the plant is in operation and bleed valves. Quick
closing valves shall be provided upstream of each HP/IP and HP/LP control valves.
IP STEAM SYSTEM
IP steam required for the MSF air ejectors shall be supplied from the steam extraction of the
BPSTs as first priority. Each BPST shall be provided with its own extraction pressure control valve
and desuperheating station. The capacity of the extraction pressure control valve and
desuperheating station of each BPST shall be sufficient to supply the air ejectors of all the
desalination units operating at peak load in high temperature mode. When both BPSTs are in
service, their extraction pressure control valves and desuperheating stations shall be working in
parallel sharing the IP steam supply load. If one BPST is tripped, the extraction pressure control
valve and desuperheating station of the other BPST in service shall immediately open more to
compensate for the lost steam without losing the pressure and temperature control.
Two (2) x 100% HP/IP pressure reducing and desuperheating stations shall be provided as
standby facility to meet the steam demand at the required pressure and temperature in case of
outage and/or part load of the BPSTs.
The BPST steam extraction pressure control valves and desuperheating stations as well as the
HP/IP pressure reducing and desuperheating station shall all run to a common IP steam header.
The header shall be sized for the whole steam demand (air ejectors) of all MSF desalination units
operating at peak load in high temperature mode.
Page: 3
From the common IP steam header separate steam lines shall run to each MSF desalination unit.
LP STEAM SYSTEM
LP steam required for the MSF brine heaters shall be supplied from BPSTs exhaust with back-up
from the HP/LP steam pressure reducing and desuperheating stations in case of BPST outage or
on part load.
Each BPST shall be equipped with its own HP/LP steam pressure reducing and desuperheating
station designed for the capacity of maximum BPST output.
The 2 x 100% HP/LP bypass steam reducing and desuperheating shall be designed for a sufficient
capacity to supply the whole steam demand of all MSFs operating in high temperature mode
during outage and/or part load of the BPST.
LP steam from the BPSTs and the HP/LP steam pressure reducing and desuperheating stations
shall be collected in a common LP steam header.
From the common LP steam header separate steam lines shall run to each MSF unit.
SCOPE OF WORKS
The scope of works shall comprise the respective components of the steam systems including all
the equipment necessary for the safe and reliable operation of the unit, and shall mainly consist of,
but not be limited to the following items:
HP steam lines from three (3) HRSGs to the common HP steam header, including the HP
steam header
HP steam lines from two (2) auxiliary boilers to the common HP steam header
HP steam lines from the common HP steam header to two (2) BPSTs
HP steam lines from the common HP steam header to the HP/IP steam pressure reducing and
desuperheating stations including the stop and isolating valves
HP steam lines from the common HP steam header to the HP/LP steam pressure reducing
and desuperheating stations including the stop and isolating valves
HP steam start-up lines from the three (3) HRSGs and two (2) Auxiliary Boilers complete with
valves and a common start-up header. The lines from the header shall be complete including
valves and dedicated pressure reducing and desuperheating stations, which shall be
connected to the LP steam header
Two (2) HP/IP steam pressure reducing and desuperheating stations complete in all aspects
including stop valves, pressure reducing and control valves and temperature control valves
Two (2) HP/LP steam pressure reducing and desuperheating stations complete in all aspects
including stop valves, pressure reducing and control valves and temperature control valves
IP steam lines from the HP/IP steam pressure reducing and desuperheating stations to
common IP steam header, including the IP steam header
IP steam extraction lines from BPSTs. Each BPST shall have its own IP steam extraction line
complete in all aspects including the stop valves, pressure control valve and temperature
control valve
IP steam lines from common IP steam header to the five (5) or more MSF air ejectors
including pressure reducing and desuperheating stations, if required
Page: 4
LP steam lines from the BPSTs to the common LP steam header, including the LP steam
header. Each BPST shall have its own LP steam lines complete in all aspects including the
stop valves and desuperheating stations
LP steam lines from the HP/LP steam pressure reducing and desuperheating stations to
common LP steam header
LP steam lines from common LP steam header to the five (5) or more MSF brine heaters
Spray water pipelines to individual desuperheating stations including spray water flow control
stations with individual flow measurement
Steam supply lines for the gland steam supply including warm up system
All required draining and venting systems
All required warm-up lines for all steam lines including the lines from and to the steam bypass
stations
All required manual and motorised valves, non return valves, safety valves, vents, drains,
hangers, pipe supports, anchors, actuators, fittings, steam traps, etc.
All necessary instrumentation and control works including also sensors, switches, transmitters,
etc. complete with wiring/cabling, junction boxes, local cubicles, connection to the DCS, etc.
Redundancy and type of instruments shall comply with Part G5.3 and Part P2.27.1
Internal pipework including acid cleaning of steam and water pipework and blowing of steam
pipework
Heat and sound Insulation of all equipment, pipework, valves, fittings etc. where necessary,
Platforms, pipe racks, galleries, walkways, stairs, supporting steel structures, etc.,
All standard equipment and accessories which are normally required and included in the works
but which are not separately listed.
LAYOUT
The steam systems are shown on the drawing:
Water/Steam Cycle Flow Diagram, drawing No. CNE/015/2002-W-00-G-D-00003
Steam/Condensate P&I Diagram, drawing No. CNE/015/2002-W-00-G-D-00010.
7.1
GENERAL DESIGN REQUIREMENTS
The stipulations in Part G5 General Technical Requirements shall be considered.

The Contractor shall be responsible for the final design, selection, procurement, installation,
commissioning and testing of the complete system and shall adhere to the applicable
Page: 5
specifications and standards. Also it will be Contractors responsibility to select adequate material
to be submit to the Engineer for review and approval.
The system shall be complete in every respect including any incidental work required for a reliable
and safe operation of the plant, which shall include any civil, mechanical, electrical, and I&C works.
All parts must be able to meet the demands of the requirements of the specification without
limitation to operating range and to the planned lifetime.
Installation, maintenance and removal of the various items shall be possible without excessive
difficulty.
The steam systems and all associated equipment shall be designed so that
their design pressures and
their design temperatures
will not be exceeded in all steady continuous conditions and all transient conditions.
In addition, all pumps, storage tanks, heaters, vessels, valves, steam traps and filters shall be
designed so that the actual capacities shall not exceed the capacities neither during steady
continuous conditions nor by transient conditions.
The steam systems and associated equipment shall be designed for a minimum operating life of 30
years without excessive maintenance and without excessive replacement of parts normally subject
to wear and deterioration in service.
HP and IP steam isolating valves shall be designed according to the double block and bleed
principle.
7.2
PIPING SYSTEMS
All steam systems shall be designed, manufactured, erected, inspected and tested in accordance
with the requirements of ASME B31.1, Power Piping Steam and Water Systems. Stress analysis
shall be elaborated for all steam piping systems.
If the Contractor normally constructs steam pipework using materials produced in accordance with
the national codes or standards of his country of manufacture, he may offer the steam systems in
accordance with ASME B31.1 but using his own material codes and standards. In this case the
Contractor have to show, to the satisfaction of the Employer/Engineer, direct equivalence of the
offered materials with those acceptable to ASME B31.1 using the rules in Paragraph PG-10 of
ASME, Section 1.
The pipework shall comply with all national and local statutory regulations and requirements of the
local authorities. The costs associated with obtaining stamps or certificates demonstrating
compliance with such regulations and requirements shall be borne by the Contractor.
The Contractor is responsible for ensuring that the internal surface of all pipes is thoroughly clean
before the pipelines are commissioned.
Internal cleaning of the pipelines shall include at least:
Compliance with the requirements of the specification Part G5.1 General Technical
Requirements Mechanical Equipment and Piping,
Thorough cleaning of all internal surfaces prior to erection to remove accumulations of dirt,
rust, welding slag due to site welding before erection.
Page: 6
Inspection of all parts prior to and during erection. Each section erected shall be cleaned out
before connecting to the next section. All headers shall be cleaned before closing up.
After erection a cleaning procedure considering acid cleaning, flushing and steam purging
(blowing out) in accordance with Parts P2.2 and G5.1 shall be carried out. This procedure
shall be issued to the Employer/Engineer for approval and be done in conjunction with the
cleaning requirements of the HRSGs and Auxiliary Boilers.
The Contractor shall provide all necessary facilities in the piping systems for carrying out the
cleaning procedure including all temporary pipework, valves, silencers if required by blow-out, etc.
7.3
PRESSURE REDUCING AND DESUPERHEATING STATIONS
Each HP/LP and HP/IP pressure reducing and desuperheating station shall comprise a stop valve,
a control valve, pressure reducing devices, a spray steam cooler with associated spray water
control valve, the control equipment, and all necessary piping, valves and instrumentation.
Pressure and temperature in the pipe lines downstream the Pressure Reducing and
Desuperheating Stations shall not exceed the design conditions of the concerning system. In a
certain extent of the pipe lines downstream of the desuperheating stations it can not be ensured
that the injection water will be total distributed in the steam flow. The part of the pipes shall be
supplied in heat resistance material and with adequate wall thickness to avoid undue stresses
and/or droplet impact erosion in the pipe wall.
Two independent hydraulic stations shall be provided for the HP/IP and HP/LP bypass stations.
One hydraulic station shall serve one set of the HP/IP and HP/LP stations including the start-up
bypass station. The other station shall serve the other set of the HP/IP and HP/LP stations. The
stations shall be designed such, that upon oil pressure failure or power failure, the valves will "failsafe" close.
Each hydraulic station shall be equipped with 2 x 100% oil pumps as well as accumulators for
troublefree change over of pumps in case of a pump failure. If oil cooling is required, it shall be
achieved by coolers being equipped with 100% redundant fans.
7.3.1 HP/LP Pressure Reducing and Desuperheating Stations

Each BPST shall be equipped with its own HP/LP pressure reducing and desuperheating station
throttling and cooling the HP steam to feed it into the exhaust LP steam header to allow:
The HRSGs and/or Auxiliary Boilers to continue generating steam for supplying it to the MSF
units e.g. in case of BPST outage or part load operation of the BPST,
Serving as a pressure relief system to exclude the risk of lifting of the boiler safety valves and
the loss of steam in the event of rapid load reduction on the ST or overproduction of steam,
Quick opening of the relevant HP/LP pressure reducing and desuperheating station and
control of the LP steam pressure in case of trip of the relevant BPST,
Control of the LP steam pressure at a set point lower than the set point of the LP back
pressure controller of the BPST governor. This shall serve as a back-up function to the BPST
governor in back pressure control mode.
The capacity of each HP/LP pressure reducing and desuperheating station shall refer to the
maximum of BPST output. In addition to the above capacity the necessary margin for the injection
condensate (spray water) has to be considered.
The HP/LP pressure reducing and desuperheating station shall preferably be arranged close to the
BPST in order to facilitate the preheating and draining of the pipework.
Page: 7
The spray steam coolers reduce the temperature of the live steam by means of main condensate.
Particular attention shall be paid to the design of the multiple orifice facility for reduction of the
steam pressure and the spray steam cooler avoiding undue stress and strain caused by excessive
velocities, vibration, differential expansion and thermal fatigue. Also, the casing shape and
transition of the wall thickness shall be taken into adequate regard.
power. The steam flow shall assist the valve closing action.
The throttle disk(s) of the pressure reducing devices shall be guided in the seat region to protect
against forced vibrations.
The HP/LP pressure and temperature control valves shall have linear control characteristic of the
steam flow versus valve stroke.
The actuator for the control valves shall be hydraulic driven and of the double acting type or single
action type with strong closing spring to ensure close control.
The valve bodies and the covers shall consist of heat resistant forged steel. They shall have
renewable seat inserts and the annular faces of the valve seats and cones and the spindles shall
be stellite armoured or heat resistant stainless steel.
The design of the valves shall allow
Pressure testing of the connected pipework in accordance to Part G5.6 Inspection and
Testing.
first start-up.
included in the scope of works for each valve.
With regard to the generation of noise and/or vibration, excessive steam velocities shall not be
allowed in the pipework downstream of the bypass steam reducing valves.
All steam valve bodies shall be thermally insulated to ensure a cooling rate which is similar to that
of the related BPST casings.
and walkways shall be provided.
7.3.2 HP/IP Pressure Reducing and Desuperheating Stations

HP steam from the HP steam header shall be throttled and cooled by
Two (2) x 100% HP/IP pressure reducing and desuperheating stations as stand-by facility
referred to the maximum steam demand (air ejector) of all MSFs operating at peak load in high
temperature mode
In addition to the above capacity the necessary margin for the injection condensate (spray water)
has to be considered.
The HP/IP pressure reducing and desuperheating station shall preferably be arranged close to the
IP steam header in order to facilitate the preheating and draining of the pipework.
Page: 8
The HP/IP pressure reducing and desuperheating station shall come in service automatically to
control the IP header pressure at a set point lower than the set point of the BPSTs extraction
control valves.
The HP/IP pressure and temperature control valves shall have linear control characteristic of the
steam flow versus valve stroke.
The spray steam coolers reduce the temperature of the live steam by means of feedwater, if
required. Particular attention shall be paid to the design of the multiple orifice facility for reduction
of the steam pressure and the spray steam cooler avoiding undue stress and strain caused by
excessive velocities, vibration, differential expansion and thermal fatigue. Also, the casing shape
and transition of the wall thickness shall be taken into adequate regard.
power. The steam flow shall assist the valve closing action.
The throttle disk(s) of the pressure reducing devices shall be guided in the seat region to protect
against forced vibrations.
The actuator for the control valves shall be hydraulic driven and of the double acting type or single
action type with strong closing spring to ensure close control.
The valve bodies and the covers shall consist of heat resistant forged steel. They shall have
renewable seat inserts and the annular faces of the valve seats and cones and the spindles shall
be stellite armoured or heat resistant stainless steel.
The design of the valves shall allow
Pressure testing of the connected pipework in accordance to Part G5.6 Inspection and
Testing.
first start-up.
included in the scope of works for each valve.
With regard to the generation of noise and/or vibration, excessive steam velocities shall not be
allowed in the pipework downstream of the bypass steam reducing valves.
All steam valve bodies shall be thermally insulated to ensure a cooling rate which is similar to that
of the related BPST casings.
and walkways shall be provided.
7.3.3 Stop Valves

Each HP/LP and HP/IP pressure reducing and desuperheating station shall be equipped upstream
with a motorised (or with hydraulic actuator) stop valve and an isolating valve.
7.3.4 Strainer
One permanent coarse-mesh steam strainer shall be provided upstream of each pressure reducing
valve and one additional temporary fine-mesh steam strainermesh size smaller than 1.6 mm shall be fitted for protection during the commissioning period. If the strainers are contained in a
separate casing this shall be supplied together with the necessary drain facilities.
Page: 9
7.3.5 Noise level

The sound pressure level inside the BPST building shall not exceed 85dB (A) when all equipment
is running at MCR. This level will be measured in one (1) meter distance from any point of the
equipment. In the case of only briefly occurring maximum operation, a sound pressure level shall
not exceed 100 dB(A) on the turbine hall floor and 110 dB(A) in the region of turbine steam inlet.
7.4
START-UP BYPASS STATION
The HP steam lines of each HRSG shall be equipped with mainly
a check valve,
a motorised isolating valve, manual shut off valve and bleed valves ,
a flow meter,
A common start-up header shall be provided.

The start-up bypass station shall be connected with the LP steam header. Individual pipes from the
HRSGs and Aux. Boilers main steam lines shall be connected to the start-up header. The
individual lines shall be equipped with manual and motorised shut-off valves, drain valves, nonreturn valves, etc. in order to allow repair works on the start-up bypass system during operation of
the plant. The start-up bypass station shall be equipped with a start-up control valve and a quick
shut-off valve. A manual shut off valve downstream of the bypass station shall also be provided in
order to allow repair works during operation of the plant. The start-up bypass station shall have
sufficient capacity to allow start-up of any HRSG or Aux. Boiler and to reach sufficient steam
pressure and temperature in order to allow connecting the boiler under start-up with other boiler(s)
which are at full load operating with the steam turbine(s).
Warm-up drain lines to the clean drain flash vessel shall be supplied to warm up the HP lines to the
BPSTs and the HP/IP - and HP/LP Pressure Reducing and Desuperheating Stations. The warm-up
drain valves shall be single-stage valves with control cones and electrical actuation. Stem and
valve cone shall machined from a single piece. The contact surfaces of the cone and the seat shall
be hardfaced to increase their resistance to wear.
7.5
STEAM SUPPLY FOR GLAND STEAM SYSTEM
Steam supply for the gland steam system shall fulfil the requirements of the manufacturer of the
BPSTs.
7.6
The HP/LP and HP/IP Pressure Reducing and Desuperheating Stations serve to meet the steam
demand of the MSFs and other consumers if any at required pressure and temperature during
normal operation and/or failure or shutdown of any steam generation facility and/or consumers.
Steam pressure and temperature control shall be automatic with the possibility of remote control
and supervision from the CCR. All steam pressure and temperature set points shall be remotely
adjustable.
The steam temperature downstream of the pressure reducing valves shall be regulated
automatically by the water injection.
The spray water demand shall be preset by steam and water flow meters.
The systems shall be provided with all necessary interlocking to avoid exceeding the design
pressure and temperatures.
Page: 10
Automatic gradual adjustment of pressure and/or temperature set points shall also be provided
where required by the control concepts.
The whole steam system shall be controlled by the DCS process control stations.
All necessary control, monitoring, interlocking and protecting functions shall be in accordance to
the stipulations in Part G5 General Technical Requirements and Part P2.27 Particular technical
Specifications I&C Systems.
The remote control and supervision of the system shall be done from the CCR. All signals for
remote tasks shall be cabled to the DCS system.
for reliable plant operation.
All the required tappings for temperature, level, pressure, etc. connections shall be provided.
7.6.1 Control of HP Steam Header

The pressure in the HP steam header shall be controlled by:
Increase / decrease the BPST load when the BPST is in backpressure control mode and
consequently control of the supplementary firing rate of the HRSGs or the firing rate of the
Auxiliary Boilers (Aux. Boiler, if the HRSGs with the supplementary firing reach their capacity
limits) in order to control the HP header steam pressure.
Supplementary firing in the HRSGs and / or Auxiliary Boilers. In this case the LP header steam
pressure shall be controlled by the supplementary firing in the HRSGs and/or firing in the
Auxiliary Boilers as the main control function with a limiter function of the HP header pressure.
Reducing the load of the GTs when all the supplementary firing burners are out of service and
a lower steam demand has occurred causing the pressure in the HP header to increase
further. This function is applicable if the electrical load is not fixed.
By the GT exhaust diverter dampers with partly exhausting of GT exhaust gas to the
atmosphere via the by-pass stacks in case that all supplementary firing burners are out of
service due to reduced steam demand and if the electrical load is fixed.
7.6.2 Control of IP Steam Header

The pressure in the IP steam header shall be controlled:
By the BPSTs extraction pressure control valves and desuperheating stations sharing the IP
steam supply load in parallel when both BPSTs are in service,
By the extraction pressure control valve and desuperheating station of the BPST in service if
one BPST is out of service or tripped. In case of a trip, the extraction pressure control valve
and desuperheating station of the BPST in service shall immediately compensate for the loss
in the IP steam supply, maintaining the pressure of the IP steam header under control,
By the HP/IP pressure reducing and desuperheating station at a lower pressure set point if
both BPSTs are out of service or at a too low part load operation or if the pressure of the IP
steam header drops to the set point of the HP/IP station.
7.6.3 Control of LP Steam Header

The pressure and, if required, the temperature in the LP steam header shall be controlled:
By the backpressure control of the BPSTs,
Page: 11
By the supplementary firing burners and/or auxiliary boilers firing if both BPSTs are in sliding
pressure mode,
By the HP/LP Pressure Reducing and Desuperheating Stations in case of:
Trip or shutdown of the BPSTs,
Part load operation requirement of the BPSTs due to dispatching requirements of the grid.
By water injection into the BPST exhaust steam (if required) to comply with the requirements
of steam conditions for the desalination plant
7.6.4 General Control Concept of the Steam Systems

Each pressure and each temperature control valve in each of the HP, IP and LP systems shall
have redundant control modules in the DCS process control stations with duty/stand-by concept
and bumpless transfer upon failure in the duty control module.
Each of the HP, IP and LP steam headers shall have a Master Pressure Controller (MPC), which
shall be a part of the Plant Master Controller (PMC). The PMC is specified in Part P2.27.1. The
Master Pressure Controllers of the steam headers shall have, but shall not be limited to the
following functions:
HP MPC:
Set point control of the HP steam header.
To generate load set point for the Supplementary Firing Burners (SFBs) load controller
and/or the auxiliary boilers load controllers in accordance with the error signal between
the actual pressure and the pressure set point in order to maintain a constant pressure in
the HP steam header.
To generate load set point for the GTG load controller in case all the SFBs are not in
service and the electrical load is not fixed in order to maintain constant pressure in the HP
steam header.
To generate position set point for the diverter damper controller in case all the SF burners
are out of service and the electrical load is fixed whereas the steam demand has reduced
causing an increase in the pressure of the HP steam header.
To generate a high pressure set point for the HP vent valve as a protection measure.
To generate a derivative ramp function for SFBs load controllers in case of GTG/HRSG
unit trip and/or SFBs trip in order to quickly recover the pressure in the HP steam header.
Co-ordination and interlock logic.
IP MPC:
To generate pressure set point for the Sub Group Control (SGC) of the BPSTs extraction
control valves.
To generate pressure set point for the HP/IP steam pressure reducing and
desuperheating station.
Page: 12
LP MPC:
To generate a set point for the BPSTs back pressure controllers in order to control the
pressure in the LP steam header.
To generate a set point for the HP/LP steam pressure reducing and desuperheating
stations.
To generate an anticipatory signal from the rate of change in the total LP steam demand
which shall be added as a forward signal to the SF Burners load controller in order to
ensure that HP steam pressure is always under control during normal and abnormal
steam demand changes.
To generate the correct opening position of the HP/LP steam pressure reducing and
desuperheating stations and to release it for quick opening when the relevant BPST is
tripped. This generated opening position shall compensate for the same amount of steam
lost due to the BPST trip in accordance with the linear characteristic curve of steam flow
versus valve stroke.
To generate load set point for the SFBs and/or auxiliary boilers firing when the BPSTs are
in sliding pressure mode, in case sliding pressure mode is offered.
The PMC shall coordinate all the functions of the Master Pressure Controllers of the HP, IP
and LP steam headers.
CNE/015/2002
P2.8
Condensate
and
Feedwater Systems
WORKING DOCUMENT
Part P2.8 Condensate and Feedwater Systems Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
PAGE
GENERAL ..................................................................................................................................... 1
SCOPE OF WORKS..................................................................................................................... 1
2.1
2.1.1
Condensate System..................................................................................... 1
2.1.2
Feedwater System........................................................................................ 2
LAYOUT ........................................................................................................................................ 3
3.1
CONDENSATE SYSTEM ................................................................................................. 3
3.2
FEEDWATER SYSTEM.................................................................................................... 4
DESIGN AND CONSTRUCT ION REQUIREMENTS................................................................... 4

4.1
CONDENSATE SYSTEM ................................................................................................. 4
4.1.1
Main Condensate Pumps............................................................................. 4
4.1.2
Pipes and Valves.......................................................................................... 4
4.2
CLEAN DRAIN COLLECTING SYSTEM......................................................................... 5
4.2.1
General Requirements................................................................................. 5
4.2.2
Clean Drain Flash Tank................................................................................ 5
4.2.3
Clean Drain Tank.......................................................................................... 5
4.2.4
Clean Drain Pumps ...................................................................................... 6
4.3
MAKE UP WATER SUPPLY SYSTEM............................................................................ 6
4.4
FEEDWATER SYSTEM.................................................................................................... 6
4.4.1
Feedwater Storage Tank and Deaerating System.................................... 6
4.4.2
FWT Heating Loop Circulating Pumps ...................................................... 9
4.4.3
Feedwater Pumps (FWP) ............................................................................. 9
4.4.4
Pipes and Valves........................................................................................ 12
P2_08Cond_FW_Drains_Warm-up_Working_Doc.doc
Page: 1
GENERAL
This spec ification covers the complete condensate, feedwater, clean drain and steam pipes warmup systems with the associated equipment, and suitable for safe, reliable and proper operation
under all possible operation conditions.
The flow, instrument and the control system shown in the following flow diagrams presents a basic
schematic arrangement of equipment.
Drawing - No CNE/015/2002-W-00-G-D-00003
Water / Steam Cycle Overview Flow Diagram
Drawing - No CNE/015/2002-W-00-G-D-00009
HRSG P&ID
Drawing -No CNE/015/2002-W-00-G-D-00010
Steam and Main Condensate System P&ID
SCOPE OF WORKS
This Part specifies the scope of works and installation as a minimum requirement covered by this
specification. Supply, services and necessary works which are not mentioned explicitly but which
are required for a safe, reliable and efficient operation and easy maintenance shall also be
included in the scope of works.
2.1
SCOPE OF EQUIPMENT
2.1.1
Condensate System
The scope of mechanical as well as instrumentation and control equipment to be provided shall
include the complete condensate system as shown on drawing No CNE/015/2002-W-00-G-D00010 Steam and Main Condensate System P&ID.
Note: The condensate pumps, including minimum flow recirculation, are not in the scope of the
condensate system, but in the scope of the Package D Desalination". For interfaces with the
Desalination Plant, see drawing No CNE/015/2002-F-00-G-D-00001.
The scope of works essentially comprises the following:
Main Condensate Return System, collecting the condensate from each Desalination Brine
Heater via a common return line up to the Steam Turbine machine hall and then to the
Deaerators of 3 HRSGs and the 2 Auxiliary Boilers.
Spray water system supplying main condensate from the main condensate line to
the ST exhaust / de-superheating station
the HP-LP reducing station (ST bypass)
the desalination units reducing stations
etc.
Spray water system supplying feedwater from the HRSG and Aux. Boiler feedwater pumps
outlet including all necessary valves, flow measurements and control to the HP/IP reducing
station. Refer to Annex I and II.
Each spray water line to each desuperheater in the steam systems, boilers and desalination
plant shall be provided with dual-redundant flow transmitters to be used in each temperature
controller for control and indication.
At least one (1) clean drain flash vessel including all necessary internals, nozzles, flanges,
local instrumentation, vent and drain system, control system, etc.
Page: 2
At least one (1) clean drain tank including all required, nozzles, flanges, local instrumentation,
vent and drain system, control system, level switches, etc.
For each clean drain tank / vessel: 2 x 100% clean drain pumps, including nozzles, flanges,
local instrumentation, vent and drain system, control system, etc.
All necessary connecting pipes, including hangers, supports, vent and drain systems, valves,
strainers, steam traps, etc.
All necessary base plates, supporting steel structures, mountings, fittings for pumps, tanks,
heaters, valves and pipes.
All necessary local and remote instruments
Fittings of piping systems
All necessary ladders, stairs and operating platforms for easy access to the equipment during
operation and/or maintenance
All required spare parts and special tools as described in the G4.6 "General Project
Requirements - Spare Parts, Special Tools and Consumables".
etc.
2.1.2
Feedwater System
This Part specifies the scope of work as a minimum requirement. Supply, services and necessary
works which are not mentioned explicitly but which are required for a safe, reliable and efficient
operation as well as easy maintenance shall also be included in the scope of works.
The numbers given hereunder are referring to 1 (one) HRSG or Auxiliary Boiler, but apply for each
HRSG / Auxiliary Boiler.
The scope to be provided shall comprise the complete feedwater system and steam piping system
as shown on drawing No CNE/015/2002-W-00-G-D-00009 HRSG P&ID and No CNE/015/2002W-00-G-D-00012 Auxiliary Boiler P&ID.
The scope of works essentially comprises the following:
One (1) de-aerator with feedwater storage tank including
all necessary nozzles, flanges, local instrumentation, vent and drain system control
system, level switches, etc.
one (1) complete spray or degassing type deaerator system including all necessary
nozzles, flanges, local instrumentation, vent and drain system, control system, internals,
etc.
make up water connection with control stations ( 2 x 100%)
spray water connection with necessary valves, flow measurements and control to HP/IP
reducing stations
heating steam pressure reducing station including all necessary nozzles, flanges, local
instrumentation, vent and drain system, control system, warming up facilities, steam side
and water side balancing connections as applicable.
Page: 3
Supporting structure, anchoring, stiffeners, baffle plates, access stairways, platforms and
ladders
2x100% circulation pump for the heating steam loop, complete with motors, couplings,
coupling protection, complete lubrication and cooling systems, base plate and frames,
insulation and noise damping elements including local instrumentation, drains and vents,
vapour extraction, control system, switches, etc.
2 x 100% horizontal HP feedwater pumps multistage split casing type, complete with motors,
couplings, coupling protection, complete lubrication and cooling systems, minimum flow
device, base plate and frames, insulation and noise damping elements including local
instrumentation, drains and vents, control system, switches, etc.
one (1) combined minimum flow / non-return valve per pump
Complete drum level split-range control stations (1 x 30% and 2 x 100% each)
All necessary connecting pipes, including hangers, supports, vent and drain systems, valves,
strainers, steam traps, etc.
All necessary base plates, supporting steel structures, mountings, fittings for pumps, tanks,
heaters, valves and pipes
Fittings of piping systems
All necessary ladders, stairs and operating platforms for easy access to the equipment during
operation and/or maintenance
All necessary electrical works.
All necessary Instrumentation and Control works
All required spare parts and special tools as described in the G4.6 "General Project
Requirements - Spare Parts, Special Tools and Consumables".
LAYOUT
3.1
CONDENSATE SYSTEM
The return condensate from each MSF Brine Heaters is pumped via a common Main Return Line
into a common header feeding the Feedwater Tanks of the HRSGs and the Aux. Boilers.
The condensate flow is controlled by control valve stations installed at the brine heaters of the
desalination plant.
The total condensate flow capacity is made up of the max. condensate flow plus all make-up water
and desuperheater spray water requirements.
All system components must be designed for zero delivery flow of the main condensate pumps.
The pumps must be protected against minimum pressure and minimum flow.
HP and LP drains of the steam lines as well as the steam header drains shall be collected in the
atmospheric clean drain tank. The HP drains and warming up steam shall be flashed into an
atmospheric HP flash tank.
Depending on the water quality (conductivity measurement) the drains shall be discharged by
means of 2 x 100 % clean drain pumps to the feedwater tank or to the waste water system.
Page: 4
3.2
FEEDWATER SYSTEM
Each HRSG and each Auxiliary Boiler shall have an independent feedwater system. The
requirements are the same for HRSGs and Auxiliary Boilers. The system receives condensate
from the common condensate header, as well as make-up water from the demineralised water
system and stores it in the feedwater tanks after passing through the deaerator.
The feedwater system shall provide the necessary feedwater flow rate to the HRSG under all
operating conditions including the de-superheating spray water requirements in case of bypass
operation, etc.
Feedwater split-range control stations (1 x 30% and 2 x 100% each) sufficient for all operation
requirements and condition shall be installed downstream the economiser. The feedwater control
valve shall control the flow quantity depending on the level in the boiler drum and the feed and
steam water flow.
The feedwater tank / deaerator shall be operated above atmospheric pressure under all load
conditions. The feedwater tank temperature shall be approximately 125C or even lower, if proper
de-aeration can be obtained, to achieve low stack temperatures for both natural gas and backup oil
firing in view of the fuel properties and exhaust gas acid dew point.
Steam for the heating of the deaerator / feedwater storage tank shall either be produced in a
separate once-through heating loop in the HRSG / Auxiliary Boiler. As a back up and for heating a
feedwater tank, which was out of operation, heating steam shall also be provided from the HP, MP
and LP steam systems. All the steam collected from the continuous blow down vessel shall be
used at the Deaerator / Feedwater Storage tank for heating the feedwater.
The feedwater storage tank level shall be controlled by adding make-up water into the deaerator
via control stations connected upstream of the de-aerator. In case of high water level in the
feedwater tank, the water shall be drained by the (emergency) drain valve to the waste water
system.
The feedwater system shall be designed for zero delivery head of the feedwater pumps and in
accordance with the relevant Boiler Codes / Standards.
4
DESIGN AND CONSTRUCT ION REQUIREMENTS
The condensate system and the feedwater system shall be designed for safe, reliable and proper
operation at all possible load conditions. The materials shall be carefully selected so as to resist to
the effects of erosion and corrosion at Site conditions.
All General Requirements specified under Part G4 and G5, are applicable as well as further
requirements / regulations from other Parts of this specification.
4.1
4.1.1
CONDENSATE SYSTEM
Main Condensate Pumps
The condensate pumps are included in the Scope of Package D Desalination. Condensate
pipes shall also be provided by the Package D Desalination up to the pipe rack. Any
condensate requirements of the Desalination Package will be provided by this contractor.
4.1.2
Pipes and Valves
4.1.2.1 General
In addition to the stipulations given in Part G5.1 the steam, condensate and feedwater piping
system shall be designed on the basis of the drawing No CNE/015/2002-W-00-G-D-00009 Steam
and Main Condensate System P&ID.
Page: 5
4.1.2.2 Design and Materials

The pipework shall be designed to withstand the closed valve pressure of the main condensate
pump and the maximum condensate temperature, with appropriate margins.
All kinds of hangers, supports, etc., shall be amply dimensioned and designed to be capable of a
hydrostatic test of the pipe system. Blocking of hangers is allowed during the hydrostatic test.
Tap connections for instruments shall be provided in the location required for testing and operation.
Piping material for the condensate system shall not be inferior to St 35.8 according to DIN or
equivalent.
The material used for valve casings shall at least be of the same quality as for the related pipes.
4.1.2.3 Drain Valves, Warm-up valves and Steam Traps
All steam drain and warm up valves shall be of an approved throttle controlling type and shall have
cast or forged steel bodies with covers and glands of approved design. The size of drain valves
shall not be smaller than DN 50.
For general requirements of the valves, see also G5.1 "General Technical Requirements Mechanical Equipment".
4.2
CLEAN DRAIN COLLECTING SYSTEM
4.2.1
General Requirements
The operating drains from the steam, condensate and feedwater system are discharged and
collected in the clean drain tank and pumped either back into the system or to the blow-down
waste water system by means of 2 x 100% pumps, based on the conductivity measurement. All
drains, of which temperature is likely to exceed 100C shall be transferred to the atmospheric
clean drain flash tank facilities. The drains of the flash tank flow by gravity to the clean drain tank.
The vapour shall be routed to the atmosphere via a flash pipe and silencer.
4.2.2
Clean Drain Flash Tank
The clean drain flash tank should be a vertical cylindrical type made from high temperature
resistant carbon steel and shall be installed above the clean drain tank in the turbine area. The HP
and MP drains shall be collected in separate headers of the tank.
The following connection nozzles shall be provided in the bottom and top parts of the clean flash
tank:
Connection for the atmospheric flash pipe
Connection for the clean drain discharge into the clean drain tank
Nozzles connected to the cylindrical section
Connections for the HP and MP drains from the collecting headers
Any other nozzles as required
4.2.3
Clean Drain Tank
The clean drains out of the clean drain flash tank as well as the LP drains are discharged into the
clean drain tank with a net capacity of 10 m as a minimum. The clean drain-collecting tank should
be a cylindrical horizontal tank made from carbon steel and designed against vacuum as well as
possible overpressure.
The following nozzles are provided at the highest point of the tank:
Page: 6
Connection for the pipe to the clean drain flash tank
Level and temperature measurement nozzles
The following nozzles shall be provided at the lowest point of the cylindrical section:
Connection to the clean drain pumps
Level measurement nozzles
Nozzles of the complete draining
For the inspection of the clean drain tank a manhole shall be provided.
A common line for tank overflow and tank draining shall be taken to the hot drainage system. The
hot drainage system discharges, after cooling down by seawater, to the seawater out fall system.
4.2.4
Clean Drain Pumps
2 x 100% clean drain pumps, which shall be of low NPSH type, shall be provided for feeding the
drains into the feedwater tank or into the blowdown basin depending on the condensate quality
and tank level. Therefore measurements of conductivity downstream of the pumps shall be
provided. The shaft seals shall be of mechanical type. The pumps materials like e.g. shafts,
impellers, etc. shall be stainless steel.
The design of the clean drain pump shall be based on the height difference of the plant, the back
pressure, the suction pressure and the pressure loss of the pipe system. The saturated
temperature of 100 C at the atmospheric pressure shall be considered.
4.3
MAKE UP WATER SUPPLY SYSTEM
Demineralised water shall be used for making up the losses of the water / steam circuit.
In case the water level in the feedwater tank drops, make-up water shall be fed to the feedwater
tank via control stations (2 x 100%) connected upstream of the de-aerators in order to minimise the
O2 content in the system. The flow and quantity of make-up water used shall be monitored
continuously.
All parts or components of the make-up water supply shall be made of stainless steel.
4.4
4.4.1
FEEDWATER SYSTEM
Feedwater Storage Tank and Deaerating System
Design Requirements
The feedwater system shall consist of feedwater storage tank(s) including the necessary
deaeration systems with the following basic design data:
Feedwater storage capacity in case of maximum outlet

flow and no inlet flow (min.)
Minutes
15
Guaranteed maximum O2 content (without chemical

injection) of the deaerated feedwater at the storage tank
outlet covering the whole operating range and regardless
of the oxygen content of all incoming condensate.
Page: 7
ppm
0.02
The deaerator and feedwater tank design pressure shall not be less than 1.3 times the max.
operating pressure.
Design Features
A geodetic height and a suction line arrangement between the feedwater tank and the boiler feed
pumps shall be provided in such a manner, that pump cavitation will be prevented under all
operating conditions (steady-state as well as transient). No pipe section shall have less than 45
(=100%) slope. Each feedwater pump shall have its own suction line connected to the feedwater
tank.
The continuous heating steam shall be distributed in the feedwater tank in case of spray type
deaeration. In case of tray type deaeration continuous heating steam will be distributed in the deaerator installed on top of the feedwater tank.
The feedwater storage tank shall be equipped with the necessary connecting nozzles and
distribution facilities.
Deaerator and feedwater storage tank shall be designed to withstand also full vacuum.
Additionally, vacuum breakers shall be provided.
The feedwater storage tank shall be equipped with all necessary valves, safety valves, level
switches, water level indicators for the complete range of water level, etc.
Suitable connections for local indication, remote measurements and sampling shall be provided.
The storage tank and deaerator shall be furnished with access manholes.
The feed water tank and the deaerator shall be equipped with clips for insulation. The insulation
clips shall not be welded onto the shell of the feedwater tank or deaerator.
A tank overflow device shall be provided. In addition, the main condensate inlet valves shall
automatically close in the event of very high level. The feedwater pumps shall switch-off in case of
very low level.
The feedwater tank shall be equipped with a safety valve for protection against high pressure.
The Contractor shall ensure and clearly guarantee the following in his offer:
The deaerator shall deliver feedwater at all loads of the HRSG / Aux. Boiler with oxygen
content not exceeding the specified value
The deaerator shall operate without objectionable noise, rumble, hammering, vibrations or
other such evidence of poor performance over the entire operating range as well as when
heated up from cold condition.
The deaerator connected to the feedwater storage tank shall preferably be of the contact spray
type. Cascade-type deaerators and similar types will also be accepted but they shall incorporate
re-evaporation.
The size of the deaerators shall be sufficient for a water flow of at least 1.1 times the maximum
feedwater flow of the HRSGs plus the feedwater injection quantity for de-superheating of HP and
IP steam.
For the design of the deaerators it shall be assumed that in addition to the brine heater condensate
an adequate quantity of make-up water saturated with O2 and possible traces of CO2 will be
supplied from the demineralised water tank. The condensate from the drain condensate tank(s)
Page: 8
and the return minimum flow and relief from the feed pumps are also returned to the feedwater
storage tanks.
The contractor shall submit his calculation to justify the proposed elevation of the storage tanks.
The pressure containing parts of the feedwater storage tanks including deaerators shall be stress
relieved in the works prior to dispatch.
The deaerator spray nozzles and the nozzle strainers shall be of stainless steel not inferior to
316L. If separate deaerators are mounted on the feedwater storage tanks they shall be made
completely of stainless steel not inferior to 316 L.
In each case the deaeration area or parts where oxygen and water are in contact shall be made
stainless steel not inferior to 316L. The entire vapour extraction system shall be manufactured
from stainless steel.
The storage vessels shall be horizontal cylindrical and shall be complete in all respects.
A distance of at least 400 mm shall be allowed between the normal regulated water of the
feedwater tank and the maximum permissible level.
To allow for possible sloping of the contents of the feed tank, a horizontal force of 10% of the
maximum vertical load must be assumed.
In order to avoid the danger of corrosion, diverter plates shall be fitted in the dead corners of the
feed tank to improve circulation. The wall thickness for the feed tank shall have a corrosion
allowance of at least 3 mm.
The stub pipes for the feedwater suction lines shall protrude sufficiently into the tank, they shall be
funnelled and fitted with vortex breakers. Stub pipes shall be welded where possible. Stiffeners
with inspection holes shall be welded in places where necessary.
Each feed tank shall incorporate 2 manholes of at least nominal size of 600 mm and a separate
deaerator shall have at least one manhole of a nominal size not inferior of 500 mm.
There shall be at least two spare stub pipes each on the steam and on the water side of the feed
tank. All valves and fittings directly above the feedwater tank shall be accessible from platforms.
The necessary instruments, control loops and valves shall be provided in compliance with the
requirements of the system. The control functions covered by these instruments and valves shall
include but shall not be limited to the following:
a) Control deaerator working pressure
b) Control feedwater storage tank liquid level
c) Isolate all the water supplies to the vessel on high water level by means of independent
motor operated valve
d) Trip the boiler feed pumps on low liquid level
Upon completion of the plant, the complete feedwater systems shall be tested together with the
desalination plant in order to verify its proper operation as well as the guaranteed O2 values of the
deaerators.
The Contractor with his Tender shall propose a detailed description of the control concept.

4.4.2
Page: 9
FWT Heating Loop Circulating Pumps
If the feedwater tank is heated with steam for proper deaeration by means of a once-through
evaporator loop in the HRSG, 2x100% circulation pumps shall be provided for this purpose
complete with motor, necessary valves and instrumentation, minimum flow device, etc.
4.4.3
Feedwater Pumps (FWP)
General Description
2 x 100 % feedwater pumps for each boiler shall be provided. The standby pump shall start
automatically in case of failure of the running pump. Special emphasis shall be placed on a design
with high reliability of the individual equipment and the whole system.
The feedwater pump sets shall be a horizontal centrifugal multistage design unit mounted on an
integral baseplate with its motor. A split casing design should preferably be provided. However, the
overriding consideration of the design shall be the highest possible reliability and availability of the
pump sets. The pumps shall be capable of resisting all NPSH transients without requiring
shutdown or tripping and without the occurrence of internal contact within the pump.
Complete bearing oil cooling and seal cooling system, the base plate, the frames foundations and
the minimum flow devices. The number of stages shall be as low as possible allowing a short
sturdy shaft design.
Capacity of Pumps
The capacity of the pumps will be selected in accordance with the requirements of the HRSG /
Aux. Boilers codes and standards.
The HRSG / Aux. Boiler feedwater pump sets shall provide the necessary feed water flow rate at
the design pressure to the corresponding steam generators under all operating cases.
The design flow rate shall comprise the boiler feed water requirements for the boiler respectively
including the spray water for attemperators and steam reducing stations at MCR operation of
HRSG / Aux. Boiler and/or ST.
The design flow rate shall be discharged against the pressure of the HRSG / Aux. Boiler's safety
valves settings with fully open safety valves.
Feedwater Pump Sets Characteristics
The feedwater pump sets characteristic curves shall be steady at any load i.e. the discharge
pressure shall decrease continuously as the discharge flow is increased from zero to rated
capacity. The pumps shall operate stable and without undue vibration in single as well as in
parallel operation mode.
The pump set characteristics shall be such that the pump set can still operate at 20% rated flow,
without minimum flow recirculation.
During HRSG / Aux. Boiler operation the stand-by pump shall always be ready for immediate
automatic start on failure of the running pump. The operating conditions of the stand-by feedwater
pump set must be reached before the HRSG / Aux. Boiler will trip or will show operating problems.
The feed pumps shall operate with constant speed.
Design Features
All equipment shall be suitable for the special requirements of the feedwater quality (for pH and O2range and possible temperature shocks). In addition, the system shall also withstand all conditions
during pickling of the HRSG / Aux. Boiler and the piping system.
Page: 10
High grade quality materials shall be used for the pump inner parts in order to avoid erosion and
premature deterioration. The feedwater pumps with all parts coming into contact with the feedwater
shall be constructed in chromium steel containing at least 13% chromium. The materials shall
satisfy without restriction the requirements of erosion and corrosion resistance resulting from
operation with demineralised water and water conditioned with volatile alkalising agents having a
pH-value equal to or greater than 7.0. Protective sleeves on the shafts are to be hard chromium
plated, cooling sections and bearing mountings of cast steel.
The pumps and the system shall be designed to operate not less than 25,000 hours before a major
overhaul i.e. dismantling of the pump is required.
All rotating components and the complete rotating assemblies (including Spare parts and
assemblies) shall be statically and dynamically balanced.
It shall be possible to start the pumps safely from cold condition without prior warming up or other
preparatory measures.
Easy access shall be provided from ground floor or from an installed platform to every valve,
instrument, utility connection (e.g. all stairways and platforms required for such purposes).
The foundations for the feed water pump sets shall be designed as reinforced concrete slabs
mounted on the foundation. The Contractor shall perform the static and dynamic computations and
shall supply shuttering-, reinforcements and detailed anchoring drawings including bending lists.
The oil coolers and the mechanical seal coolers of the feed pumps shall be cooled by the closed
cooling water system.
All equipment must be capable to safely run down upon a power failure without suffering any
damage of the pump or its bearings.
The pumps shall be located on the ground floor besides the boiler, below the feedwater storage
tank.
Each feedwater pump set shall be equipped with individual suction lines and individual min. flow
line connected directly to the feed water tank. Each feedwater pump set shall be protected against
suction failure by interlocks including the open position of the suction valve and adequate level in
the feed water tank.
Each feedwater pump shall be equipped with vibration sensors for alarm and protection.
Construction Requirements
In order to simplify the plant arrangement, booster pumps shall not be used.
The design pressure of the feed pumps shall be at least 1.2 times the pump zero flow pressure at
input speed, at cold conditions and under maximum suction pressure conditions.
The minimum flow device shall be designed for a flow not exceeding 20% of the flow rate at MCR
load.
Bleed water from the balancing device shall be recycled to the suction nozzle.
Design and materials of construction shall consider the possibility of cavitation. Temporarily quick
and large temperature variations must be absorbed by any part of the construction without undue
stresses. Exciting forces should be eliminated or restricted to a minimum.
Thrust Balancing and Bearings
The axial thrust of the pump rotor shall be balanced mainly by a balance disc or piston reacting
according to the feedwater pressure.
Page: 11
All unbalanced axial forces shall be taken by amply designed, axial thrust bearings of the tilting pad
type. The bearing shall be effective in both axial directions and shall be dimensioned in such a
manner that even in the event of short-duration cavitation no damage to the pump will occur. There
should always be a defined force on that bearing.
For taking the radial forces, the shaft shall run on generously dimensioned forced oil-lubricated
journal sleeve type bearings supported in bearing houses. The bearings shall be designed to
accommodate displacement of the pump impeller due to thermal expansion. The bearing block
shall be split for easy maintenance and removal. Antifriction type bearing will not be accepted.
Leakage of oil to the outside of the bearing housing must be prevented.
Lubrication System
The pumps shall be equipped with forced lubrication, each feed pump set shall have its own
system with oil cooler and 2 x 100% oil pumps for automatic start in the event of a drop in
lubricating oil pressure. Adequate feed of oil shall be ensured under start-up and run-down
conditions. The maximum bearing metal temperature shall not exceed 80oC.
The oil system shall be equipped with all necessary filter, (double filters), strainers, pipes, valves,
etc. necessary for a reliable, safe and proper operation.
Changeover of the filters in operation must be possible without interruption and they must be easy
to clean.
Sealing
The gland seals shall be of the mechanical seal type of a well-reputed manufacturer. Seal faces
shall provide at least 8,000 running hours before replacement becomes necessary.
The closed cooling water circuit, if so required, shall provide cooling water for the gland seals. If so
required by the pump design, the cooling water for the seals shall be discharged into the sewer in
case of emergency i.e. upon a cooling water flow failure.
Base Frames and Foundation
Motor and main pump shall be arranged on common frame and/ or baseplate of sufficient stiffness
to withstand all static and dynamic forces produced by load and torsion under all operating
conditions.
The base-plate shall be fitted with drip tray facilities, and provisions for drainage shall be provided.
Any insulating or damping material needed to mitigate vibrations or to be incorporated in
foundation, shall be provided.
Minimum Flow Device
The minimum flow system shall protect the feed pump if the main throughput falls below the
minimum flow rate set by the pump manufacturer.
Each pump shall be equipped with its minimum flow system comprising of one automatic combined
check valve/minimum flow valve and its individual minimum flow line. Each individual minimum flow
line shall be routed back to the feedwater tank.
Sound Absorbing Hood
If the noise emitted by the boiler feed pump set or any part of it, exceeds 85 dB (A) at 1 m
distance, a sound absorbing hood shall be provided (tolerance +3 dB(A)). The minimum noise
damping effect shall be 10 dB(A), but the emitted noise shall be below 85 dB(A) in any case with
+3 dB(A) tolerances.
Page: 12
Suction Strainer
A strainer shall be provided on the suction side of each feedwater pump. During the first month of
operation, the strainer screens shall be duplicated with a fine mesh basket with provisions for water
cleaning without dismantling. The free screen area shall be 5 times the inner area of the line as
minimum. The strainer shall be provided with differential pressure gauge and alarm. Strainer
screens shall be made of stainless steel.
Strainers shall be included in the suction lines to protect the pumps from the damage under all
operating conditions. The strainer mesh size shall not exceed 0.5 mm. The free area of the strainer
shall be at least equivalent to 5 times of the cross-section area of the corresponding suction pipe.
4.4.4
Pipes and Valves
General
In addition to the specification given in Part G5.1, the steam, condensate and feedwater piping
system shall be designed on the basis of the drawing No CNE/015/2002-W-00-G-D-00010
Feedwater System P&ID.
Design Features of Pipes
The main steam line shall be provided with measurement points to allow the exact survey of the
pipe run. The pipeline route shall be measured after the first start and, if necessary, be corrected
by the Contractor. The measurement points shall be installed to check the changes in pipe
alignment between the erection and operating conditions and to study the behaviour of the pipes
during the whole operating period.
Spray water for steam temperature control and steam reducing station shall be tapped from the
feedwater piping system downstream of the feed water pumps or economiser outlet.
The steam pipe work, the boiler feedwater system and the condensate system shall be designed in
such a way that it withstands the stresses imposed by the media handled.
The feedwater pipe work and shut off valves in the pump discharge shall be designed for zero
delivery head of the feedwater pumps.
The velocities in the suction pipes of the pumps during full load operation should be in the limits of
0.5 1 m/s. The Contractor shall optimise the velocity in the feedwater suction line in order to
prevent positively forming up of steam bubbles in the line, it is expected that the velocity will be in
the range of about 0.5 m/s.
All kinds of hangers, supports, etc., shall be designed to be capable of a hydrostatic test of the
pipe system. Blocking up of hangers is allowed during the hydrostatic test.
The Contractor shall submit the design and computation results of high pressure pipes, such as
computer-calculated stress analysis, proper isometric drawings, etc. to the Employer / Engineer for
approval. The computation and drawings shall show the magnitude and direction of the thrusts and
resulting bending moments at the terminal points when the connected pipe is operating at the
design pressure and temperature.
In any case, the com putation and design of all piping shall be performed such, that the resulting
piping has a sufficient wall thickness for adequate elasticity and the resulting stresses under design
conditions to meet the relevant standards.
Cold pull-up shall be avoided. In case cold pull-up cannot be avoided in order to achieve a piping
system free of excessive stresses and reactions at equipment connections for all operating
temperatures, it may be applied prior written approval from the engineer.
Isometric drawings of pressure pipe work, which show, among others, the magnitude and direction
of the thrust on the turbine steam chest, HRSG / Aux. Boiler superheater outlet header,
Page: 13
economiser inlet header, feed pumps, heat exchanger and reducing stations, both in the hot and
cold condition, shall be submitted to the Engineer for approval.
Provision shall be made for steam blowing and chemical cleaning. Additional internal parts for
valves, strainers, etc., needed for cleaning, pressure tests and blow-out process and preservation,
shall be supplied by the Contractor responsible for the equipment in question.
Tap connections for instruments shall be provided in the locations required for testing and
operation.
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 as the adjacent
pipe-work, they shall match correctly the bore of the adjacent piping and shall be proportioned to
avoid undue stress.
Steam and Feedwater Valves
The minimum requirements for pressure valves of the thermal cycle components shall be as
follows:
Spindles:
Mating faces:
high temperature-resistant alloy steel

stellite, or within the range of 20 Cr Mo 17,
X5 Cr Ni 199,X5 Cr Ni Mo Nb 1912,
Monel 400, X8 Ni Mo 6530 and
X8 Ni Mo Cr 6018.
Arrangements shall be provided to prevent any accumulation of pressure between the disc of any
pressure steam or feedwater parallel or wedge gate valves.
The material used for valve casings shall be of the same quality as for the related pipes.
Drain Valves and Traps
All drain valves shall be of an approved throttle controlling type and shall have cast or forged steel
bodies with covers and glands of approved design. The size of drain valves shall not be smaller
than DN 50.
5
The Instrumentation and Control herein shall meet the requirements in Part G5.2 and P2.27
Instrumentation and Control Systems. The scope of work shall be in accordance with the flow and
control diagrams, indication, alarm, trip and other I&C layout lists.
The instrumentation and control equipment shown herein shall form the minimum requirement,
completed by the Contractor accounting for the special features and design particulars of his
equipment as well as his experience as to operational safety, efficiency of control and ease of
supervision of the unit. Modifications are subject to the Engineers approval.
A sufficient number of field sensors and local/ remote indicators is to be provided to secure a
reliable and safe operation, monitoring and protection of the equipment specified herein.
Wherever possible, field signal distributors and local indicators and transmitters shall be mounted
in groups to allow an easy operation, monitoring and maintenance.
The local instrumentation shown in the respective flow diagram shall be provided with the
associated isolating and test valves as needed. Sealing water connections shall be supplied for all
equipment normally operating under vacuum. The capability of withstanding vacuum shall be taken
account of in the selection of the respective local instrumentation equipment.
Page: 14
The Contractor shall provide additional instrumentation if so required in order to achieve a reliable,
safe and proper operation of the system.
Independent of all safety devices such as safety valves, adequate number of measurements shall
be provided for monitoring and protection of the relevant equipment.
Protection devices shall be provided for/ against:
Bearing temperature
Under-running of operation limiting curve
Differential pressure suction filter
Dry operation of pumps
Pump cavitation
Minimum flow
Cooling water flow
Suction valve position
Discharge valve position
The formal requirements, the technical requirements and the scope of inspections, test and quality
assurance measures are specified in Part G5.6 General Technical Requirements Inspection and
Testing
CNE/015/2002
P2.9
WORKING DOCUMENT
Part P2.9 Closed Cooling Water System Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
PAGE
GENERAL ..................................................................................................................................... 1
LAYOUT ........................................................................................................................................ 2
SCOPE OF WORKS..................................................................................................................... 2
3.1

3.1.1
Closed Cooling Water Pumps.......................................................................... 4
3.1.2
Closed Cooling Water Heat Exchangers........................................................ 4
3.1.3
Closed Cooling Water Tank ............................................................................. 5
3.1.4
Chemical Dosing Unit....................................................................................... 5
3.1.5
Pipes and Valves............................................................................................... 5

3.1.5.1 Pipes........................................................................................................ 6
3.1.5.2 Valves ...................................................................................................... 6
INSTRUMENTATION AND CONTROL ....................................................................................... 6

4.1
LOCAL INSTRUMENTS................................................................................................... 7
4.2
REMOTE SUPERVISION AND CONTROL..................................................................... 7
INSPECTION AND TESTING....................................................................................................... 7
CORROSION PROTECTION....................................................................................................... 7
P2_09closed_cooling_water_Working_Doc.doc
Page: 1
GENERAL
The CCW system is an intermediate cooling cycle to transfer heat generated in various plant
equipment via the closed cooling water heat exchangers. The primary circuit coolant in the heat
exchangers will be seawater - Service Cooling Water System.
This CCW system shall serve all closed water circuit cooling water requirements of the plant
station "L" Phase I in general for all the following parts:
Gas Turbine Generator Units
Heat Recovery Steam Generator Units
Steam Turbine Generator Units
Desalination Plants
Auxiliary Steam Generator Units
Balance of Plant, (including Fuel Gas Compressors, HVAC systems, etc., if applicable)
The cooling medium in CCW system shall be demineralised water, dosed by an appropriate
corrosion inhibitor, to be specified by the Contractor. The make up water shall be supplied from the
make-up water system via a level control valve to the CCW system. The expansion tank can either
be of atmospheric or pressurised type filled with nitrogen.
Four ( 4 x 50 %) closed cooling water pumps shall be provided which supply sufficient water flow to
all consumers via the 3 x 50% primary CCW heat exchangers where the heat is transferred to the
seawater coming from the Service Cooling Water system. The CCW pumps shall be provided with
a minimum flow re-circulation arrangement, if required due to the design.
The main consumers of the closed cooling water circuit are, but shall not be limited to:
The gas turbine generator units,

-
Lube oil coolers
Generator air coolers
Hydraulic oil coolers
The steam turbine generator units

-
Lube oil coolers
Generator air coolers
Hydraulic oil coolers
Gland steam condenser
Feed water pumps coolers
Sample coolers
Gas and or compressor coolers
Desalination plants coolers
Other coolers
Page: 2
It shall be possible to adjust the closed cooling water flow to each consumer by manually
adjustable throttling valves.
The closed cooling water pumps and the whole closed cooling water system shall be capable of
withstanding the transient pressures associated with a rapid closure of the check valve due to a
pump shutdown followed by the start of the stand-by pump.
Piping shall be suitably routed and shall serve any equipment of this project, requiring cooling
water.
The intent of this specification is to define the minimum technical requirements of the closed
cooling water system for the complete L station plant. The Contractor shall be responsible for the
final design, selection, procurement, installation, commissioning and testing of the complete
system and shall adhere to the applicable specifications and standards.
LAYOUT
The Closed Cooling Water Systems are shown on the drawing:
Closed Cooling Water Systems P&I Diagram. CNE/015/2002-W-00-G-D-00005
The heat exchangers with the primary circuit coolant sea water are located between the HRSG 3
and steam turbines. Sufficient place shall be provided for withdrawing of the tube bundles and a
free passage must be left clear.
The CCW - pumps shall be located on ground level beside the heat exchangers.
The CCW - tank shall be positioned at a sufficient height.
SCOPE OF WORKS
The closed cooling water system shall be complete in every respect and suitable for safe reliable
operation.
Supplies, services and components which are necessary for a safe and reliable operation of the
system and are not mentioned explicitly are also to be included in the scope of works.
The scope of main equipment is as follows, but shall not be limited to:
Three (3 x 50%) Seawater / Closed Cooling Water Heat Exchangers, complete with vent and
drains, support structure, base plates with anchoring features etc., All three in operation at
reduced load and one can be isolated for maintenance and or repair and the remaining two
can operate with 100% station requirement.
Four (4) horizontal centrifugal pump sets complete (4 x 50 %) matching the closed cooling
water requirements, complete with coupling, drive motors, base plates etc.. Two pumps shall
run at maximum load condition. The third or fourth pumps shall start upon failure of one
operation pump automatically or in emergency case (additional flow requirements)
Closed Cooling Water Tank, complete with support structure, fastening, nozzles, level
measurement equipment, (supplied with a nitrogen system, if required)
Facilities for inhibitor dosing for corrosion protection,
Page: 3
All required pipes, all type of valves, expansion joints, drains, vents, fittings, and any
accessories,
All local control and remote, measuring and monitoring equipment,
All electrical equipment.
3.1
The CCW - System shall be designed for continuous operation under all prevailing climatic and load
conditions. The cooling capacity shall be at least 10% more than the cooling requirement for the
most severe combination of plant in service with the most severe combination of ambient and sea
water temperatures.
The stipulations in Part G5 General Technical Requirements shall be considered.
The proposed number and size of the different coolers shall be listed in the offer in order to get the
total cooling capacity for the primary CCW heat exchangers for review during evaluation period
available. As guideline, the total maximum cooling capacity is estimated with approximately
75 MW, corresponding to 110% total design cooling capacity. This figure shall be reviewed and
corrected during contract negotiations and finally revised under close co-ordination between the
contractors concerned at final design.
The cooling capacity shall enable to operate all coolers in the system simultaneously at their
maximum cooling demand.
System design pressure
6 bar
System test pressure
1.5 times design

pressure
The closed cooling water mass flow and the delivery head of the cooling water pump may be
altered if necessary during the final design or if required and verified during commissioning or the
Defects Liability Period to take care of the actual required min./max. cooling water demand and
head losses of the consumers.
The system design pressure shall be adjusted in case the water hammer calculation shows a
higher value than 6 bar.
The Contractors final design calculations shall be submitted to the Employer / Engineer for review
and approval.
All equipment including the pump sets shall be located on foundations/plinths having a height of
approximately 0.4 m above the floor level and with undisturbed access space, free of pipes or
similar obstacles, of at least 0.8 m between the installed equipment and on the surrounding walls
or walkways to ensure proper access for maintenance and operation.
All motor operated valves shall be arranged within 0.9 to 1.1 m above ground level with same
space in front of them as stated before. All valves to be manually operated shall be in reach from
the ground level. If not possible, access for operation and maintenance purposes shall be provided
by means of galleries, platforms, wall ways to and around plant for valves, gauges and other
equipment.
Materials shall be carefully selected to prevent erosion and corrosion.
Insulation shall be provided in order to prevent condensation of the ambient air humidity at the
relevant CCW equipment, such as piping and tanks.
The sound pressure level shall not exceed 85dB (A) when all equipment is running. This level will
be measured in one (1) meter distance from any point of the equipment.
Page: 4
3.1.1 Closed Cooling Water Pumps

4 x 50 % closed cooling water pumps shall be provided, two will be normally in operation whereas
the third and the fourth ones are available for automatic start on a trip of one operating pump or
available in case of maintenance of one pump. Notwithstanding the above the design of the
system shall ensure that single pump operation is also possible either in an emergency case e.g. in
case neither stand-by pump starts upon a failure of a pump or when the plant will be operated in
part load e.g. during winter time. The delivery head of the pump shall be designed to allow a safe
provision of all closed cooling water consumers at the lowest possible operating pressure.
The suction pressure of the pumps and the minimum system pressure shall be maintained by the
high level cooling water tank(s).
The closed cooling water pumps shall be of horizontal centrifugal type.
The pumps shall be standard units of a reputable manufacturer and shall conform to the
requirements of the standards selected for the design.
The driving motor shall be mounted on the extension of the pump bedplate and shall drive the
pumps directly through flexible couplings, provided with removable coupling guards.
The casing and other casting parts of the pumps shall be of ductile cast iron with both suction and
discharge connections flanged. Impeller and shaft shall be of stainless steel. The supporting frame
shall provide suitable support for the casing and bearings.
Shaft seals shall be of mechanical type. Bearings shall be of oil lubricated ball type.
Each closed cooling water pump shall be provided with a strainer located upstream of the pump,
between valve and pump inlet.
3.1.2 Closed Cooling Water Heat Exchangers

Three (3 x 50%) Seawater / Closed Cooling Water Heat Exchangers shall be provided. They shall
be designed for 50% duty each i.e. all shall be in operation at reduced load, whereas one of them
can be put in standby, for maintenance and repair. A cleanliness factor of no more than 95% shall
be foreseen in the design.
The construction of the heat exchangers shall be of straight tubes with two (2) passes at tube and
shell side. The tube side shall be designed for the sea water flow and the shell side for the
demineralised water of the closed cooling water system. The design shall be such that during
operation the shell side water pressure is always higher than the tube side pressure. At both ends
flanged water box covers shall be available for easy tube cleaning and maintenance. The water
box covers shall be mounted on a cantilever with hinges.
The design of the heat exchangers shall be in accordance with all applicable international
standards. Only proven products shall be delivered.
Design pressure shall not be less than 6 bar on the on the cooling water side. Test pressure shall
be 1.5 times the design pressure.
The Heat exchangers shall be equipped with safety valves, supports, suitable valves and pipework
for venting, draining as well as pressure measuring devices, etc..
The flow velocity in the tubes on the primary side shall not exceed 2.0 m/s.
Following materials shall be provided as a minimum requirement:
Tubes
Titanium
Tube Plates
Titanium clad
Shell
90/10 CuNi
Water Boxes
90/10 CuNi
Page: 5
For flushing purpose the coolers shall be equipped with the necessary pipe work and valves to
allow for reverse flushing on the seawater side. In addition it shall be possible to fill the coolers on
the sea water side with potable water during outage periods.
3.1.3 Closed Cooling Water Tank

The Closed Cooling Water Tank shall be designed in accordance with the relevant approved
standards.
A constant inlet pressure of the closed cooling water system shall be provided by means of one
cooling water expansion tank, which shall be installed on a sufficient height. Water losses of the
closed cooling water cycle shall be compensated by make-up water from the make-up water
system supplied to the cooling water system. Control shall be achieved by an automatic water
level controller.
The Closed Cooling Water Tank shall be large enough to compensate level variations at operation
and at start-up and shut-down of the cooling water cycle. However, its capacity shall be designed
according to the system requirements, but at minimum 10 m3. It shall be assumed that the
temperature difference will be in the range of 45 K for calculation of the volume to be compensated
within this tank.
The cooling water expansion tank shall be of vertical straight cylindrical type, either made of
corrosion resistant material or made of fabricated carbon steel plates. The tank made of carbon
steel plates shall have a protective coating against corrosion. Thickness, type and application of
the inner coating shall be subject to approval by the Engineer. In case of a carbon steel tank it
shall be assured that the water in the expansion tank is always chemically conditioned. Provided
that the Contractor has well known experience and references, glass fibre reinforced material is
also acceptable but subject to approval.
The tank shall be equipped with a rubber bag to avoid air invasion or shall be of pressurised type
filled with nitrogen In case the tank is pressurised type filled with nitrogen it shall be connected to a
nitrogen system, including nitrogen bottles, reducing and isolating valves, non return valves,
pipework etc., which maintains a nitrogen pressure of at least 0.1 barg. The tank design pressure
shall be min. 6 barg.
Tank exceeding 1.0 m in diameter shall be provided with at least one (1) manhole cover of at least
500 mm diameter. Smaller tanks shall have a sufficient number of inspection ports.
Tank shall be with insulation to prevent heat from the environment.
3.1.4 Chemical Dosing Unit

The CCW - system shall be provided with a chemical dosing equipment as described in Part P2.14.
3.1.5 Pipes and Valves

All piping, valves, instrumentation and control equipment shall be provided to fulfil the technical
requirements of the system.
3.1.5.1 Pipes
All pipes to be provided under this specification shall be specially cleaned and shall be free of rust
and mill scale and shall be properly corrosion protected before leaving the workshop for shipment
in order to avoid that time consuming pipe cleaning has to be carried out at site.
Page: 6
The velocity of the fluid shall be within the values of 0.71.5 m/s for suction and 1.53.0 m/s max.
for discharge lines of the pumps. All forces and moments on equipment shall not exceed the
allowable limits of the manufacturer. Expansion joint shall be provided at the pipe connections to
the pumps and/or heat exchangers if necessary.
A duplex strainer shall be provided upstream of each pump.
The pipes shall be installed above ground. Drains, vents and isolating valves shall be provided as
required. The pipe system shall be designed considering different settlements between pipes
installed on soil and equipment installed on foundations. On all such locations where different
settlements may occur, expansion joints or loops have to be provided.
The cooling water piping system shall be designed according to the relevant standards.
The pipe connections shall be carried out with butt welded joints throughout. However, flange
connections shall be used on control valves, equipment i.e. cooling water consumers, heat
exchangers, etc. and where technically advisable.
Sight glass type flow supervision devices shall be installed at each heater discharge pipe branch to
the distribution system return pipe.
3.1.5.2 Valves
Isolation valves in the cooling water system shall be of the butterfly type. Each cooling water heat
exchanger must be provided with isolation valves at the primary and the secondary pipe
connections. For small sizes (DN 50 and smaller) gate or globe valves shall be used. Special
adjustable flow control valves shall be provided at outlet pipe connection. It shall be possible to
adjust the cooling water flow by throttling of the valves. Where 2 x 100% coolers will be provided
i.e. lube oil and hydraulic oil coolers, etc. it shall be possible to adjust the cooling water flow
through the stand by coolers to about 20 to 25% of the normal water flow.
Casing materials shall preferably be of spherical graphite iron cast or welded carbon steel
construction. Internals shall be resistant against the media handled.
Valve casings shall be inside lined with bituminous of adequate thickness. Outside protection shall
be in accordance with the connected pipe system.
The pump discharge butterfly valves shall be of the ex-centric flap design provided with an
hydraulic drive for open/close operation and variable closing speed to be adjusted during
commissioning and according to the water hammer calculation, for smooth automatic operation
during start and stop of the pumps and or switch over to the standby pump.
All control, monitoring, interlocking and protecting functions of the CCW- System shall be in
accordance to the requirements specified in Part P2.27.
The remote control and supervision of the system shall be done from the CCR.
for reliable plant operation. The stipulations in the general and particular technical specifications
for instrumentation and control shall be considered.
All signals for remote tasks shall be cabled to the DCS system.
4.1
LOCAL INSTRUMENTS
The scope of local instruments shall contain but not be limited to the following items:
Page: 7
For each closed cooling water consumer on the closed cooling water side:
temperature gauge and pressure gauge at the inlet,
temperature gauge at the outlet,
Temperature and pressure gauges at the inlet and outlet of the closed cooling water heat
exchangers,
pressure and temperature gauges in the main supply line to the consumers,
pressure gauges at the pumps inlet and outlet side,
local level indication on the expansion tank.
4.2
REMOTE SUPERVISION AND CONTROL
The pumps shall be remote operated. All drain and vent valves required for automatic startup/shut-down operation shall be motorised so that remote start-up/shut-down of the cooling water
system is possible.
The following tasks shall be considered as a minimum:
Remote indication of pressure and temperature in the main supply and return line,
Pressure low alarm in the main supply,
Flow-low alarm for the feedwater pump cooling circuits,
Expansion tank level analogue indication and alarms,
Pumps dry running protection interlocked with the expansion tank level,
Stand-by logic for stand-by pumps,
Remote operation for all motors and motor operated on/off and control valves,
On/off level control of the expansion tank by the motorised filling valve from the make-up water
supply.
Corrosion protection shall be carried out according to the General Technical Requirements as
CNE/015/2002
P2.10
WORKING DOCUMENT
Part P2.10 Black Start / Emergency Power Supply Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
PAGE
BLACK START AND EMERGENCY POWER SUPPLY............................................................. 1
SCOPE OF WORKS..................................................................................................................... 2
2.1
DIESEL ENGINE............................................................................................................... 2
2.2
GENERATOR AND AUXILIARIES .................................................................................. 2
2.3
GENERATOR MAIN CONNECTION ............................................................................... 2
2.4
LV EQUIPMENT ............................................................................................................... 3
2.5
CONTROL AND MONITORING EQUIPMENT ................................................................ 3
2.6
COMMON EQUIPMENT AND SERVICES ...................................................................... 3
2.7
DOCUMENTS TO BE SUBMITTED WITH T ENDER...................................................... 3
TECHNICAL REQUIREMENTS................................................................................................... 4
3.1
LAYOUT ............................................................................................................................ 4
3.2
CONSTRUCTION REQUIREMENTS............................................................................... 4
3.2.1
Diesel Engine ................................................................................................ 4
3.2.2
Fuel supply and injection system .............................................................. 4
3.2.3
Air intake and exhaust system ................................................................... 5
3.2.4
Generator....................................................................................................... 5
3.2.5
Generator Main Connection........................................................................ 6
3.2.6
Voltage Regulator......................................................................................... 6
3.2.7
Generator Protection ................................................................................... 6
3.2.8
Synchronisation Equipment ....................................................................... 7
3.3
CONTROL AND MONITORING EQUIPMENT ................................................................ 7
3.4
OPERATION MODES....................................................................................................... 8
3.4.1
Emergency supply........................................................................................ 8
3.4.2
Test Run ........................................................................................................ 9
P2_10Blackstart_and_Emergency_Working_Doc.doc
Page: 1
BLACK START AND EMERGENCY POWER SUPPLY
This section covers the black start and emergency diesel generator power supply
To the black start of one Gas Turbine
and
For safe shut down of the plant and emergency supply of essential consumers of L Station
Phase I in case of grid black out over a longer time period.
There shall be two (2) Black Start Units and two (2) Emergency Units provided by the Contractor,
which shall be installed in separate rooms in order to minimise the risk of damage in case of a fire
incident.
2 x 3 diesel generators shall be applied as Blackstart Diesel Generators, whereas the summarized
capacity of 3 generators shall have the necessary capacity of one black start unit as described
herein. The diesel generators shall have equal capacities. The black start power shall be made
available with one push button operation from the CCR by starting and synchronising the diesel
generators automatically without any manual interference.
The generating units shall suitably be selected for the intended purpose and shall be capable to
supply power to all the equipment needed for a black start.
Each of these units shall be designed to cover 100% of the total required load and each unit shall
have 50% spare capacity. With two Black Start Power Generation Units operating in parallel it shall
be possible to start two gas turbines simultaneously without any restriction. It shall also be possible
to start the future Phase II gas turbines. Thus, necessary provisions shall be made i.e. spare
cubicles (minimum three (3) numbers) shall also be provided together with other requirements
which may be needed.
The Contractor has to prove by calculations the suitable capacities of these generator units.
The emergency diesel generators shall be connected to the 0.4 kV Emergency Distribution Board
as indicated in the typical single line diagram drawing No.CNE/015/2002-W-00-E-D-00100.
Concerning the black start power requirements it is foreseen that one of the gas turbines shall be
started after tripping of all gas turbines and no power is available from the 400 kV network system.
In this event generators are required, which can supply at the 11 kV-Station service board level the
required loads for start up, refer to the main single line diagram Drwg. No. CNE/015/2002-S-00-ES-00001. After having started one gas turbine, it shall be possible to connect the gas turbine to the
grid and to supply power to the plant via the step up transformers of the other gas turbines. It shall
however, also be possible to start the other gas turbines with the black start generator unit.
Depending on the system power requirement for the starting devices >10 MW, gas turbines with
dual firing capability Natural Gas/Diesel Oil may be provided.
The above mentioned generator sets with the respective associated equipment shall comply with
the requirements of Part G4 General Project Requirements, Part G5 General Technical
Requirements, Part P4 Technical Schedules and Data Sheets and Part G6 Attachments and
other Parts of these specifications whenever applicable.
Fire fighting / fire detection systems will be provided for diesel generator building and the
equipment in accordance with Part P2.23 Station fire fighting and fire protection system of this
specification.
Page: 2
SCOPE OF WORKS
The scope of works of this specification shall cover but shall not be limited to the following:
2.1
DIESEL ENGINE
For each diesel engine (two (2) for black start (whereas one unit consists of 3 diesel generators as
described in Clause 1) and two (2) for emergency) complete with:
Base plate
Spring elements
Fuel system, complete with fuel day tanks, fuel oil strainers, fuel forwarding pumps, duplex fine
fuel oil filters, injection pumps, all necessary pipework, etc.
Lubricating oil system with oil pump, duplex full flow filter, lube oil cooler, hand-operated oil
pump, standstill interval lubricating equipment (where necessary), all necessary pipework,
protection devices, etc.
Cooling water system, complete with radiator, expansion tank, cooling fan, thermostatoperated control valves, electrical standstill heating with associated circulating equipment, all
necessary pipework and auxiliaries, etc.
Combustion air suction system with air intake, metal duct, filter, etc.
Exhaust gas system with turbo-charger, piping, silencer, heat insulation, expansion joints, etc.
Fuel oil tank complete with level indication device, automatic filling system, dewatering device,
sludge tank, etc. And interconnecting piping between day tank and diesel engine complete
compressed air starting system including air bottles, air compressor to refill the empty air
bottles within lees then 45 minutes, etc.
Governor and protection system.
2.2
2.3
GENERATOR AND AUXILIARIES

two (2) synchronous black start generators and two (2)emergency generators, complete with
all auxiliaries, including at least:
Generator air cooling system
Excitation system
Voltage regulator
Protection equipment of the digital type automatic/manual synchronising apparatus

together with all necessary synchronising, measuring and control instruments.
GENERATOR MAIN CONNECTION
Generator main connections complete with at least the following:
11 kV line connection cubicles for the black start generator connection
Provisions for connection to the future Phase II
LV line connection cubicle for the emergency generator connection
All necessary CT's and VTs
Star-point cubicle and earthing system
All necessary control terminal cabinets.
2.4
Page: 3
LV EQUIPMENT
Two (2) local control boards each suitable for automatic and manual operation of the
emergency diesel generator and black start units; complete with synchronising equipment
interposing relays for remote control through DCS, etc.
All necessary hot-dip galvanised steel base frames, bolts, etc.
110 V DC supply (dual infeed with decoupling diode and voltage monitoring) for the control
and protection equipment.
2.5
2.6
CONTROL AND MONITORING EQUIPMENT

Four (4) sets, each set, for the black start and for each of the emergency generators, of
completely wired, equipped and factory-tested local control cubicles comprising all necessary
local measuring, control, instrumentation and monitoring equipment, including all annunciators,
pressure gauges, thermometers, flow meters, etc. The control system shall be microprocessor
based with redundant structure. Each set of the local control cubicles of each unit shall be
hardwired interfaced with the DCS for command / interlock signals and shall additionally have
dual-redundant serial link interface with the DCS for information and alarm signals.
COMMON EQUIPMENT AND SERVICES
All the necessary couplings and coupling covers
All necessary venting, draining and emptying equipment
All necessary pipework, compensators, fittings, automatic actuators, fastenings, etc.
All necessary base frames, base plates, anchor bolts, supports, covers, etc.
All required embedded parts in first and second concrete
All necessary safety measures
All cables for power, control, monitoring, protection, signalling, regulating, etc.
All necessary supporting structures, trays and fixing materials for cable laying
All necessary local junction and terminal boxes
One set of special tools and equipment for maintenance, inspection and repair in steel boxes
including identification and operating instructions
All standard equipment and accessories normally included in the supply schedule but not
separately listed.
Complete detailed labelling of all installations as required in Part G5 "General Technical

Requirements".
2.7
DOCUMENTS TO BE SUBMITTED WITH TENDER
In Addition to the requirements indicated in Part P4 Technical Schedules, the following

documents shall be submitted:
Correction curves for power output and fuel consumption for different ambient temperatures up
to 50C
Correction curves for power output and fuel consumption for different ambient pressure
General load curve (circle diagram) in relation to power factor
Page: 4
Detailed list of consumers to ensure smooth operation of all essential consumers in

emergency situations. (Same applies to the black start units).
TECHNICAL REQUIREMENTS
The requirements specified in Part G5, "General Technical Requirements", shall apply, as well as
all other requirements from the other Parts of this specification.
3.1
LAYOUT
Each diesel generator set and all related cubicles, housings, the associated electrical power,
control, measuring, protection, regulating and signalling equipment shall be located inside the
relevant plant building, indicated in the plant layout.
3.2
CONSTRUCTION REQUIREMENTS
All parts shall be designed that maintenance is only necessary at intervals of a minimum of 720
operating hours. Parts subject to wear and tear shall be easily replaceable.
3.2.1 Diesel Engine

The engine shall be water-cooled, with a closed circuit radiator and fan. The radiator and fan
assembly, which shall be installed outside the diesel generator room, shall have the necessary
anti-corrosive treatment/material. A suitable electrical heating of the cooling water during standstill
of the diesel generator set shall be provided, if required, to allow for the specified starting time.
The diesel engine shall be started by compressed air. The compressed air bottles of each unit shall
have the capacity for at least five (5) consecutive starts.
The diesel engine shall be directly coupled to the generator and both installed together on a
common base frame. Vibration absorbers shall be used to prevent transmission of vibrations to
the surrounding area.
The exhaust gas turbo-charger shall be of the water-cooled type including charge air cooler.
3.2.1.1 Lubrication system

The engine and the generator shall be fully force-lubricated. The main oil pump shall be geardriven by the main shaft. Where necessary, a suitable interval lubricating equipment shall be
provided to allow for the specified starting time.
3.2.1.2 Governing system

The governing system shall comply with CIMAC (Conseil International des Machines a
Combustion) or ISO requirements. The cyclic irregularity and angular deviations shall be in
compliance with Clause 22 of CIMAC.
3.2.2 Fuel supply and injection system

The engine's fuel oil tank shall be sufficiently sized for 12 hours of continuous full-load operation of
emergency generators as well as black start diesel generators. The tank shall be filled-up
automatically by a fuel pump controlled by level sensors installed in the tank.
An integrating fuel meter shall be installed, suitably connected to the engine's fuel admission and
return system, to measure the actual consumption of the engine.
The outlet connection of the extraction line shall be arranged at least 10 cm above the fuel tank's
bottom or otherwise suitably positioned in order not to take in sludge or water which may have
accumulated.
Page: 5
The ventilation openings of the tanks shall be protected by a flame trap.

The final acceptance test shall be carried out in compliance with CIMAC.
3.2.3 Air intake and exhaust system

The engine shall be fitted with an outdoor oil-wetted air-intake filter.
Flexible connections to the air intake duct, exhaust line and all other external pipework shall be
provided.
Temperature-resistant materials shall be used for the exhaust piping and the required expansion
bellows. Expansion joints in the exhaust pipe shall be made of metal and exhaust silencers shall
be galvanised.
The engine exhaust gas outlets and ventilation inlet ducts shall be arranged to ensure that the
exhaust gas is not channelled back into the ventilation air inlet system.
3.2.4 Generator
The relevant IEC regulations shall apply, except where more stringent rules are stated below.
The generators shall be air cooled with forced ventilation. A heater shall be provided to protect the
Generator against humidity during stand-still.
Six double element Pt 100 temperature sensors shall be provided, embedded in the stator
windings and wired to terminal boxes.
Overvoltage protection shall be provided.
The generator shall possess the necessary characteristics for synchronisation with the mains or
plant generators. It shall be suitable for unrestricted parallel operation with the plant's generators or
with the mains, as well as for stand-alone operation. The generators shall be equipped with a
governor to be able to adjust the droop between 2 and 8%.
3.2.4.1 Bearings
Bearings and, if necessary, also couplings and auxiliary lines shall be insulated so as to ensure
that no damage or injury of any kind would result through currents caused by shaft voltages.
3.2.4.2 Excitation
A brushless rotating diode rectifier excitation system shall be provided.
The rotating diodes shall be easily accessible for maintenance.
The excitation equipment shall be so designed that the highest voltage is reached at 5/4 load and
a power factor of 0.7. The excitation response ratio shall be greater than 1.0/second
(IEC 60034 3).
During short circuits, the time taken to de-excite from rated voltage to 10% of rated voltage shall
not exceed 8 seconds. The de-excitation time for open circuit de-excitation from rated voltage to
10% of rated voltage shall not exceed 30 seconds.
The excitation and de-excitation control equipment shall be combined with the voltage regulation
equipment in cubicles and shall be located in the diesel generator room.
Page: 6
3.2.5 Generator Main Connection

The generator main connections shall be provided with power cables. The power cables are
described in Part G5, "General Technical Requirements". If more than 2 parallel cables per phase
are required, appropriate steel-enclosed box for paralleling arrangement shall be provided.
All necessary current and voltage transformers for protection, excitation, measuring, etc. shall be
provided in the generator star point cubicle and in the diesel-generator's line connection cubicle
which feeds power to the relevant generator circuit breakers (11kV respectively 0.4kV incorporated
in the relevant switchboards).
3.2.6 Voltage Regulator

A solid state type voltage regulator, with automatic and manual control within 5 % an accuracy of
0.5 % of the rated voltage, ranging from no-load to full-load conditions at rated frequency, shall be
provided. A suitable transfer control system with transfer switch and necessary meters and
controls shall be provided for a smooth bumpless transfer from automatic to manual and from
manual to automatic voltage control. Bumpless and smooth transfer shall be automatically initiated
in the case of a sudden failure of the voltage regulator.
The Contractor shall supply all required auxiliaries such as generator field breaker,
discharge/suppression resistor, motor-operated voltage adjusting rheostat and other accessories
which are required for safe and continuous operation.
3.2.7 Generator Protection

The protective relays used for generator protection shall be of the digital/numerical type. The relays
shall be of a well proofed design with 5- 10 years operational experience.
All relays shall be from a reputed manufacturer, preferably from the same manufacturer of the main
generator protection relays. (Reference is made to Part P2.26.12 of this specification.)
The protective relays shall be installed in a steel-sheet cubicle, this cubicle shall be mounted in the
diesel Generator room along with the other cubicles for control, monitoring, regulating, signalling
excitation and voltage regulation. The scope of protection relays shall be but not be limited to, the
following:
Differential protection (87G)
Voltage controlled inverse time overcurrent protection (51N)
Reverse power protection (32R)
Overvoltage protection (59)
Rotor earth-fault protection (64R)
Negative phase sequence protection
Stator earth fault alarm
Over-temperature protection (stator windings) (49S)
Overcurrent relay (sensitive for stator ground, fault) (51G)
Excitation loss protection
Diode failure relay (exciter)
Electrical/mechanical overspeed protection
Page: 7
3.2.8 Synchronisation Equipment

A parallel-switching apparatus shall be provided to facilitate synchronisation of the diesel
generators to the relevant busbar, and vice versa from the local control board or from the Central
Control Room through the DCS. The parallel-switching apparatus shall be suitable for manual and
automatic synchronisation. The automatic synchronisation shall be initialised either manually or
automatically through a voltage monitoring device (adjustable time and voltage).
Measures shall be taken to accommodate the voltage drops due to reactive components during
synchronisation, including providing regulators with droop -characteristics.
The parallel switching measuring instruments such as twin-voltmeter, synchronoscope,
synchronoscope relays and twin-frequency meter shall be integrated with the equipment for speed
regulation and voltage adjustment in the local control cubicle in the diesel generator local control
centre.
Synchro-check relays shall be provided to prevent the respective circuit breakers from closing
during synchronisation while the plant's normal supply and the diesel generator's supply are out of
synchronisation.
3.3
CONTROL AND MONITORING EQUIPMENT
The following control and monitoring equipment shall be provided at the local Control Panel:
Minimum At The Load Control Panel:
Remote/Local Selector Switch
Automatic/Manual Selector Switch
Engine On/Off
Selector Switch For Synchronising Point (Generator Circuit Breaker/Bus Coupler/Transformer

Infeed)
Selector Switch - Manual Synchronising
Automatic synchronising
Automatic start and synchronising
Selector switch: manual/automatic
Voltage regulator
Voltage regulator higher/lower switch
Voltage set point adjustment switch
speed regulation higher/lower switch
Circuit breaker control switches implemented in a mimic diagram
Indication instruments for:
cooling water inlet and outlet temperature
fuel oil tank level
lube oil pressure
Page: 8
lube oil temperature(s)
lube oil tank level
generator active power
generator reactive power
generator current (all three phases)
generator voltage with selector switch
generator frequency/engine speed
generator stator winding temperature (six)
synchronising facilities (double frequency meter, double voltmeter,
synchronoscope
exciting current
All required positions and alarm indication
All required interface facilities for remote control and monitoring through the DCS.
Additional features shall be provided if required for safe and satisfactory operation and supervision
of the plant. Adaptation of the specified scope and design of the control and monitoring equipment
shall be done where needed to match with the requirements of the offered equipment.
All control and monitoring cubicles shall be installed locally in the diesel generator rooms.
All necessary interlocking and alarm circuits shall be provided to eliminate any possible damage to
the equipment due to malfunctioning of instruments or operational errors. Technical features of the
controls and instruments shall comply with all the requirements under Part G5 "General Technical
Requirements'.
Alarms from the diesel Generator set shall be annunciated individually on the local annunciator unit
at the local control board in the diesel generator local building.
In addition, these alarms shall be transmitted to the Central Control Room in the form of two group
alarms, one for annunciation fault/trip conditions and one for signalling extreme operating
conditions.
3.4
OPERATION MODES
3.4.1 Emergency supply

(Reference is made to drawing 11 kV / 380 V Station Service Supply, Typical Single Line
Diagram, drawing number CNE / 015 / 2002 W 00 E D 00101)
To avoid overloading of the diesel generators, only those consumers will be supplied by the
emergency diesel generators that are needed for safe shut down of the plant.
Should the Grid voltage fail, the emergency diesel generators will maintain all essential services as
battery chargers, lighting system, turbines turning gears of and others.
All GT, BPST, HRSG, Common Service and other 380 V Boards will be divided by a normally
closed sectional breaker in two sections. The essential loads (necessary to be supplied in case
of grid voltage fails) will be connected to the essential section.
Page: 9
The essential sections are connected via coupling breakers and cables to the related 380 V
emergency Board.
If the selector switch is in the "Automatic Start," position, the emergency diesel generator shall
start-up automatically after a time delay when the normal busbar voltages of any essential service
busbars fails.
After the diesel generator has been brought successfully into operation the generator circuit
breaker will close and the 380 V Emergency board will be energised.
After this
a.
The sectional breaker in each 380 V Board (GT, BPST, HRSG, Common Services and others)
will open
b. The coupling breaker between the emergency board and the essential section of the various,
above mentioned 380 V boards will close automatically. The essential loads will then be
supplied by the diesel generator now.
When the grid voltage will be restored, the normal supply via the 11 kV /0,4 kV transformers shall
be synchronised via the sectional breakers that connect the essential section with the normal
supplied section of the related 380 V Boards before supply from the diesel generator is cut off.
That is, the coupling breaker between the emergency board and the essential section of the
several 380 V boards will open.
Upon resumption of the normal power supply to all 380 V Boards of the plant, the diesel generator
shall automatically be shut off.
3.4.2 Test Run

It shall also be possible to synchronise the diesel generator to the normal supply (without
disturbances to the plant's normal operation), e.g. for testing purposes.
For these purposes, the cable coupling between the 380 V Station Service Board will be closed
and energise the 380 V Emergency Board. The synchronising points shall be the Generator circuit
breaker. The circuit breakers at both sides of this cable coupling and the cables itself shall be
designed to transmit the nominal power of the diesel generator.
It shall also be possible to test the synchronisation sequence from the local control panel through
"Test" buttons. It shall be possible to simulate an absence of voltage on the busbars, start up the
diesel generator and activate the switching sequence for the circuit breakers. It shall also be
possible to simulate the return of voltage on the busbars and activate the reverse operation of
shutting down the diesel generator and switching sequence of the circuit breakers.
The start-up, selection of synchronisation point, initiating of automatic synchronisation and
shutdown of the whole diesel generator set, including all necessary auxiliaries shall be either from
the local control panels and/or from the Central Control Room through the DCS.
A Test Run facility shall be also provided for the Black Start Diesel Generators.
For the electrical control system refer also to Part P2.26.11 of this specification.
CNE/015/2002
P2.11
Instrument and Service Air System
WORKING DOCUMENT
Part P2.11 Instrument and Service Air System Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
PAGE
GENERAL ..................................................................................................................................... 1
SCOPE OF WORKS..................................................................................................................... 1
2.1
GENERAL ......................................................................................................................... 1
2.2
LAYOUT ........................................................................................................................................ 3
DESIGN / CONSTRUCTION REQUIREMENTS.......................................................................... 4

4.1
GENERAL ......................................................................................................................... 4
4.2
SUCTION AIR FILTER..................................................................................................... 5
4.3
SILENCERS...................................................................................................................... 5
4.4
AIR COMPRESSORS....................................................................................................... 5
4.5
AFTER COOLERS ........................................................................................................... 6
4.6
WATER SEPARATOR ..................................................................................................... 6
4.7
AIR RECEIVERS .............................................................................................................. 7
4.8
AIR DRYER....................................................................................................................... 7
4.9
AFTER FILTERS .............................................................................................................. 8
4.10
PIPEWORK AND VALVES .............................................................................................. 8
4.11
PRESSURE DAMPERS ................................................................................................... 9
4.12
SERVICE AIR ................................................................................................................. 10
4.13
CORROSION PROTECTION......................................................................................... 10
4.14
INSTRUMENTATION AND CONTROL MATERIAL AND CONFIGURATION ............ 10
CONTROL SYSTEM................................................................................................................... 10
TESTS......................................................................................................................................... 11
6.1
WORKSHOP TESTS...................................................................................................... 11
6.2
SITE TESTS.................................................................................................................... 11
P2_11instrument_service_air_Working_Doc.doc
Page: 1
GENERAL
This specification covers the complete service air system and instrument air system for satisfactory
operation.
The system and its components supplied to meet this Technical Specification shall also conform to
the applicable requirements of these and other general articles or specifications of the Contract
Documents.
However, if any equipment/device not covered by the specification but deemed to be necessary at
the discretion of the Employer/Engineer for safe and reliable operation of the system, it shall also
be provided.
2
2.1
SCOPE OF WORKS
GENERAL
The service and instrument air system shall produce and deliver all compressed air required for all
associated equipment of the Jebel Ali L Phase I Station and Desalination Plant unit for the
following:
Service air for operation of mechanical air tools, wrenches, etc., during all modes of unit
operation and for maintenance purposes.
Instrument air of high purity, oil-free and moisture-free compressed air to all pneumatically
operated plant instrumentation and control devices.
The scope of works comprises all equipment, pipes with supports, valves, instrumentation and
controls necessary to ensure proper, safe and easy operation and maintenance of the compressed
air system under normal and abnormal conditions.
The distribution pipework shall ensure safe supply of compressed air to the whole plant. Necessary
arrangements shall be made that a plant trip due to a pipe failure in either of the compressed air
lines is positively prevented.
2.2
SCOPE OF EQUIPMENT
The service and instrument air plant shall include the following equipment but not limited to:
Four (4)
weather proof louvre, suction air filters and silencer
Four (4)
water cooled oil free rotary screw type compressor units. Each compressor shall be
directly coupled to the driving electric motor. Each compressor unit shall be designed
for 50% capacity of the total instrument air plus service air peak consumption required
of the entire plant. Each compressor unit shall be provided complete with the electric
motor, direct coupling, after cooler (water cooled), water separator and all ancillary
equipment, as shown in the drawing CNE/015/2002-W-00-G-D-00004 Instrument and
Service Air System.
Two (2)
identical systems of air dryers and filters for instrument air only. Each system shall
consist of 2 x 100% dryers, 2 x 100% duplex filters upstream the dryers and 2 x 100%
duplex fine filters downstream the dryers.
Two (2)
duplex filters (2 x 100%) for service air.
Two (2)
instrument air receivers (2 x 100%) and shall have useful storage capacity of 30
minutes based on the entire plant instrument air peak consumption. The receivers shall
be complete with all ancillary equipment.
Page: 2
Two (2)
service air receivers (2 x 100%) and shall have useful storage capacity of 30 minutes
based on the entire plant service air peak consumption. The receivers shall be
complete with all ancillary equipment.
One (1)
complete set of piping system, valves, pipe supports, hangers, etc. for the entire
instrument and service air system
One (1)
complete and sufficient set of instrumentation and controls to the approval of the
Employer/Engineer for the entire instrument and service air system
Each compressor unit shall be provided with its own dedicated PLC type control panel.
The control panel shall be configured redundant with redundant PLCs and shall be fault
tolerant such that a single fault shall not trip the compressor and shall not invalidate the
protection system. The control panel shall be complete in all aspects including all
controls, indications and alarms. In remote control mode, the compressor shall be
controlled by the DCS. Each of the redundant PLCs in each control panel shall have
dual-redundant serial link interface with the DCS process control station. In local
control mode, the compressor shall be controlled automatically by its own control
panel. Manual start/stop facility shall also be provided in manual mode from either the
DCS operator station in remote mode or from the local control panel in local mode.
Complete scope of supply of electric and control cables for all the compressors, dryers
and other equipment. The control cables shall be segregated from the electrical cables.
The cables of each compressor and each dryer and each of the redundant equipment
shall be segregated in a separate route.
Each set of the two sets of dryers shall be provided with its own dedicated PLC control
panel. The control panel shall be redundant with redundant PLCs and shall be fault
tolerant such that a single fault shall not cause a trip to the dryer and shall not
invalidate the protection. Each of the redundant PLC in each control panel shall have
redundant serial link interface with the DCS process control station.
Motorised shut-off valve with manual isolation valves and manual bypass valve shall be
provided at the discharge header from the service air receiver. The motorised valve
shall close automatically when the pressure of the instrument air at the discharge
header of the instrument air receivers falls down to a preset limit.
The motors of the compressor unit shall be supplied from the essential switchboard,
which will be supplied by the black start diesel generator during black out.
The dryers control panels shall be supplied from the redundant UPS 220V AC through
a manual changeover switch, which shall be provided within the scope of supply.
The compressor units control panels shall be supplied from the redundant 24V DC
battery systems from two separate sources to be supplied by two separate cables for
each control panel. If the manufacturer standard design is AC power supply for the
control panel , in this case the control panels shall be supplied from the redundant UPS
220V AC through a manual changeover switch, which shall be provided within the
scope of supply. The 24V DC power supply is the specified requirement. Alternatively,
the UPS AC power supply must be justified by the supplier and subjected to the
Employer/Engineer approval.
One (1)
complete set of spare parts for the entire system shall be provided subjected to the
Employers/Engineers approval.
One (1)
complete set of special tools including the PLCs programmes shall be provided for the
entire system subject to the Employers/Engineers approval.
Page: 3
Any other equipment not mentioned above but deemed to be necessary at the discretion of the
Employer/Engineer shall also be provided.
All additional equipment necessary for plant system such as:
Local pressure accumulators for single large users to prevent a pipeline pressure drop of more
than 1 bar during peak demands
All electrical connections up to the low voltage terminal boards of panels, cubicles, motors,
valves, etc.
All interconnection piping for air distribution to all users of the power plant.
All minor pipes necessary for installation and operation
Lifting and hoisting devices for easy compressor maintenance
All necessary base frames, base plates, anchor bolts, supports, etc
All steel parts embedded in foundation.
All standard equipment and accessories that are normally included in the delivery
Platforms, stairs and ladders as specified in G5.4 Civil Works required for operation and
maintenance.
LAYOUT
The P&I diagram of the system is shown on the Tender drawing No. CNE/015/2002-W-00-G-D00004.
The air compressors and the air dryers shall be located at a central location inside a separate
service building hall with adequate air ventilation system.
A centralised instrument and service air system shall be provided for the entire power and
desalination plant. The system shall comprise of 4 x 50 % compressor units. Each compressor unit
shall be sized for 50% capacity of the total instrument air plus service air peak consumption
requirement for the entire power and desalination plant. All four compressor shall be connected to
a common header. 2 x 100% duplex filter shall be provided for the service air followed by 2 x
100 % air receiver. A motorised shut off valve with manual isolations valve and bypass valve shall
be provided at the discharge header of the service air receivers. The motorised valve shall close
automatically when the pressure of the instrument air at the discharge header of the instrument air
receiver falls down to a preset limit and the interconnection shall be open. Two redundant pressure
transmitters shall be provided and shall be connected to the DCS process control station and the
automatic control function of the motorised valve shall be designed in the DCS process control
station. A manual facility to open/close the motorised valve shall also be provided from the DCS
operator station in CCR. Two (2) dryers systems shall be provided for instrument air. Each system
shall consist of 2 x 100 % dryers, 2 x 100% upstream duplex filter and 2 x 100% downstream fine
filters. The discharge of the two dryers systems shall be connected to 2 x 100% air receivers. Each
of the instrument air and service air receivers shall have a useful storage air of 30 minutes capacity
based on the plant air peak consumption.
The layout arrangement shall provide adequate access for safe, simple and easy operation. For
maintenance an overhead lifting device shall be provided. Major pipes and ducting are to be
grouped logically and shall be laid on sleepers or pipe racks.
It shall be possible to withdraw one complete compressor package unit without dismantling other
units or other major components of the station.
Page: 4
Each compressor will be provided with separate air intake ducting including individual inlet air
filters and silencers. The air will be fed from the compressors via air coolers to the air receivers.
The consumption of air is mainly intermittent. Therefore, the air receivers together with the
distribution pipe work shall serve as a pressure accumulating system against pulsation and allows
for short time peak consumption without the need of a compressor start. All equipment must be
designed for an extremely wide operating range.
Air storage volume, compressor running periods, and compressor capacity is closely inter-related.
The total system shall be optimised for maximum reliability and safety as well as minimum total
operating cost.
After calculation of the service and instrument air consumption of the entire plant, including all
losses, the Contractor shall determine the rated flow of each compressor train and its size.
The air receivers shall store sufficient air for the peak consumption with a pressure drop of less
than 0.4 bar.
The operating pressure of the system shall be about 8.0 bar gauge on the user terminal during
normal operation. The pressure variations must not exceed 1.0 bar. This requires a minimum
discharge pressure for the compressor of 9.0 bar gauge plus all pressure losses in the system.
The terminal valves must restrict the maximum possible air flow to the actually required one in
order to avoid excessive pressure losses in case of failure.
For a later interconnection to Jebel Ali L Phase II a connection point shall be foreseen.
The leak rate of the complete system must be less than the value specified in G5.6 Inspection and
Testing.
4
4.1

GENERAL
The equipment and material shall conform to high standards of engineering, design, workmanship
and construction and shall be capable of operating efficiently and satisfactorily without excessive
wear or maintenance under the service conditions.
All components shall be selected from designs, proven in service with at least 5 years satisfactory
operating experience. The equipment shall be heavy duty type and be designed for a minimum
anticipated plant life of 30 years.
In order to reduce the Site work to a minimum, prefabricated and/or skid mounted equipment shall
be supplied wherever possible.
Particular attention shall be paid to keep noise and vibration levels at a minimum and to reduce it
to the inevitable values. This is particularly valid for the compressors itself, but also for suction,
discharge and distribution piping as well as all valves or fittings. Low noise level equipment shall be
selected.
The values must not exceed those of internationally acknowledged standards or the specified
values in G4 General Project Requirements of the Contract Documents.
In any case the noise shall be less than 85 dBA at 1 m distance from the noise source.
If a single large user (more than 5 % of one compressors capacity) is a peak demand only, a local
pressure accumulator drum shall be provided. It shall prevent a local pressure drop of more than
1.0 bar.
Page: 5
The continuous large users shall be equipped with a trip valve. It shall stop the airflow if the air
pressure drops below a certain value. Should this not be acceptable, other measures such as
separate piping shall be provided.
Certain reliable measures against pressure drops are required for single large users.
However, upon failures, e.g. hose rupture, pressure drops shall be avoided. This shall be achieved
by flow restriction devices on each user terminal.
All temporary and hose connections shall be limited to the pipes with a quick shut-off coupling.
4.2
SUCTION AIR FILTER
The filter shall retain all particles possibly harmful for the compressor, the valves or other
equipment in the system. In any case the filter shall be capable of dealing with the dust
concentration of the Site area.
The inlet filter to the compressor shall be designed for the maximum flow at the worst conditions.
Each compressor shall have its own suction filter. The filter shall be adequate for operation in a
dust-laden atmosphere and to be designed for service intervals not shorter than 1,000 operating
hours.
The open cross section of the air suction duct shall be covered by a stainless steel mesh. In the
compressor room a single, dry type filter shall be installed for each compressor train.
The maximum allowable pressure drop shall be 30 mbar. The minimum particle size to be retained
shall be 3 micron. Each filter shall be equipped with a differential pressure indicator that shall give
an alarm in case the maximum allowable pressure drop is exceeded.
The filtering element shall be made of fabric cloth. Regeneration shall be possible by back purging with compressed air.
The construction shall favour noise absorbing design.
All surfaces inside the filter shall be corrosion resistant.
4.3
SILENCERS
Downstream of the suction filter a silencer shall be installed. It shall absorb noise emitted through
the cross section of the duct as well as noise emitted via the surfaces of the pipes. Appropriate
connections with the duct are necessary.
The minimum damping effect shall be 10 dB, both axial and perpendicular to the axis.
A combined construction with the filter is not acceptable.
All surfaces inside the silencers shall be corrosion resistant.
4.4
AIR COMPRESSORS
The air compressors shall compress air from atmospheric pressure to compressed air system
pressure.
The compressors shall be a water cooled, oil free, rotary screw type including after cooler.
The compressor shall be driven by a suitably rated electric motor as specified in Part G5.2
Electrical Equipment. The drive coupling to the compressor shall be a flexible direct coupling. Vbelts coupling will not be acceptable.
Lubricating oil pumps shall be of positive pressure, fed by suitably rated motors. 2 x 100% electric
motor driven lubricating pumps shall be provided for each air compressor. .
Page: 6
Oil filters shall be easily replaceable and the lubricating system shall be protected from
overpressure by means of a relief valve. A dip stick or sight glass shall indicate crankcase oil level.
Each item requiring water cooling shall be connected to the cooling water system and include
isolating valves at the inlet and outlet of each exchanger sub-circuit.
As the compressor may be shut down for long periods of time, all air passages must be corrosion
resistant against condensing moisture from the air.
In order to prevent noise vibration conduction along the suction and discharge piping, flexible pipe
links shall be installed on the compressor nozzles. Also cooling water connections shall be by
flexible links.
The compressor with all components including intermediate and after coolers shall be mounted on
a common base plate or skid, equipped with springs and dampers for absorbing all vibrations.
4.5
AFTER COOLERS
One (1) after cooler shall be provided for each compressor. The after coolers shall be designed for
worst conditions of inlet air and cooling water.
The maximum allowable air temperature downstream of the after cooler shall be 10C above the
cooling water supply temperature.
The cooler shall be of shell and tube type with easily removable tube bundle for chemical cleaning.
Water velocity through water tubes shall be limited to 1.9 m/s during maximum conditions.
The cooling water connections shall consist of flexible pipe links.
All parts in contact with air shall be of corrosion resistant material. The tubes shall be of copper nickel alloy, the shell and the tube plates of galvanised carbon steel or better material. Surface
areas shall allow a minimum-fouling factor as recommended by the Tubular Exchanger
Manufacturers Association (TEMA).
The cooling water pipe shall be fitted with a common in line strainer and an electrically operated
On/Off flow control valve. The instrument system shall ensure that the water flow is stopped when
the compressor is not in running. A visible water flow indicator shall be included in each of the subcircuits to heat exchangers.
4.6
WATER SEPARATOR
The water separator (collection - drums) shall protect all downstream equipment from water
droplets or water mist.
The after cooler separators shall be fitted with condensate local indication, high level alarms and
shutdown switches.
One drum is required after every cooler.
At least the collection drum behind the after cooler shall be equipped with a stainless steel wire
mesh. Its minimum droplet removal efficiency shall be 99.9 %.
The accumulated water shall be drained off by an automatic condensate trap. The condensate
traps shall be equipped with hand - operated bypass valves.
All connections shall be flexible links.
4.7
Page: 7
AIR RECEIVERS
The air receivers shall store an ample amount of air sufficient for 30 minutes storage capacity
based on the plant air peak consumption, reduce the frequency of compressor starts and stops,
and reduce pressure pulsations.
The construction shall be a vertical welded cylindrical vessel.
The design pressure shall be 17 bar.
A 600 mm manhole shall be provided.
The vessels shall be of galvanised carbon steel.
Between vessel bottom head and drain valve a sight glass shall be provided to detect condensate.
Draining must be possible when the vessel is pressurised.
4.8
AIR DRYER
The dryer shall be capable of maintaining the dew point of -20C for the instrument air system
during maximum instrument air consumption and maximum air/cooling water temperature. The
required dew point shall be regarded as the dew point at the pressure prevailing at the dryer
discharge.
Air dryer shall be twin tower desiccant type with electric heater. For larger volume externally
heated zero purge loss twin tower dryers shall be preferred.
Purge volume control valves shall be needle type lock shielded and a purge flow meter shall be
included.
Dryer controls shall be electro - pneumatically operated.
Total cycle time shall be a minimum of 8 hours and shall include suitable cooling and pressure
adjustment periods.
Facilities shall be included to effect a gradual depressurisation and re-pressurisation of the towers
to avoid mechanical breakdown of the desiccant beds.
At changeover both absorber beds must be at equal pressures and temperatures. Silencers shall
be fitted on blow down lines.
Regeneration air flow and process air flow directions through the desiccant beds shall be in
opposite directions.
Desiccant material shall be activated alumina type for reasons of physical strength against
changes in temperature and pressure.
Thermostatic devices must be included to limit temperature rises caused during regeneration.
Visual indication is to be provided on the drier to indicate change over failure or purge valve failure.
The failure alarm circuit is to be interlocked with the electric heater controls.
Potential free contacts are to be provided to repeat the failure alarm to the common control panel.
Where the inlet air temperature to the air drier exceeds 50C the drier shall incorporate a
refrigerated type pre-cooler in order to optimise the dryer package sizing. In such case the precooler shall be packed onto a common base frame with desiccant dryer.
Each tower shall include a pressure/temperature safety relief valve and pressure indicator. A dew
point alarm and indication equipment are to be provided. Visual indication of dew point shall be
given by means of colour change indicators.
Page: 8
Each drier shall incorporate duty and standby pre-filters fitted with the drier to provide protection
from water droplets and oil.
Pre-filters shall be oil removing type in all cases to allow for emergency running conditions with
other air compressors. They shall be capable of removing oil down to 0.5 ppm (relative to 20C).
Pre-filters shall be fitted with differential pressure service indicators and automatic drain trap with
bypass.
Isolating valves shall be installed either side of each pre-filter for maintenance.
Each drier shall incorporate duty and standby after filters, fitted with the dryer to protect the
network downstream from dust particles. They shall have a minimum efficiency of 99.99 % at 1
micron.
The pressure drop at full flow conditions and across the complete dryer/filter package shall not
exceed 0.5 bar when clean and 0.65 bar when in service.
PLC control panel shall be provided for each dryer unit. Fully automatic sequence shall be
provided for the dryer including the regeneration process.
4.9
AFTER FILTERS
Normally, the air should not contain any scale, debris, droplets or other foreign matter when
reaching the after filters. However, for protection of the distribution piping in case of failure or
malfunction of upstream equipment, after filters shall be provided.
The design flow shall be identical with the compressor capacity. The filtration efficiency shall be
99.99 % with all particles down to 1 micron.
The filter shall be provided with differential pressure service indicator, which shall also give, an
alarm if the maximum allowable pressure drop (30 mbar) is exceeded.
The service intervals shall not be less than 1,000 operating hours.
The after filters shall be of the duplex type with depth filtration elements. The filtering elements
shall be of a corrosion free felt or mat, which can be regenerated to a certain extent.
4.10 PIPEWORK AND VALVES

All interconnecting pipework as well as the piping to all users in the power plant shall be provided.
This includes pipe supports, pipe racks and steelwork for piping in trenches and protection sheets
for street crossings, etc.
The distribution pipework consists of two ring headers in the turbine hall and two sets of branch
lines to all other users, one system for instrument and the other for service air.
For continuous service air user, fixed connections are required. The air system shall be piped to
the equipment nozzle. Isolating and non-return valves shall be provided close to the equipment,
either directly on the provided equipment nozzle or 1 m apart from the equipment.
For continuous service air users fixed connections are required. The air system shall be piped to
the equipment nozzle. Isolating and non-return valve shall be provided close to the equipment,
either directly on the provided equipment nozzle or 1 m apart from the equipment.
The pipe sizing shall ensure low noise, moderate velocities, small pressure drop, virtually no
pressure pulsation and a large storage volume.
For the compressor suction and discharge piping only long radius elbows shall be provided.
Page: 9
The total pressure drop to any consumer shall not exceed 0.3 bar measured between air receiver
and the consumer during its peak consumption and also during normal consumption of all other
users.
The velocities in the compressor suction piping shall not exceed 4.0 m/s upstream of the silencer
and 6.0 m/s between silencer and compressor. In the distribution piping the velocities shall not
exceed 6.0 m/s for normal operating conditions, and 8.0 m/s for peak consumption.
Minimum pipe size for headers shall be DN 50.
The design of the piping system with all accessories like vents, drains, fittings and instrument
connections shall be as specified G5.1 Mechanical Equipment and Piping.
On each terminal point whether from branch line, header or equipment an isolating valve shall be
provided. Each branch line shall be connected to the header with a ball valve.
The branch pipes shall be distributed in such a way that all individual lines terminate near the users
and shall be provided with Isolating valves at the beginning and at the end.
A ball valve shall be installed at each instrument take-off connection and shall be located as close
to the main line as possible. These connections shall be taken off the top of the mains.
Except for throttling services, all valves shall be ball valves. Their free cross section shall be
identical with the connected pipes. Valve casing materials shall be made from spherical graphite
cast iron or welded carbon steel construction. Internals shall be resistant against the media
handled. The offered materials and valve design shall be subjected to the approval of the
Engineer.
Pipe materials shall be galvanised, carbon steel (St. 35 or similar). Only the short (less than 2 m)
connecting piping between the sub-headers for instrument air and the instruments shall be made of
seamless copper pipes 6 x 1 mm, according to DIN 1754 or equivalent. Fittings shall be made of
copper or brass compression type according to DIN 2353 or equivalent.
Seamless pipes shall be used for the entire system.
The pipe connections shall be carried out as screwed ones up to DN 50. For pipe sizes DN 80 and
upwards on control and isolating valves, equipment, etc. and where technically advisable, flange
connections shall be used. Site welding of hot dip galvanised pipes shall not be permitted.
All bolts must be galvanised.
The number of connections from ring main and headers shall be at least 15 % larger than
necessary at design stage. They shall serve for future air consumers. Each of these connections
shall be equipped with a ball valve.
Immediately upstream of every consumer connection, i.e. next to the valve, a tapping for pressure
measurement shall be provided.
A sampling connection is necessary behind every equipment in the compressed air system.
The air distribution system shall be designed as a ring main system and be sized on a rather liberal
basis.
4.11 PRESSURE DAMPERS

For consumers with a short time peak consumption of more than 1 % of one compressor's
capacity, a local pressure collapse (i.e. a pressure drop of more than 1.0 bar) must be prevented
by pressure dampers.
Page: 10
The dampers are small, welded air storage vessels installed next to the consumer, sized for the
needs of that consumer.
The inner surface shall be painted or galvanised. If reasonable and possible, dampers shall be
avoided by generous pipe sizing.
Appropriate calculations and measuring tapping shall be provided for the specified cases, remote
users and where particularly requested by the Engineer.
Measurements during commissioning will finally decide if, where and which pressure dampers shall
be provided.
4.12 SERVICE AIR

In order to supply compressed air to all locations in the buildings, (the boiler, or other plant
facilities) local air stations shall be provided.
Identical air hoses 15 m long of DN 20 shall be provided at no more than 20 meter intervals around
the plant. The connection to the distribution piping shall be by quick shut off couplings. Sufficient
number of flexible hose reels shall be provided and stored inside cabinets at various sections of
the plant.
The number and distribution of the air stations shall allow to reach any point inside the buildings as
well as all equipment in other plant areas, with a 15 m long hose connected to a local air station.
4.13 CORROSION PROTECTION

The outside surfaces of all equipment, pipes and valves shall be painted except if produced of
corrosion free material like copper or stainless steel.
The piping system including the suction piping shall be made of galvanised pipes. The valves shall
be of corrosion resistant material.
The inner equipment surfaces possibly in contact with humid air, shall be galvanised or made from
corrosion resistant or corrosion free material.
The air receiver shall be painted inside as well as outside.
For the galvanised materials a corrosion allowance of 1.0 mm and for painted materials, 2.0 mm
shall be provided.
4.14 INSTRUMENTATION AND CONTROL MATERIAL AND CONFIGURATION

All instrumentation and control tubing, manifolds, valves and fittings shall be of stainless steel 316
TiSS. The design and configuration shall fully comply with the Specification in Part G5.3 and Part
P2.27.1
CONTROL SYSTEM
The system will be controlled and supervised by the DCS system via the CCR operator
workstations.
Three (3) redundant pressure transmitters shall be provided at the compressors discharge
common header and shall be connected to the DCS process control station. In the DCS process
control station separate redundant modules shall be provided for each compressor unit. 2V3
analogue selection logic shall be provided and the selected signal shall be used for controlling the
compressors. A Function Group Control (FGC) shall be provided with a selection of the
compressors as duty1, duty2, standby1 and standby2. The FGC shall either be activated by the
operator from the compressors screen at the DCS operator station in CCR or from the Plant
Page: 11
Master Sequence (PMS). Once the FGC is activated, it shall start duty1 compressor and the duty
dryer unit. Duty2 compressor shall be started automatically by the Pressure Controller. A further
drop in pressure and/or a trip in the duty compressor, shall automatically start standby1
compressor. Further drop in the pressure and/or trip in the running compressor shall automatically
start standby2 compressor
Each compressor unit shall be provided with its own control panel. Two redundant pressure
transmitters and high high pressure switch shall be provided at the discharge of each compressor.
These instruments shall be used for dedicated control of the compressor in local mode. Each of the
redundant PLCs in each control panel shall have redundant serial link interface with the DCS
process control station.
Final control design is subject to the Employer/Engineers approval.
6
6.1
TESTS
WORKSHOP TESTS
All components of the service and instrument air equipment shall be tested in accordance with the
relevant Standards and Codes and as specified in G5.6 Inspection and Testing.
6.2
SITE TESTS
See Part G5.6, Inspection and Testing.
CNE/015/2002
P2.12
Not Used
Part P2.12 Not Used
Page: i
NOT USED
P2_12Not_Used.doc
CNE/015/2002
P2.13
WORKING DOCUMENT
Part P2.13 Steam/Water Sampling System Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
PAGE
GENERAL ..................................................................................................................................... 1
SCOPE OF WORKS..................................................................................................................... 1
LAYOUT ........................................................................................................................................ 2
INSTRUMENTATION ................................................................................................................... 3
5.1
COMPONENT -RELATED INSTRUMENTATION ............................................................ 3
5.2
DEGREE OF REMOTE CONTROL ................................................................................. 3
5.3
CLOSED-LOOP CONTROL............................................................................................. 4
5.4
SPECIAL PROTECTION REQUIREMENTS................................................................... 4
5.5
CONTROL SYSTEM......................................................................................................... 4
P2_13steamwater_sampling_Working_Doc.doc
Page: 1
GENERAL
This specification covers the sampling system and the associated equipment as well as sample
coolers, pipework valves in every respect and suitable for satisfactory operation of the Jebel Ali L,
Phase 1, power and water production facility.
The Contractor shall be fully responsible for the design, detail engineering, manufacture,
transportation, erection and commissioning of the sampling system. The Contractor shall be
responsible to execute all tests as required by the Contract Documents (refer to Tests of this
chapter and Part G5.6) and all other tests he considers as necessary for a safe and reliable
operation. In case the ambient temperature at the location where the sampling rack will be installed
exceeds the max. allowable temperature of the analysing equipment, the sampling rack shall be
installed in an air-conditioned container.
SCOPE OF WORKS
The scope of supply of the sampling system is required to collect samples from various locations to
cool the samples, reduce the sample pressure and to perform manual sampling and continuous
chemical analyses as required.
Cooling water for the sample coolers shall be provided from the closed cooling water system.
The following sampling locations shall be provided as minimum for local and remote supervision of
operation for the CCPP unit, for early recognition of disturbances and for the clarification of the
causes of damages:
Location
Number
Continuous Analysis
Conductivity
pH-value
Oxygen
x
Feedwater Inlet to HP Economiser

(conductivity measurement before and after
ion exchanger)
5*
HP Drum Blow Down (conductivity

measurement without ion exchanger)
5*
HP Drum Saturated Steam
5*
HP Superheater Outlet (conductivity

measurement with ion exchanger)
5*
LP Drum Blow Down (conductivity

measurement without ion exchanger)
5*
LP Superheater Outlet respectively

saturated steam (conductivity
measurement with ion exchanger)
5*
Main Condensate Pump (discharge line)

(conductivity measurement with ion
exchanger)
* one each HRSG and Auxiliary Boiler
manual analysis
Page: 2
One sampling rack shall be provided for continuous analysis of the samples to be collected.
Each Sampling line of the sampling system shall be equipped with following components:
sample cooler (if sample temperature is more than 30 C)
pressure reducing valve
analysis pump (if sample pressure below atmospheric)
hand operating extraction valve
All necessary pipes, valves, measurement, control and monitoring equipment
In addition to the sample coolers stated above, at least two (2) sample coolers (for all units)
required for testing of the boiler shall be provided. These coolers shall be of movable type and
shall be complete with all facilities for connection on sample and cooling side. A sufficient number
of tapping connections for these sample coolers shall be provided.
LAYOUT
The sampling rack shall be located in the ST building.

The tapping points and the measurements are shown in the following principle flow diagrams:
HRSGs CNE/015/2002-W-00-G-D-00009
Closed Cooling Water System CNE/015/2002-W-00-G-D-00005
Water Steam Cycle Flow Diagram CNE/015/2002-W-00-G-D-00003
Steam/Condensate CNE/015/2002-W-00-G-D-00010
Feedwater System CNE/015/2002-W-00-G-D-00011
Auxiliary Boiler CNE/015/2002-W-00-G-D-00012
Distillation System P & I Diagram CNE/015/2002-F-00-G-D-00001
Sea Water Flow Diagram, Phases I & II CNE/015/2002-H-00-M-D-00001
Each tapping point shall be equipped with one non-return valve and two isolating valves.
A typical arrangement of equipment for a sample conditioning is a sample cooler with a local
temperature indicator of the sample downstream. Electro actuated shut-off valves shall be provided
in the sampling pipes, which shall be closed automatically in case of failure of the cooling water
supply (excessive temperature of the sample). A throttle valve shall be located downstream of the
sample coolers and the shut-off valve in order to avoid steaming of the sample. After the throttle
valve parallel sampling lines are installed for automatic and manual analyses or for blowdown
drain.
The sampling equipment shall be selected to fulfil the following requirements:
The sample coolers shall be arranged for external counterflow, and shall be complete with
all required separating and throttling valves
All sample coolers shall be provided with stainless steel trays. The drain of these trays
shall be connected to the waste drain system
All sampling pipework valves and reducing valves shall be fabricated from stainless steel
(equivalent of F 66 as per ISO 683/XIII)
Tapping pipe up to the separating valves shall be of stainless steel
For steam sample coolers, the length of the sampling pipe shall preferably not exceed
25 m, while for water and condensate sample coolers no limitation on the length of the
sampling pipes is given. Bends with large radius shall be used
Electro actuated shut-off valves shall be provided in the sampling pipes or the coolers
shall be designed so that no detrimental consequences will occur on interruption of
cooling water supply
Owing to the elevated temperature of the cooling water, all measurements for which a
temperature correction is not possible shall be cooled by a cooling aggregate or separate
electric sample coolers shall be provided for each measuring point
The velocities in sampling pipes shall be about 0.25 up to 2 times of the velocity in the
main pipe, in order to obtain nearly isokinetic flow conditions
For the sample coolers stated above, the possibility to take manual samples shall also be
provided
On components where the steam or water flows in two parallel streams, the tapping
connections shall be provided in both streams
Direct and after-cation exchanger conductivity measurements. The measuring signals of

the conductivity cells shall be compensated for a temperature of 20C.
INSTRUMENTATION
5.1
5.2
Page: 3
COMPONENT-RELATED INSTRUMENTATION
Regarding the sampling system-related instrumentation, reference is made to the following
documents:
The tapping points and measurements are shown in the principle flow diagram of the
HRSGs CNE/015/2002-W-00-G-D-00009, Closed Cooling Water System CNE/015/2002W-00-G-D-00005, Steam/Condensate CNE/015/2002-W-00-G-D-00010, Feedwater
System CNE/015/2002-W-00-G-D-00011, and Auxiliary Boiler CNE/015/2002-W-00-G-D00012.
All Instrumentation shall be according to Part P4 Technical Schedules and Part P2.27
Instrumentation & Control
DEGREE OF REMOTE CONTROL
Electro actuated shut-off valves.
Page: 4
5.3
CLOSED-LOOP CONTROL
Not applicable.
5.4
SPECIAL PROTECTION REQUIREMENTS
The following critical scenarios, entailing plant damage and personnel hazards, shall be kept under
control by means of I & C equipment, especially for the case of power failure with interruption of
cooling water supply. These are mainly:
Excessive temperature of the sample
Steaming of the sample
For hot samples, solenoids for sample lines shall be provided where necessary, which shall close
the lines before the maximum allowed temperature is exceeded. The fail safe position of the
solenoids shall be fail to close in order to cut the sampling lines in case of power supply failures.
5.5
CONTROL SYSTEM
Remote instrumentation is to be connected to the plant DCS system.
The corrosion protection shall meet the General Technical Requirements of Part G5.5.
CNE/015/2002
P2.14
Steam / Water Circuit Chemistry / Dosing
WORKING DOCUMENT
Part P2.14 Steam/Water Circuit Chemistry/Dosing Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
PAGE
GENERAL ..................................................................................................................................... 1
SCOPE OF WORKS..................................................................................................................... 1
LAYOUT ........................................................................................................................................ 5
4.1
PUMPS.............................................................................................................................. 5
4.2
VALVES ............................................................................................................................ 6
4.3
TANKS .............................................................................................................................. 6
4.4
CHEMICAL DRAIN SYSTEM........................................................................................... 6
4.5
PIPES................................................................................................................................ 6
INSTRUMENTATION & CONTROL............................................................................................. 7

5.1
COMPONENT -RELATED INSTRUMENTATION ............................................................ 7
5.2
5.3
CLOSED-LOOP CONTROL............................................................................................. 7
5.4
5.5
CONTROL SYSTEM......................................................................................................... 7
P2_14steamwater_dosing_Working_Doc.doc
Page: 1
GENERAL
This specification covers the general technical requirements for the scope of the following systems:
Ammonia (NH3) dosing station for condensate and make-up water / feed-water
Hydrazine (N2H4) dosing station for condensate and make-up water / feed-water
Corrosion inhibitor dosing station for the closed cooling water system
Tri-sodium phosphate dosing station for the HRSG and Auxiliary Boiler
with all necessary equipment for satisfactory operation of the Jebel Ali Power and Desalination
Station L - Phase I facilities.
The system and its components supplied to meet this specification shall also conform to the
applicable requirements of this and other general articles or specifications of these Contract
Documents (Part G5 General Technical Requirements).
The Contractor shall be fully responsible for the design, detail engineering, manufacture,
transportation, erection and commissioning of the whole chemical dosing system. The Contractor
shall execute all tests as required by the Contract Documents (refer to Tests of this chapter and
General Technical Requirements Part G5.6) and all additional tests considered necessary to
ensure a safe and successful operation.
SCOPE OF WORKS
The scope of supply of the chemical dosing systems is required to control the water chemistry
within the water/steam cycle to avoid the following:
Corrosion caused by oxygen
Depositions (scaling) caused by excessive hardness
The chemical dosing stations shall be suitable for carrying out the following functions:
Condensate/Feedwater Systems
For the purpose of corrosion protection the pH-value of the condensate/HRSG & Auxiliary
Boiler feed water shall be adjusted by the injection of aqueous ammonia (NH3) solution. An
oxygen scavenger solution (aqueous hydrazine (N2 H4) or substitute chemical) solution shall be
injected for oxygen removal within the water/steam cycle and for wet preservation purposes.
The use of hydrazine should be limited as far as possible, due to its hazardous effects.
The injection points for the ammonia and oxygen scavenger solutions shall be at the feedwater
pumps suction lines and at the condensate extraction pump pressure line.
The amount of chemicals shall be determined by the feedwater flow and by the actually
measured pH-value and oxygen content of water samples extracted at the sampling points of
the water/steam cycle.
A less toxic alternative oxygen scavenging agent may be proposed, designed for the piping
materials and water/steam conditions to be used, with detailed information on specific
consumption and cost in comparison to hydrazine dosing.
Tri-sodium phosphate (Na3PO4) shall be added into the boiler drums to avoid deposits of
hardness in the boiler tube system.
Page: 2
The injection point for the tri-sodium phosphate-solution shall be at the boiler drums.
The amount of chemical shall be determined from the hardness and pH-value actually
measured at boiler blow-down.
One tri-sodiumphosphate dosing station shall be provided for each of the HRSGs and each
Auxiliary Boiler. One ammonia dosing station each for the HRSGs and for the Auxiliary Boilers
and one hydrazine dosing station shall be provided to serve each of the condensate/feedwater
system.
One mobile hydrazine dosing station shall be supplied for wet preservation purposes.
To avoid corrosion problems and for adjustment of the pH-value in the closed circuits of cooling
water system a suitable corrosion inhibitor shall be added to the water at high level tank of the
closed cooling system.
The dosing amount of the conditioning chemical shall be determined by the pH-value actually
measured.
One corrosion inhibitor dosing station shall be provided for the closed cooling water system.
The systems shall include the following equipment, which shall be seen as major system
components and in no way exclude other necessary components and equipment not mentioned:
One Packaged Ammonia Dosing Station, consisting of:
Two ammonia preparation and dosing tanks with total storage capacity for at least 15 days of
power plant operation, complete with electric agitator and all connections and fittings on the
tank itself and an external indicator device with magnetic float (LISHL) and magnetically
operated contact switches, also for chemicals and dilution water, high and low alarm contacts,
strong solution measuring tank on the top of the feed tank, activated carbon venting filter,
venting line to the outside of the building and filling line due to the latest safety and
environmental regulations.
Ammonia dosing pumps, complete with flow control, manually operated valves and all
accessories according to boiler/power plant configuration and number of injection points,
suction filter, relief valve, pulsation damper and local pressure gauge. For each operational
injection point 100 % standby dosing pump capacity shall be provided.
Ammonia solution dosing pipelines to the injection points at the water/steam cycle, including
injection points as complete weld-on units, with solenoid valve, shut-off valve and check valve
according to boiler/power plant configuration and number of injection points.
Control and switch board complete with all push buttons, indication lamps, fuses, relays,
switches etc. and electric cables.
Associated surge tanks (pressure accumulator) and flow meters
Two (2) Barrel Pumps (one as standby):

For concentrated ammonia solution, with appropriate piping for discharge of ammonia solution
from drums into the strong solution measuring tanks.
Page: 3
One (1) Packaged Hydrazine Dosing Station for the Water Steam Cycle, Consisting of:
Two hydrazine preparation and dosing tanks of vertical design with total storage capacity for at
least 15 days of power plant operation, complete with strong hydrazine solution proportioning
vessel, electric agitator, strong solution measuring tank on the top of the feed tank, local level
indication with level contact switches and all accessories, manually and pneumatically operated
valves, a water meter with pre-settable counter to control diluting water, all necessary
connections and fittings as well as inertisation gas pressure-equalising lines (System enabling
dosing tank filling without hydrazine emission to the atmosphere, N2 purging if required.) with
activated carbon venting filter according to the latest safety and environmental regulations.
Hydrazine dosing pumps, complete with flow control, manual operated valves and all
suction filter, relief valve, pulsation damper, local pressure gauge and manually operated
valves to all injection points. For each operational injection point 100 % standby dosing pump
capacity shall be provided.
Hydrazine solution dosing pipelines to the injection points at the water/steam cycle, including
injection points as complete weld-on units, with shut-off valve and check valve, PN 16
according to boiler/power plant configuration and number of injection points.
Associated surge tanks (pressure accumulator) and flow meters.
Two (2) Barrel Pumps (one as stand by):

For concentrated hydrazine solution, with appropriate piping for discharge of hydrazine solution
from drums into the strong solution measuring tanks.
One (1) Mobile Hydrazine Dosing System for Wet Preservation Purposes, Consisting of:
One hydrazine preparation and dosing tank of vertical design with suitable storage capacity,
complete with strong hydrazine solution proportioning vessel, electric agitator, strong solution
measuring tank on the top of the feed tank, local level indication with level contact switches and
all accessories, manually and pneumatically operated valves, a water meter with pre-settable
counter to control diluting water, all necessary connections and fittings as well as inertisation
gas pressure-equalising lines (System enabling dosing tank filling without hydrazine emission
to the atmosphere, N2 purging if required.) with activated carbon venting filter according to the
latest safety and environmental regulations.
Hydrazine dosing pumps, complete with flow control, manual operated valves and all
valves to all injection points. 100 % standby dosing pump capacity shall be provided.
Flexible hydrazine solution dosing hose with flange connection, solenoid valve, shut-off valve
and check valve, PN 16 according to boiler/power plant configuration.
Water meter with pre-settable counter to control diluting water
Page: 4
One barrel pump for concentrated hydrazine solution, with appropriate piping for discharge of
hydrazine solution from drums into the strong solution measuring tank.
Packaged Tri-Sodiumphosphate Dosing Stations, each Consisting of:
Two tri-sodiumphosphate solution preparation and two dosing tanks with total storage capacity
for at least 15 days of power plant operation, preparation tank of vertical design, complete with
electric agitator, dissolving basket, manually and pneumatically operated valves, a water meter
with pre-settable counter to control diluting water, local level indication with level contact
switches and all necessary connections, fittings and accessories.
Two dosing tanks complete with all connections and fittings on the tank itself and external level
indicator devices with magnetic float (LISHL) and magnetically operated contact switches.
Tri-sodiumphosphate dosing pumps complete with flow control, suction filter, relief valve,
pulsation damper, local pressure gauge and manually operated valves to all injection points, all
accessories according to boiler/power plant configuration and number of injection points. For
each operational injection point 100 % standby dosing pumps / capacity shall be provided.
Two transfer/circulation pumps of 2 x 100 % capacity complete with drive motor, couplings,
flushing connection including transfer pipelines to the dosing tank.
Tri-sodiumphosphate solution dosing pipeline including injection points as complete weld-on

units, with solenoid valve, double shut-off valves and check valve, PN 16 according to
boiler/power plant configuration and number of injection points.
Drum/bag lifting and tipping device, hydraulically or electrically operated.
One (1) Corrosion Inhibitor Dosing Station for the Closed Cooling System, Consisting of:
Two Corrosion Inhibitor solution preparation and dosing tanks with total storage capacity for at
least 15 days of power plant operation, complete with strong solution proportioning vessel,
electric agitator, strong solution measuring tank on the top of the feed tank, local level gauge
and high and low alarm contacts and all necessary connections and fittings.
Two Corrosion Inhibitor solution dosing pumps (one as stand-by), complete with flow control,
valves and flow meters.
One Corrosion Inhibitor solution dosing pipeline to the injection point at the closed cooling
system, including injection points as complete weld-on units, with solenoid valve, shut-off valve
and check valve.
One Control and switch board complete with all push buttons, indication lamps, fuses, relays,
Two (2) Barrel Pumps:

For concentrated corrosion inhibitor solution, with appropriate piping for discharge of corrosion
inhibitor solution from drums into the strong solution measuring tank.
Page: 5
General
All additional necessary equipment for a proper and safe operation of the chemical dosing
system shall be included e.g.:
Complete network for make-up water for dissolving, dilution and flushing purposes
All electric connections up to the low voltage terminal boards or boxes of panels, cubicles,
motors, valves, etc.
All valves for operation
All interconnecting piping including pipelines for chemical solutions, dissolving, dilution,
flushing and safety-flow pipes, etc.
All minor pipes necessary for installation and operation as drainage pipes, sampling pipes,
etc.
All lifting and hoisting equipment for chemicals handling and maintenance, where
necessary
All safety equipment according to the state-of-the-art and International safety standards
including safety shower and eye wash facilities near the chemical tanks
For each dosing station collecting basins with minimum 1.5 m holding capacity
All necessary base frames, base plates, anchor bolts, supports, etc.
All steel parts embedded in foundation
All standard equipment and accessories that are normally included in the delivery.
All spare parts and special equipment and tools required for satisfactory operation of the
chemical dosing systems
LAYOUT
The chemical dosing stations for the condensate/feedwater and the closed cooling water system
shall be located in the vicinity of the respective system. In case of outdoor installation the dosing
systems shall be provided with an ample roofing for sun and weather protection.
The process flow of these plants is shown on the flow diagram CNE/015/2002/W-39-G-D-00050.
and construction and shall be capable of operating efficiently, satisfactorily and without excessive
wear or maintenance under the service conditions sated in these specifications and in Vol. VI, Part
G5 "General Technical Requirements". The pumps dry suction protections shall provide alarms in
the local control room as well as in the CCR.
4.1
PUMPS
The dosing pumps for ammonia, hydrazine, tri-sodiumphosphate and corrosion inhibitor shall be of
the diaphragm type with adjustable strokes and shall be corrosion proof and leak proof.
The dosing pumps belonging to the same dosing station are to be interconnected with each other
on the suction and discharge sides to permit the use one pump as redundancy. Particular
Page: 6
attention shall be paid to the design of the suction lines to avoid evaporation of the
ammonia/hydrazine solution especially during parallel operation of the dosing pumps.
As far as possible, the dosing pumps shall be identical and interchangeable. All pumps shall be
designed for continuous operation.
The material of the dosing pumps shall be generally stainless steel.
4.2
VALVES
Each pump shall be provided with a suction filter and isolation valves. The dosing pumps shall be
provided with safety valves at the discharge to protect the pump against overload in case of
blockage of the discharge piping. The safety valve outlet piping shall return to the storage/dosing
tank.
The arrangement of the injection nozzles shall be in such a way that easy replacement is possible
and the injection point is in counterflow. Separate isolation and non-return valves shall be arranged
up-stream of the nozzles.
The material of the valves, fittings, etc. shall be generally stainless steel.
4.3
TANKS
The preparation and dosing tanks (2 X 100 % each) for ammonia, hydrazine, corrosion
inhibitor and tri-sodiumphosphate dosing stations shall have the following features:
Closed standard tanks with screwed filling cover (gas tight for ammonia and hydrazine)
Reinforced top for installation of mixtures
Material shall be glass fibre reinforced with PVC-liner. Alternatively stainless steel can be
accepted. However, Hydrazine preparation and dosing tank shall be made of stainless
steel
The tanks shall be suitably protected against destruction.
All agitators shall be stainless steel and flange mounted
The preparation and storage tanks shall be complete with all required valves, fittings and local
instruments. Safety showers and eye wash facilities shall be located near the chemicals tanks.
4.4
CHEMICAL DRAIN SYSTEM
The preparation and dosing tanks shall be mounted inside catch basins of adequate size which
shall be connected to the chemical drain system. The catchment basins shall be equipped with 2 x
100 % drainage pumps, complete with motor, necessary valves, connecting pipework and all other
accessories. Drainage and connecting piping to the chemical waste water treatment system shall
be provided.
4.5
PIPES
For the ammonia, hydrazine, corrosion inhibitor and tri-sodiumphosphate piping system stainless
steel shall be used.
The connections of the tri-sodiumphosphate pressure piping system shall be welded type fittings.
The other connections in the pressure piping system as mentioned in this chapter above shall be
normally screwed or flanged type.
INSTRUMENTATION & CONTROL
5.1
5.2
Page: 7
Regarding the chemical dosing-related instrumentation, reference is made to the following
documents:
Chemical Dosing flow diagram (drawing No. CNE/015/2002/W-39-G-D-00050.)
Parts G5 General Technical Requirements and P2.27. Instrumentation & Control
Dosing quantities shall be adjusted as per results of the water sample analyses. The operation of
all dosing pumps shall be controlled locally and from the CCR. Automatic stroke control of the
dosing pumps shall be provided in accordance with the pH value in the system and the rate of
make up water flow as well as any other necessary parameters. Additionally, stroke control shall
also be provided from the DCS operator stations in the CCR.
5.3
CLOSED-LOOP CONTROL
Not applicable.
5.4
The following critical scenarios, entailing plant damage and personnel hazards, shall be kept under
control by means of I & C equipment. These are mainly:
High and low level of preparation and dosing tanks
Fail safe condition of all dosing equipment in the event of power or control air failure
5.5
CONTROL SYSTEM
The Contractor shall provide complete control and switch cabinets for each dosing station group.
The following minimum shall be mounted on the control cabinets:
Start and stop push buttons for the dosing pumps and agitators
Pumps and agitators status light indications
Alarm lights and audible alarms to indicate high and low level of preparation and dosing tanks
Starting, stopping of the dosing pumps as well as stroke control / adjustment shall be provided
from the DCS operator stations.
Group alarm to the Distributed Control System (DCS)
The corrosion protection shall meet the General Technical Requirements of Part G5.5.
CNE/015/2002
P2.15
WORKING DOCUMENT
Part P2.15 Demineralised Water Plant Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
PAGE
GENERAL ..................................................................................................................................... 1
SCOPE OF WORKS..................................................................................................................... 1
2.1
2.2
ADDITIONAL EQUIPMENT ............................................................................................. 5
LAYOUT ........................................................................................................................................ 6
4.1
PUMPS.............................................................................................................................. 7
4.2
VALVES/PIPING............................................................................................................... 7
4.3
TANKS .............................................................................................................................. 8
4.4
PRE - COAT FILTERS ..................................................................................................... 9
4.5
ION EXCHANGERS ....................................................................................................... 10
4.6
REGENERATION SYSTEM ........................................................................................... 10
4.7
AIR BLOWERS............................................................................................................... 11

5.1
COMPONENT -RELATED INSTRUMENTATION .......................................................... 11
5.2
DEGREE OF REMOTE CONTROL AND AUTOMATION............................................. 12

5.2.1
Redundancy and Protection ..................................................................... 12
5.3
SPECIAL PROTECTION REQUIREMENTS................................................................. 13
P2_15demineralised_water_Working_Doc.doc
Page: 1
GENERAL
This specification covers the general technical / performance requirements of the following
systems:
Regeneration station with chemical storage tanks
Regeneration wastes neutralisation station
Distribution system for demineralised water to all consumers
with all necessary equipment for satisfactory operation of the Jebel Ali Power and Desalination
Station L - Phase I units.
Sufficient space shall be reserved on the Demineralisation Plant Area for future extension of the
Demineralised Water Plant.
All provisions/tie-ins shall be made to enable easy extension of the Demineralised Water Plant in
the scope of future Jebel Ali L plant Phase II, in which the Water Demineralisation Plant shall be
extended by one additional mixed bed exchanger train of the same net production capacity. The
chemical storage, regeneration, neutralisation, and other common facilities to be supplied with
Jebel Ali L, Phase I shall be designed with sufficient capacity to also cover the requirements of the
third mixed bed exchanger train after plant extension.
Contractor's work shall include but not be limited to the engineering design, fabrication, material
testing, delivery, installation, testing, commissioning and handing over of the equipment.
The system and its components provided to meet this Specification shall also conform to the
applicable requirements of this and other general articles or specifications of this Contract, i.e. Part
G5 General Technical Requirements.
SCOPE OF WORKS
The scope of work of the water treatment plant and its associated equipment is mainly required to
produce demineralised water for the make-up of the water losses in the steam/condensate cycles
and the closed cooling water system, for the 400 kV S/S terminal washing system and for the GT
inlet air cooling system for future requirement. But it shall also deliver demineralised water to each
GT set for on- and off-line compressor washing.
The Contractor shall be fully responsible for the design detail engineering, manufacture,
transportation, erection testing, commissioning and handing over of the whole water treatment
plant.
All following percentage values for redundancy of components refer to the total requirement of
Jebel Ali L Station Phase I.
Main components of the Water Demineralisation Plant shall be two (2) identical ion exchanger
trains with a net capacity not inferior to 2 x 90 m/h (2 x 100 %), regeneration stations for acid and
caustic mixing and dosing, waste water neutralisation facilities, and two demineralised water tanks.
During normal operation one exchanger train shall be in operation, providing 100 % water
production and one train shall be in regeneration / stand-by.
Each exchanger train shall consist of one polishing pre-coat filter and one mixed bed exchanger
filled with strong acid and strong basic resins. One pre-coat filter shall be located after each
distillate water booster pump.
Page: 2
Distillate will be taken from the MSF evaporators, collected in the separate auxiliary distillate
header of the desalination plant and transferred to a buffer tank with 100 m capacity, to be located
adjacent to the make up water treatment plant. The transfer flow shall be controlled by level
indication of the distillate water buffer tank. A suitable by-pass (to the buffer tank) facility shall be
provided.
From there the distillate water will be pumped by three (3 x 100 %) distillate water booster pumps
through the pre-coat filters.
The pre-coat filters shall remove fine suspended matter from the produced distillate, which may be
produced by corrosion processes.
During the passage through the exchanger beds, the residual salt ions are almost completely
removed from the distillate water to ensure the make up water quality requirements with regard to
residual conductivity and salt traces.
The demineralised water shall be pumped to the two make up water tanks with a net capacity of
1500 m each. From there the make up water shall be transferred to the water/steam cycle to
recover the steam losses. The make up water demand of the closed cooling systems, of the
400 kV S/S terminal washing and GT inlet air cooling system, and other consumers shall also be
provided from the same tank.
The conductivity of the distillate water, to be treated in the make up water treatment plant, is
expected to be in the range of 20 S/cm but can reach up to 30 S/cm. Thus, the demineralisation
plant shall be designed for the higher conductivity value of the distillate..
The temperature of the distillate can be up to 60C. Suitable ion exchanger resins shall be selected
for this maximum temperature.
For filling purposes it shall be possible to operate both trains simultaneously.
The plant design and all above mentioned net flow rates shall be based on 72 hour operation of
each stream without the need to regenerate the plant.
The operation and regeneration of the plant shall be done automatically. However provisions shall
be made for manual operation.
The start-up/shut-down of the plant shall be controlled automatically by the level of the make up
water tanks.
Necessary automatic interlocks for start-up, circulation and shut-down of the plant shall be
provided.
The caustic soda solution required for ion exchanger regeneration shall be taken from the bulk
caustic soda storage tank of the Blending Plant and transferred by suitable pumps and piping (to
be provided) to the caustic solution storage tanks of the Demineralised Water Plant.
The regeneration wastes from the water demineralisation plant and the effluents from the demister
cleaning of MSF units shall be collected in a neutralisation tank. The tank's capacity shall be
sufficient for minimum three mixed bed regenerations. The mixing of the wastes with the
neutralisation chemicals shall be done by mixing ejectors and neutralisation pumps.
The neutralised effluents of the neutralisation tank shall be transferred by the neutralisation pumps
to the waste water cooling and monitoring basin of the Waste Water Treatment Plant. From there
the neutralised waste water will be discharged via the circulating water outfall system into the sea.
The make up water treatment plant will be located inside the water treatment building, except for
the demineralised water and chemical storage tanks which shall be installed outside.
Page: 3
All regeneration and chemical wastes collected in the neutralisation tank shall be neutralised in the
neutral pH range before being discharged to the cooling and monitoring basin of the waste water
treatment system.
A separate combined basin shall be provided for acid cleaning and rinsing of the demister pads of
the Desalination Plant, which shall be located near and connected to the neutralisation tank. Each
of the cleaning and rinsing chambers shall be sized for the simultaneous use of approximately
thirty (30) demister pads of standard size. Additional emergency shower and eye wash facilities
shall be provided and located near the acid cleaning basin.
The scope of work comprises all equipment, pipes with supports, valves, electrical work,
instrumentation and controls necessary to ensure proper, safe, reliable, and easy operation and
maintenance of the make-up water plant under all conditions, even if not mentioned in this
specification.
Platforms, stairs and ladders, lifting beams, etc. required for operation and maintenance of the
equipment shall be included in the scope of supply.
All interconnecting pipework as well as the piping to all users in the power plant shall be provided.
This includes pipe supports, pipe racks and steelwork for piping in trenches or protection sheets for
street crossing, etc..
The two mixed bed exchangers shall be capable of being operated in parallel (e.g. during refilling
of storage tanks).
The plant shall be sized to provide for its own requirements of regeneration and backwash water
over the specified net throughput capacity.
2.1
SCOPE OF EQUIPMENT
The make up water treatment plant shall include the following equipment, which shall be seen as
major system components and in no way exclude other necessary components and equipment not
mentioned.
Scope of Equipment to be provided for Each of the Two Ion Exchanger Trains
One (1) pre-coat filter made from stainless steel, complete with supporting legs, lifting
eyebolts, sight glass, associated piping from stainless steel, set of valves from stainless steel,
sampling equipment and necessary instrumentation
Three (3) Sets of filter sets for the pre-coat filters
One (1) Mixed bed exchangers made from carbon steel hard rubber lined, complete with
supporting legs, lifting eyebolts, manholes, sight glasses, nozzle bottom with nozzles, water
inlet distributor, intermediate distributor/drainage system from stainless steel, associated
piping from stainless steel and set of valves from stainless steel or PE-HD, sampling
equipment and necessary instrumentation
Two (2) Mixed bed exchanger resin filling charges
One (1) Resin strainer (trap) to be installed down-stream of each exchanger complete with
insert and differential pressure measuring device with contact switches
Scope of Common Equipment of the Demineralised Water Plant
Distillate water transfer system, necessary valves, pressure gauges, piping and fixing material
One (1) distillate water buffer tank, made from stainless steel not inferior to 316L, with a
capacity of 100 m, complete with supporting legs, lifting eyebolts, manhole, insulation,
associated piping from stainless steel, set of valves and necessary instrumentation and control
Page: 4
Three (3) distillate water booster pumps (3 x 100%), made from stainless steel, complete with
electric motors, pressure gauge, piping and fixing material
Two (2) Hydrochloric acid storage tanks made from carbon steel/hard rubber lined or suitable
stainless steel to be mounted within a catch basin with sufficient capacity to take up the total
volume of the tank, total storage capacity for 3 months, complete with supporting saddles,
lifting eyebolts, manhole, vent trap, associated piping and set of valves from PE-HD and
necessary instrumentation
Two (2) Acid unloading pumps (2 x 100%), made from suitable plastic material, complete with
electric motor, necessary valves, pressure gauge, piping and fixing material
One (1) Flexible hose for acid tank car/lorry connection with one extra set of couplings to be
mounted on the truck
Two (2) Caustic soda solution storage tanks made from stainless steel with min. 6mm
thickness to be mounted within a catch basin with sufficient capacity to take up the total
volume of the tank, total storage capacity for 1 month, complete with mechanical agitator
electrically driven, supporting saddles, lifting eyebolts, manhole, vent trap, associated piping
and set of valves from PE-HD and necessary instrumentation. Heating of the tank shall be
provided, if so required.
Two (2) Acid dosing pumps (2 x 100%) for regeneration and neutralisation made from cast
iron/hard rubber lined or suitable plastic material complete with valve, pulsation damper,
pressure gauge, necessary operating valves, piping and fixing material
Two (2) Caustic soda dosing pumps (2 x 100%) for regeneration and neutralisation made from
stainless steel or cast iron/hard rubber lined, complete with electric motor, safety valve, suction
valve, pulsation damper, pressure gauge, necessary operating valves, piping and fixing
material
Two (2) caustic soda unloading pumps (2 x 100%) made from stainless steel, complete with
electric motor, necessary valves, pressure gauge, piping and fixing material, if required for
unloading from road tanker
Two (2) Acid injection points with mixing piece
Two (2) Caustic soda injection points with mixing piece
One (1) Neutralisation tank made from glass reinforced plastic (GRP), complete with
supporting beams, lifting eyebolts, manhole, internal distribution system with mixing ejectors,
associated piping and set of valves from PE-HD and necessary instrumentation
Two (2) Neutralisation pumps (2 x 100%) made from suitable plastic material, complete with
electric motors, necessary valves, pressure gauges, piping and fixing material
Two (2 x 100 %) Dilution/Regeneration pumps made from stainless steel, complete with
electric motors, necessary valves, pressure gauges, piping and fixing material
Two (2 x 100 %) Mixed bed air blowers made from stainless steel, complete with electric
motors, suction air filters, suction and discharge silencers, relief valves, necessary operating
valves, pressure gauges, piping and fixing material
One (1) Regeneration station for acid dilution control, complete with all necessary flow
indicators for acid and dilution water, necessary operating valves, piping and fixing material
One (1) Regeneration station for caustic soda dilution control, complete with all necessary flow
indicators for caustic soda and dilution water, necessary operating valves, piping and fixing
material
Page: 5
Two (2) Make up water tanks with a net capacity of 1500 m each, made from stainless steel
not inferior to 316L, complete with supporting legs, lifting eyebolts, manhole, insulation,
associated piping from stainless steel, set of valves and necessary instrumentation and
control. See also General Requirements for Tanks.
Two (2) make up water discharge pumps (2 x 100 %), made from stainless steel not inferior to
316L, complete with electric motor, necessary valves, pressure gauges, piping and fixing
material
One (1) Set of complete interconnecting piping for the specified components, including all
necessary valves, pipe supports, hangers, fixing material, etc., with interconnection facilities,
i.e. shut off valves, blind flanges, etc. for future connection to Phase II.
Transfer piping for transfer of NaOH solution from the bulk caustic soda storage tanks of the
Blending Plant to the caustic solution storage tank of the Demineralised Water Plant, made
from stainless steel with all necessary valves and connection flanges. Concerning the interface
see D1.
One (1) Set of complete local and remote instruments for measuring the flow rates,
conductivity, Silica, pressure and levels of the different measuring points
One (1) Set of Electric panels, complete with all push buttons, indication lamps, alarm tableau
indication and recording instruments, etc.
One (1) Set of Electric switch panels, complete with all necessary motor protection switches,
relays, fuses, etc.
One (1) Set of electric and control cables
One (1) Set of spare parts
One (1) Basin for acid cleaning of demister pads of the MSF Desalination Plants with acid
proof coating, acid supply connection from the acid storage tank, service water supply
connection for acid dilution, drainage connection to the neutralisation tank and emergency
shower / eyewash facilities near the basin. To increase the cleaning effect, an air bubbling
system shall also be provided.
2.2
ADDITIONAL EQUIPMENT
All additional equipment necessary for a proper, safe and reliable operation of the make up
water treatment plant shall be included e.g.:
All electric connections up to the low voltage terminal boards of panels, cubicles, motors,
etc.
All interconnection piping system for the distribution of the demineralised water all plant
users, like water/steam cycle circuits, each GT for compressor washing, 400 kV
switchyard area, laboratory, etc.
Provision of an appropriate number of taps, showers, hose couplings and washing

facilities with connection to the drinking water system
All minor pipes necessary for installation and operation as drainage pipes with connection
to the waste water system, vents, etc.
All safety equipment as emergency showers, eye-washers, plastic suits, protective gloves
and shoes, masks, safety goggles, suitable first aid set inclusive eye wash bottles,
medicaments, antidote chemicals, etc.
Page: 6
All protection equipment against corrosion wherever necessary
All necessary base frames, base plates, anchor bolts supports, etc.
All steel parts embedded in foundation
All platforms, ladders etc. for easy operation
Lifting and hoisting equipment for operation, maintenance and repair
All standard equipment and accessories which are normally included in the supply
schedule but which are not separately listed
All chemical loading/unloading station shall be provided with flushing water supply
connection and have drain connection at the lowest point to remove the chemicals to
neutralisation tank
Acid vapour scrubber complete with water supply and drains
LAYOUT
The Demineralised Water Plant and its associated equipment shall be installed at zero ( 0 m)
level in the water treatment building, indicated in the General Layout Plan No. CNE/015/2002-X01-G-D-00025.
The electrical control and switch panel shall be installed in a separate room of the water treatment
building.
The chemical storage tanks shall be installed outside the Demineralised Water Plant Building,
above acid and caustic proof concrete tubs. The basin for demister pad acid cleaning shall be
located outside in the vicinity of the Demineralised Water Plant.
The process flow of the system is shown on the tender drawing No. CNE/015/2002-W-39-G-D00051.
The layout arrangement shall provide adequate access for safe, simple and easy operation.
Special care shall be taken for the easy and safe handling of the chemicals and for the acid and
caustic protection of all mechanical and civil components.
and construction and shall be capable of operating efficiently, satisfactorily and without excessive
wear or maintenance under the service conditions stated in these specifications.
Each system shall be designed, fabricated, inspected and tested in accordance with the latest
issue of the applicable codes and standards and with the construction requirement stated in Part
G5 "General Technical Requirements".
The equipment shall also comply with all federal, state and local laws and regulations of the place
of installation. Consultant and Contractor shall exercise due care to advise each other as to their
current knowledge pertaining to federal, state and local laws and regulations.
The demineralised water quality shall meet the following water purity requirements:
Silica
< 0.02 mg/l as SiO 2
Iron
< 0.02 mg/l
4.1
Copper
< 0.003 mg/l
Sodium
< 0.01 mg/l
Conductivity
< 0.2 S/cm at 25 C
pH
6.5 7.5
Page: 7
PUMPS
In general horizontal, centrifugal pumps shall be provided complete with electric motors and
couplings.
All pumps shall be fitted with check and minimum flow devices on the discharge side and shut off
valve on the discharge and suction side and pressure indicator. In general pumps shall be
equipped with mechanical seals.
All acid and caustic dosing pumps shall be of the diaphragm dosing pumps. Pressure damping
vessel shall be provided in discharge side of dosing pumps. Each dosing pipeline shall be
equipped with flow meter.
The material of the pumps shall be of stainless steel along with all bolts, nuts and washers,
corrosion proof against all possible concentrations of acid/caustic and resistant against all
conditions during operation.
Demineralised Water Pumps with all parts coming into contact with demineralised water shall be
constructed in chromium steel containing at least 13 % chromium. The materials shall satisfy
without restriction the requirements of erosion and corrosion resistance resulting from operation
with demineralised water.
All pumps shall be designed for continuous operation.
All pumps for chemicals shall have a drain connection at the lowest point to remove residual
chemicals to the neutralisation pit.
4.2
VALVES/PIPING
In general, diaphragm shut-off valves shall be used in the system.

The material of the valves shall be stainless steel or PE-HD. All piping shall be according to
International standard (DVGW, AWWA, or equivalent).
Care shall be taken for the selection of the diaphragm material.
All remotely controlled valves and pneumatic valves shall be provided with sealed gas filled
inductive limit switches in all cases where their open or closed position must be signalled to the
control room and/or where these conditions must be fed to the interlock circuits for ensuring safe
operation of the plant.
All water pipes within the make up water treatment plant shall be PE-HD.
All flanges for chemical lines shall be protected with plastic/elastic or acid/caustic proof material
shells.
All internal pipes for acid solution shall be of PE-HD with a shell made of stainless steel. All pipes
for the caustic soda solution shall be of PE-HD.
All flanges of acid and caustic lines shall be according to International Safety Standards.
Only standard pipe fittings (e.g. elbows, T-pieces) shall be used.
Page: 8
Minimum diameter of tubes shall not be less than 20 mm, except for impulse measuring lines.
All GRP and PE-HD piping arranged outdoors shall be resistant against UV-radiation.
The caustic solution transfer piping between the bulk caustic soda storage tank of the Blending
Plant and the caustic solution storage tanks of the Demineralised Water Plant shall be equipped
with a connection to the distillate water supply and all necessary valves and discharge connections
to enable rinsing of the transfer piping during low temperatures in winter to avoid freezing of the
caustic solution within the pipe.
4.3
TANKS
All tanks shall be vacuum resistant against a pressure of not higher than 0.9 bar (a).
Chemical Storage Tanks
The chemical storage tanks for the storage of hydrochloric acid and caustic soda solution shall be
of the horizontal cylindrical type made of material as stated above. However, the caustic & acid
tanks may alternatively be made from GRP with PVC liner.
The tanks shall include flanges and dished ends, insulation clips (if required) and saddles for
mounting on concrete pads.
All nozzles shall be with flanged ends and shall be mounted on top of the tanks.
The caustic soda solution storage tanks shall have one (1) electric type immersion heater and a
mechanical agitator. Heater shall be designed to maintain a constant minimum temperature of
15oC. Heater must be sealed hermetically to avoid short circuiting due to dampness and shall be
from stainless steel. The mechanical agitator shall be operable only while the caustic storage tank
is filled sufficiently (automatic lock controlled by level monitor). In addition to the filling facility of the
caustic soda tank from the Blending Plant, it shall also be possible to fill the tank by road tankers.
All necessary connections as required for the tanks and in addition two spare connections shall be
provided.
All mountings and piping connections at the acid storage tank shall be arranged on top of the
tanks.
A ladder shall be furnished to provide convenient and safe access to each tank manhole and topmounted nozzle connections. It shall be attached to each tank by welding of other means.
The storage capacity of the caustic soda tank shall be sufficient for 1 months operation however,
the storage capacity of the hydrochloric acid tank shall be sufficient for 3 months operation of the
make up water treatment plant. The capacity of the acid storage tanks shall be sufficient to also
cover the acid demand for acid cleaning of the demister pads of the MSF desalination units.
The complete chemical unloading system shall be designed in accordance with International safety
standards. Three complete sets of personal protection devices shall be provided by the Contractor
(e.g. safety eyeglasses and one emergency shower system).
Neutralisation Tank
All effluent from the make up water treatment plant shall be neutralised before being discharged to
the waste water monitoring basin of the Process Waste Water Treatment Plant. Therefore, when
using acid or caustic soda for regeneration of the ion exchangers, the effluents shall pass the
neutralisation tank for pH adjustment before being discharged to waste water system.
The material of the neutralisation tank shall be glass reinforced plastic (GRP).
Page: 9
The neutralisation tank shall be fitted with a complete mixing system with water jets fed through the
pressurised circulating line of the neutralisation pumps.
The complete outside of the neutralisation tank shall be easy accessible for inspection and
maintenance.
The Contractor shall furnish all equipment required for proper operation of the neutralisation
system including the chemical injection system.
The capacity of the neutralisation tank shall be designed so that the effluent from the make up
water treatment plant and additional chemical wastes collected from the power and desalination
plant areas can be taken up and neutralised. The tank capacity shall be sufficient for minimum
three mixed bed regenerations.
Two level switches mounted in the neutralisation tank shall be used for automatic control of the
main pump (selected by means of a selector switch). The main pump shall start up when reaching
the high level switch and shall stop when the neutralisation pit level has reached the low level
switch.
The neutralisation tank shall be emptied in one hour with one neutralisation pump in operation.
The pH-value in the pressure line of the neutralisation pumps shall be continuously measured and
recorded by the control system.
Distillate Water Buffer Tank
The material of the make up water tank shall be stainless steel not inferior to 316 L.
installation of the tank shall be above zero (min 0 m) level on concrete foundations.
The
The contractor shall furnish all equipment required for proper operation such as level controller and
all necessary connections.
Make up Water Tanks
The make up water from the make up water treatment plant shall be stored in two (2) make up
water storage tanks.
The material of the make up water tank shall be stainless steel not inferior to 316 L.
installation of the tank shall be above zero (min 0 m) level on concrete foundations.
The
The contractor shall furnish all equipment required for proper operation such as level controller and
all necessary connections.
To achieve independence from the Demineralised Water Plant output and the varying feed water
demand of the water/steam cycle, the make up water tanks shall have a capacity of 1500 m each.
The own requirements of the mixed bed exchangers and the acid and caustic dilution systems for
demineralised water shall also be covered from the make up water tanks.
4.4
PRE - COAT FILTERS
Two pre-coat filters shall be provided for the polishing of the distillate water before entering the
make up water treatment plant. The pre-coat filters shall be constructed of stainless steel, not
inferior to 316 L with a design pressure of 8 bar or filtered water pump shut off head, whichever is
greater. Each pre-coat filter shall be complete with manholes, sight glass, flanged pipe connections
and structural steel supporting legs.
Page: 10
4.5
ION EXCHANGERS
The mixed bed ion exchanger units shall be vertical axis pressure vessels and shall be constructed
of welded carbon steel, with a design pressure of 8 bar or distillate water/transfer water pumps
shut off heads, whichever is greater.
The ion exchanger vessels shall be 4 mm thick rubber lined inside. The lining shall be spark tested
with a 5000 volts for each mm thickness along with 5000 Volts as basic value.
The inside chemical distribution and under drain system shall be acid and caustic resistant.
Each ion exchanger vessel shall be provided with the necessary flange connection and manholes.
The manholes shall have an access of 600 mm.
All vessels shall be provided with three observations windows. Windows shall have a clear opening
at least 7,5 cm wide by 30 cm vertical height. The mixed bed exchangers shall have generally
three observation windows.
The exchanger tanks shall be supplied with all internals prior to shipment. All internal piping
systems of the hub or header-lateral type shall be installed in the exchange units using flanged
gasketed connections where attached to the vessel nozzles. All piping shall be rigidly supported
and braced to withstand motion of water and resin beds. The vessel internals shall be arranged so
that no subfill will be required to support the media.
Design of the internal piping shall provide uniform collection or distribution of flow throughout the
entire exchange bed volume avoiding excessive velocity of channelling in any part. The under
drain system shall provide uniform collection of effluent at rated capacity and shall be designed to
distribute backwash water uniformly through the bed. The backwash collector system shall be
designed to remove effectively the maximum expected quantity of backwash water when
backwashing with water having the maximum expected temperature without loss of serviceable
material.
The internals of the mixed bed exchangers (e.g. distributors) shall be strongly fitted to avoid resin
losses during regeneration.
The number of nozzles in each exchangers shall be at least 70/m 2.
All ion exchanger shells shall have all internals shop mounted in true alignments, properly secured
and/or braced to prevent misalignment, loosening or damage during shipment.
Contractor shall not claim a greater capability of the resin offered than does the resin
manufacturer. All resin shall be new, unused material received in manufacturer's original unbroken
containers. A resin proprietary to the Contractor shall only be allowed if a compatible substitute is
identified.
Additional auxiliaries shall comprise inlet and outlet pressure gauges, automatic sequence,
conductivity controllers, sampling valves on inlet and outlet connection, etc..
4.6
REGENERATION SYSTEM
All resins shall be regenerated in the exchanger vessels. The regeneration system shall perform all
regenerating functions.
The regeneration system shall consist of caustic soda and hydrochloric acid storage tanks,
chemical dosing pumps and the necessary distribution system.
All piping including regenerating chemical feed and regenerating feedwater and drainage shall be
furnished. All controls required for regeneration shall be provided.
Page: 11
Both the hydrochloric acid and caustic soda solutions are to be diluted by mixing in-line. The
equipment furnished shall permit accurate control of both rate and volume of regenerating
solutions.
All mixing chambers for acid dilution shall be PTFE-lined.
Alternatively the acid and caustic dilution systems may be offered on the basis of measuring tanks.
If required an electrical heater for regeneration solution shall be provided.
4.7
AIR BLOWERS
The mixed bed air blowers (2 x 100%) shall be of the rotary piston type.
The blowers shall be furnished with the electric motor drives and all necessary equipment.
The noise level shall be less than 85 dB(A) in 1 m distance of the noise source.
5.1
The scope of instrumentation shall meet the following basic requirements:
The Instrumentation herein shall meet the requirements given in Part G5 General
Technical Requirements and P2.27 Instrumentation & Control
Flow diagram CNE/015/2002/-W-39-G-D-00051. In addition to this, the following requirements

apply:
Each exchanger train shall be equipped with an outlet (orifice actuated) flowmeter of the
recording indicating and totalising type. The totaliser shall actuate a timer, which the dial
is calibrated in m 3 of water. This unit shall ring an alarm when the progress hand crosses
the setting of the adjusted hand. All batch totaliser units shall permit adjustment from 20%
to 150% of the calculated capacity
The batch totaliser shall have a visible progress indication so that the quantity of treated
water available prior to the next regeneration is clearly indicated. The batch totaliser shall
be reset at the end of the regeneration cycle manually for readjustment of the total
capacity. The functions shall be done by the remote control system
One pH-measurement, complete with recorder and high/low value alarms for
neutralisation tank shall be included with connection to the digital control system
A motorised flow control valve shall be installed before the distillate buffer tank and
controlled by conductivity measurement of the incoming distillate water to protect the tank
from contamination in case of high conductivity
Level indication of make up water storage tank, regeneration water tank and neutralisation
tank shall also be included with connection to the digital control system
Conductivity measurements with cells, recorders, all circuitry and connection to the digital
control system shall be furnished as follows:
After the distillate pumps
At outlet line of each mixed bed exchanger
In the make up water tank
Page: 12
5.2
After the demineralised water transfer pumps
Before the control valve in front of the distillate buffer tank
The conductivity recorder shall be provided with automatic temperature compensation and
have adjustable high level alarm contacts. Silica analyser recorder shall be provided with
high value alarm indication. Level indication with high and low alarm shall be provided for
each chemical storage tank
Differential pressure gauges shall be supplied with high alarm at the resin traps
One temperature measuring device shall be provided, to be arranged downstream of the

distillate pumps, equipped with indication and maximum alarm contact and to be
connected to the digital control system for indication in the local control room.
Level signals shall be provided, using three redundant level transmitters for distillate water
and demineralised water tanks as follows:
control levels high and low or analogue control signal
Alarm levels high-high and low-low
Dry running protection low-low-low
High-high-high level protection, wherever necessary
DEGREE OF REMOTE CONTROL AND AUTOMATION
The Water Treatment Plant remote control and supervisory system is specified in Part P2.27
Instrumentation and Control.
5.2.1 Redundancy and Protection

Redundantly designed pumps and compressors shall be switched over automatically to the stand
by assembly in case of defect.
All measuring and control facilities shall be designed for fully automatic continuous operation
including regeneration and rinse.
All safety and protection functions for the plant and individual components shall run fully automatic
in any case without manual operation.
The design of the plant shall provide safe operation for easy filling, cleaning, maintenance and
repair. All the plant and their automatic control shall be designed and implemented in such a way
that a breakdown of power or compressed air will not cause critical situation and plant shall be put
in a safe condition.
In case of service position the plant will be started and stopped automatically according to the level
of the make up water storage tank. If necessary the demineralisation train shall be put in
recirculating operation.
The initiation of regeneration shall normally be on the basis of water volume treated and the quality
(conductivity) of the effluent.
If, during its service run, a demineraliser train delivers unacceptable water, the flow to the
demineralised water tank shall be automatically stopped. If the poor quality persists for a pre-set
time period an alarm shall be actuated.
5.3
Page: 13

Active and passive interlocks shall be provided for combination of settings which may lead to
malfunction, corrosion or destruction of plant components, e.g.:
Dosing of acid and caustic shall only be possible if sufficient dilution water is supplied
Protection against running dry of parts of the plant
Dry running protection of all pumps
CNE/015/2002
P2.16
Not Used
Part P2.16 Not Used
Page: i
NOT USED
P2_16Not_Used.doc
CNE/015/2002
P2.17
Chemical Laboratory
WORKING DOCUMENT
Part P2.17 Chemical Laboratory Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
PAGE
GENERAL ..................................................................................................................................... 1
SCOPE OF WORKS..................................................................................................................... 1
CHEMICAL LABORATORY AND FURNITURE ......................................................................... 1
CHEMICAL LABORATORY EQUIPMENT .................................................................................. 3

4.1
EQUIPMENT FOR ROUTINE WATER ANALYSIS......................................................... 3
4.2
EQUIPMENT FOR ADVANCED CHEMICAL ANALYSIS............................................... 5
4.3
EQUIPMENT FOR BACTERIOLOGICAL & ENVIRONMENTAL ANALYSIS ............... 6
4.4
EQUIPMENT FOR OIL TESTING .................................................................................... 6
4.5
GLASSWARE AND LABORATORY TOOLS.................................................................. 7
4.6
LABORATORY CHEMICALS ........................................................................................ 14
4.7
STANDARD ANALYTICAL REFERENCE BOOKS...................................................... 19
P2_17Chemical_Laboratory_Working_Doc.doc
Page: 1
GENERAL
This specification describes all equipment, apparatus and chemicals which shall be provided for
the chemical laboratory of the Jebel Ali L, Phase 1 power and water production plant and its water
treatment facilities. The laboratory shall be designed as an advanced analytical chemical
laboratory and shall be located in the water treatment building.
The equipment supplied shall be of the latest and most modern design and fit for the purpose
envisaged.
The main purpose will be the basic routine analysis work done on all kinds of water for the Plant
such as water for the water/steam cycle (condensate, feedwater), distillate water, sea water, brine,
clear water, cooling water, waste water, etc., as well as the major tests and analyses of fuels,
lubricants and transformer oils.
Furthermore, equipment for extended and advanced water / waste water and oil / waste oil, etc.
analysis shall be provided, such as:
Bacteriological analysis (e.g. Total heterotrophic bacteria)
Environmental analysis, such as

-
Heavy metal determinations
Organic micro pollutants
Poly aromatic hydrocarbons (PAH)
Air emission (CO, NO x , SO2, VOC, PM10)
The individual items are as follows:
Chemical laboratory furniture
Chemical laboratory equipment
Chemicals for laboratory use
Safety devices
Others as specified elsewhere in the Contract
SCOPE OF WORKS
The Scope of supply shall at least be in accordance with the lists according to Clause 4. Additional
items deemed to be necessary shall be added and listed on a separate list to be attached.
Prospectus, leaflets and explanatory literature, demonstrating kit and explicate specification of
apparatuses offered shall be attached to the bid.
CHEMICAL LABORATORY AND FURNITURE
The laboratory shall consist of the following rooms:

-
General Laboratory
Instrument Laboratory, including

-
Metal lab for ASS (Room)
Page: 2
Org. micro-pollutants lab. GC/MS (Room)
Fuel oil lab (Room)
Metallurgical lab for X-ray fluorescence (Room)
Bacteriological laboratory (Room)
Balance room
Storage room
-
For Glass / plastic ware, etc.
For chemical reagents
For gas system
Four office rooms Staff
Library and conference room
Dining room with necessary items like fridge, microwave oven, hot plate, kettle, etc.
Toilets Male & Female
Locker ROOM & shower facility
Administration & Calculation room with the following equipment

-
Computer with accessories (e.g. printer, scanner, CD RW, etc.)
Photocopier
Camera
Calculators (scientific)
Provision shall be made such that the air temperature of the laboratory rooms are kept within + 0.5
K to the adjusted temperature at all times.
All laboratory furniture including the following shall be provided:
a.
Wall-working tables for 4 chemists/laboratory assistants (20 meters total running length), with
acid proof surface tiles, integrated wash basins, supply of electrical power, gas, warm/cold
water, demineralised water, and compressed air at each workplace.
b.
Intermediate-working tables/cupboards
c.
Analytical-balance tables
d.
Fume-cupboard (Hood) with exhaust fan
e.
Demineralised water tank for laboratory purposes, 100 litre capacity with CO2-trap, made from
polypropylene, with connection to the demineralised water plant. Connection point shall be
after the mixed bed exchanger and before the make up water storage tank, if necessary with
pressurising pump. The demineralised water supply of each workplace shall be served from
the laboratory demineralised water tank. Required piping shall be made of polypropylene.
For Production of silica- free water for silica test, arrangements have to be made for recirculation of
demineralised water through cartridges, consisting of resins.
a.
Chemicals -cabinets, lockable
b.
Poison - chemicals cabinet, lockable
Page: 3
c.
Signs for safety instructions, endangered areas and cabinet contents
d.
Collecting tanks for organic and aqueous liquid and solid chemical wastes
e.
Water, gas, air fittings and accessories
f.
Table - drainage system including pipework and installation, connection to neutralisation tank
and drainage
g.
Forced ventilation
h.
Compressed air supply from instrument supply system for wall working tables
i.
One (1) Safe, 80 litres capacity, for valuables, platinum crucibles and dangerous poisons
j.
Safety devices including two emergency showers and two eye showers, 10 personnel safety
equipment sets, two first aid sets, etc.
k.
Also any other necessary furniture the supply of which the Contractor foresees for the
chemical laboratory
l.
All office furniture which are necessary for a four man office including for Chief Chemist.
m. Laboratory air conditioning, heating radiators and heat exchangers.
All above mentioned particulars shall be stated by the Contractor with full dimensioned
drawings for all furniture required in the chemical laboratory
Foundation drawing where necessary
Circuit diagrams where necessary
CHEMICAL LABORATORY EQUIPMENT
The following instruments, apparatus, technical particulars, glassware and chemical agents shall
be provided by the Contractor with all necessary calibration facilities and catalogues for the
instruments. In addition any other equipment, glassware or instruments the supply of which the
Contractor foresees for the chemical laboratory shall be provided.
All laboratory chemicals required for the above listed analysing methods and the corresponding
calibration procedures, sufficient for two years of laboratory use shall be provided.
4.1
EQUIPMENT FOR ROUTINE WATER ANALYSIS
No.
Equipment Name
Purpose
Microprocessor pH Meter
To measure pH in water samples
pH Meter (Portable)
To measure pH of samples at site
Microprocessor Conductivity Meter
To measure conductivity in water samples
Microprocessor Conductivity &

Salinity Meter
To measure low level conductivity at site and for

salinity measurement
Dissolved Oxygen Meter
To measure dissolved oxygen at site
Turbiditymeter
To measure turbidity of different samples
Pocket Colorimeter
For chlorine analysis in water samples
Page: 4
No.
Equipment Name
Purpose
Refractometer (hand held)
For concentration determinations of chemical

tanks
Analytical Balance
For routine laboratory analytical purpose
10
Precision Balance
Routine Laboratory use
11
Toploader Balance
Routine Laboratory use
12
Gas Monitor (Portable) - Methane
For Gas leak check in the Station
13
Gas Monitor (Portable) - Hydrogen
For monitoring Hydrogen gas in plant
14
Gas Monitor (Portable) Hydrogen

sulphide
For monitoring H2S gas in plant
15
Ex Meter N (Explosivity meter)
For checking explosive gases in the Station
16
Universal Heating & Drying Oven
For general laboratory use
17
Multiple Water Bath
For TDS, etc. determination in routine samples
18
Open Bath Circulator
For sample cooling and temperature adjustments
19
Density / Specific Gravity Meter
To determine density / specific gravity of samples
20
Lovibond Comparator
For routine check
21
Rotary Slide Vane Pump
For vacuum filtration
22
Automatic Scale
For chemical weighing
23
Grinder
For sample preparation
24
Hot Plate 120 mm Diameter
For heating samples
25
Hot Plate 400 x 200 mm
For heating samples
26
Powertrol Universal Heater
For distillation of samples
27
Magnetic Stirrer with Heating Plate
For heating and stirring sample
28
Comparator, Sediment Cone,

Settlometer kit, etc.
For routine sewage analysis
29
ASTM Hydrometer 0.650 1.100 For density check of liquids

(Set)
30
ASTM Hydrometer 0.600 2.000 For density check of liquids

(Set)
31
Oxygen Indicator (Portable)
For oxygen check in air
32
Stainless Steel Vacuum Filter
For general filtration
33
Digital burettes
For routine titrimetric analysis at site
34
Dispersers Auto & Manual (Different For base/acid/solvent dispensing

volume)
Page: 5
No.
Equipment Name
35
Portable Mixed bed De-Ionised Water For producing de-ionised water

Assembly
36
Thermometers, General purpose
37
Spectrophotometer with UV and Visible For colourimetric analysis of routine samples

range
38
Oil Content Analyser
39
Auto Titrator Potentiometric Titration For quality check of bulk chemicals used in the
Apparatus
station
40
Refrigerator
For reagent / sample preservation & for ice
41
Sieve shaker with set of Test Sieves
For the sieve analysis of samples like Limestone
42
Transfer pipettes of varying volume
For sample and reagent pipetting
43
Auto Burette sets Different volume
For routine titrations
44
Ice cube maker (Ice making machine)
Making ice cubes for the sample preparation and

other cooling purpose
45
Desiccators different sizes
For sample / Chemical storage
46
Furnace to the range of 1100 C
For deposit analysis
47
Ultrasonic cleaning bath
For glass ware and equipment cleaning
48
Digital Thermometer Thermocouple For temperature measurement at site

probe type
49
Golfer cart / Personnel carrier (Electric) For sample collection and site visits in the plant
area
50
Trolley cart Wheel type
51
pH meter with digital recorder function For desalination/degasser acid cleaning and other
and connected laptop computer
plant activities at site
4.2
Purpose
For laboratory general use
For oil content analysis in water
For routine sample collection
EQUIPMENT FOR ADVANCED CHEMICAL ANALYSIS
No.
Equipment Name
Purpose
Microprocessor Ion Meter
For the determination of cations and anions in

different type of liquid samples
Atomic Absorption / Flame Emission Used for metals and heavy metals in water and oil
Spectromenter with graphite furnace samples
and Mercury/Hydride system
Total Organic Carbon Analyser
For the determination of Carbon in water samples
Ion Chromatograph
For the determination of ions in water samples
Page: 6
No.
Equipment Name
Gas Chromatograph with TCD, FID, For analysing pollutants in drinking water (e.g.
ECD detectors and Sample extraction VOC & halo VOC) and natural gas analysis
system
Water purification system
For the production of extra pure DM water
GC MS with data acquisition system
For the analysis of wide range of elements in low

level concentration
X-Ray Fluorescence Analyser
For metallurgical and compound analysis
4.3
Purpose
EQUIPMENT FOR BACTERIOLOGICAL & ENVIRONMENTAL ANALYSIS
No.
Equipment Name
Purpose
Precision Incubator
For bacteriological analysis
Cooled Incubator
For BOD analysis
Hot Air Steriliser
For drying up to a temperature of 200 C
Automatic Laboratory Steam Steriliser
For sterilisation use
UV Steriliser
For glassware / apparatus and reagent

sterilisation
Colony Counter
Water Bath
Laboratory Centrifuge
General Purpose
Binocular Microscope
10
Filtration Unit
11
BOD Track
For BOD determination in effluent samples
12
BOD/COD/TOC/AOX/TN/TSS/
Surfactant/Nitrate Analyser
For bacteriological sample analysis
13
Sound level meter
For sound measurement
14
Flue gas analyser with data acquisition For stack emission check
system, portable
4.4
EQUIPMENT FOR OIL TESTING
No.
Equipment Name
Purpose
Pensky-Martens Semi-Automatic Flash For the determination of flash point in different oil
Point Tester
samples
Page: 7
No.
Equipment Name
Purpose
Viscosity Bath
For the determination of viscosity of liquid

samples
Extraction Apparatus for determination For oil extraction to determine sediments

of sediments in oil
Automatic
Analyser
Pour Point Tester
To determine the pour point of fuel oils
Laboratory Precision Gas Calorimeter
For the determination of calorific value of fuels
Water / Oil Bath
General Purpose
Particle Size Analyser - Portable
To count the number of particles of different sizes

in oil samples
Dissolved Gas Analyser (DGA) - To determine the dissolved gases in transformer

Portable
and such oils
10
Saybolt Furol Viscosimeter
To determine the viscosity of heavy fuel oils
11
Dean and Stark Distillation Apparatus
For the determination of water content in %
12
Tintiometer ASTM Colour
For the determination of colour of oil samples
13
Auto Titrator with potentiometric & Karl For the determination of acid/base number &
Fischer Coulorimetric Technique
water content in oil samples
14
X-Ray Fluorescence Spectrometer For sulphur determination in fuel oils and other
Table top energy dispersive type
elemental analysis
4.5
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Digital
Salt-in-Crude For checking salt content in crude oils
GLASSWARE AND LABORATORY TOOLS

Basin. Platinum with plastic pattern, 35 ml
Basin. Platinum with plastic pattern, 50 ml
Beaker Borosilicate glass, 50ml
Beaker Borosilicate glass, 100 ml
Beaker Glass, Tall/Short,.200 ml
Beaker. Glass, Tall/Short, 300 ml
Beaker. Glass, Tall/Short, 500 ml
Beaker, Polyethylene, 50 ml
Page: 8
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Beaker, Polypropylene, 250 ml
Boat, Combustion, 58x10x8 mm
Boat, Weighing boat, Disposable, 30ml, 500/pk
Boat, Weighing boat, Disposable, l00ml, 250/pk
Boss heads (Kept with stands), Assorted
Bottle, Aspirator, Borosilicate, 2000 ml
Bottle. Aspirator, Polythene, 2000 ml
Bottle, Aspirator, Polythene, 5000 ml
Bottle, Aspirator, Polythene, 10000 ml
Bottle, Dropping, Glass Amber
Bottle, Dropping, Glass Amber, 5 ml
Bottle, Dropping, Glass Amber, 10 ml
Bottle, Dropping, Glass Clear, 2 ml
Bottle Dropping Amber, Flat stopped, 50 ml
Bottle Dropping Amber, Flat stopped, 100 ml
Bottle Dropping Clear, Flat stopped, 50 ml
Bottle Dropping Clear, Flat stopped, 100 ml
Bottle Dropping Amber, pipette 50 ml
Bottle Dropping Amber, pipette 100 ml
Bottle Dropping Clear, pipette 50 ml
Bottle Dropping Clear, pipette 100 ml
Bottle, Dropping, Safety, Polythene, 15 ml
Bottle, Dropping, Safety, Polythene, 60 ml
Bottle, Dropping, Safety, Polythene, 250ml
Bottle, Dropping, Screw cap, Polythene 60ml
Bottle, Dropping, Screw cap, Polythene, 250
Bottle. Screw cap, for oil, 500 ml
Bottle. Shelf type, Amber, Narrow neck, 500 ml
Bottle, Shelf type, Clear, Narrow neck. 250 ml
Bottle, Shelf type, Clear, Narrow neck. 500 ml
Bottle, Shelf type, Clear, Wide neck, 500 ml
Bottle, Threaded, Plastic cap, Narrow. 500 ml
Bottle, Threaded. Plastic cap. Wide, 100 ml.
Bottle, Threaded. Plastic cap, Wide, 250 ml
Bottle, Threaded, Plastic cap. Wide. 500 ml
Bottle, Threaded, Plastic cap, Narrow, 1000 ml
Bottle, Polythene, Amber, 50/60 ml
Bottle, Polythene, Amber, 100/125 ml
Bottle. Polythene, Amber, 250 ml
Bottle, Polythene, Amber, 500 ml
Bottle, Polythene, Amber, 1000 ml
Bottle, Polythene, Translucent, 250 ml
Bottle, Polythene. Translucent, 500 ml
Bottle, Polythene. Translucent, 1000 ml
Bottle. Polyethylene, Narrow neck, 250 ml
Bottle, Polyehtylene, Narrow neck, 500 ml
Bottle. Polyehtylene. Narrow neck, 1000 ml
Bottle. Polyehtylene Narrow neck, 5000 ml
Bottle, Nalgene PP. Autoclavable, 250 ml
Bottle, Nalgene PP, Autoclavable, 500 ml
Bottle, Nalgene PP. Autoclavable, 1000 ml

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Bottle. White screw cap, Plastic, 250 ml

Bottle. Polyethylene, Narrow neck, 100 ml
Bottle, Plastic, 500 ml
Bottle, Gas washing, Glass, 150 ml
Bottle, Washing. Polythene, 500 ml
Bottle, Washing, Polythene, 1000 ml
Bottle. Wash bottle, Plain, 250 ml
Bottle, Wash bottle, Distilled water, 250 ml
Bottle, Wash bottle, Deionised water., 250 ml
Bottle, Wash bottle, Acetone, 250 ml
Bottle, Weighing. 20 ml
Bottle, Weighing, 70 ml
Brushes. for burettes. Assorted
Brushes. for flasks & Test tubes, Assorted
Brushes. Wooden. Full + Tips
Bulb, Suction/Pressure, PVC
Burette, Automatic, Amber, 25 ml
Burette, Automatic, Amber, 50 ml
Burette, Automatic, Clear, 25 ml
Burette, Automatic, Clean, 50 ml
Burette, Auto,Clear,29/32 Neck. 10 ml
Burette. Automatic, Filler
Burette, Micro, Clear, 2 ml
Burette, Micro, Clear, 25ml
Burette, Micro, with base, Amber, 5 ml
Burette, Micro. with base. Clear. 5 ml
Burette, Automatic, Reservoir, 2000 ml
Burette, Straight, Clear. 10 ml
Burette, Straight, Clear, 50 ml
Burette. Straight, Clear, 100 ml
Burette, Straight, Amber, 10 ml
Burette, Straight, Amber, 25 ml
Burner, Bunsen, Ordinary
Burner, Bunsen. Flat flame
Burner, Meker
Clip, Mohr, Brass-Nickel, 50 & 70 mm
Clip, Screw type, Hoffmann, 12 mm
Clip, Screw type, Hoffmann, 25 mm
Clip, Screw type, Hinged bottom, 12 mm
Clip, Screw type, Hinged bottom, 25 mm
Column, Separating, 14.5/23
Column, Separating, 29/32
Condenser. Davis, 29/32 socket, 300 mm
Cork borer with sharpener
Cork, Stopper, Assortment, 8/12 to 30/34
crucible without lid, Fused silica, 38 ml
Crucible without lid, Fused silica, 90 ml
Crucible with lid, Porcelain
Crucible. Coach, Hard-porcelain, 17 ml
Crucible, Coach, Hard-porcelain, 35 ml
Crucible with lid, Platinum, 20 ml
Crucible with lid, Platinum, 30 ml
Page: 9
Page: 10
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Crucible, Filter glass Rubber sleeves, 50 ml

Cylinder, Measuring, Glass 5 ml
Cylinder, with stopper and detachable base, 100 ml
Cylinder, Measuring, Glass. 2000 ml
Cylinder, Mixing, with stopper, 250 ml
Cylinder, Measuring, Polythene, 25 ml
Cylinder, Measuring, Plastic, 50 ml
Cylinder, Nesslers, with glass stopper, 113 mm
Cylinder, Nesslers, with glass stopper, 250 mm
Cylinder, Nesslers, with glass stopper, 50 ml
Cylinder. Nesslers, with glass stopper, 100 ml
Cylinder, Plain glass. No mark
Desiccator, Glass with porcelain plate, 10 cm diameter
Desiccator, Glass with porcelain plate, 30 cm diameter
Desiccator, Glass. Plain, 210/240 mm dia.
Comparator disc. Chlorine, 0.1 to 1.0 ppm
Comparator disc, Chlorine. 0.2 to 4.0 ppm
Comparator disc, Chromate, 4/35
Comparator disc, Phosphate, 0 to 100 ppm
Comparator, Lovibond, pH, 4 to 11
Comparator, Lovibond, pH, 6 to 7.6
Comparator, Lovibond, pH, 7.6 to 9.2
Comparator cell, 10 ml
Comparator cell stopper, 10 ml
Dish, Evaporating, Glass. 90 ml
Dish, Evaporating, Glass, 170 ml
Dish, Evaporating, Glass, 320 ml
Dish, Evaporating, Porcelain, 60 ml
Dish, Evaporating, Quartz, 45 ml
Dish. Evaporating, Quartz, 90 ml
Dish, Petri, Borosilicate glass, 100 mm dia.
Dish, Petri, Borosilicate glass, 120 mm dia.
Dish, Watch glass, 40 mm dia.
Dish. Watch glass. 50 mm dia.
Dish, Watch glass with flat bottom, PP, 60 mm dia.
Dust mask, Moulded shape, Pack of 50 Nos.
Filter paper, Whatman No.1, 12.5 cm
Filter paper, Whatman No.1, 15 cm

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Filter paper, for oil, 20 x 20 cm
Flask, Conical, Wide mouth, 100 ml
Flask, Conical, 200 ml
Flask, Erlenmeyer with stopper.30 ml
Flask, Erlenmever with stopper,50 ml
Flask, Erlenmeyer with stopper,100 ml
Flask, Erlenmeyer with stopper,200 ml
Flask, Erlenmeyer with stopper. 300 ml
Flask, Erlenmever with stopper. 500 ml
Flask, Round bottom, Single neck, 250 ml
Flask, Round bottom, Single neck, 500 ml
Flask, Round bottom, Three neck, 500 ml.
Flask, Round bottom Three neck, 1000 ml
Flask, Volumetric Glass, 10 ml
Flask, Volumetric Glass. 250 ml
Flask, Volumetric Glass, 2.5 ml
Flask, Volumetric Glass, Amber, 25 ml
Polythene, 50 ml
Polythene, 100 ml
Polythene, 500 ml
Forceps, Fine, Stainless steel, 130 mm
Forceps, Rough, Steel-Nickel, 150 mm
Forceps, Curved, Stainless steel. 105 mm
Funnel, Glass, No stem, Plain. 155 mm
Funnel, Glass, No stem, Plain, 200 rum
Funnel, Glass, Ribbed, 65 mm dia.
Funnel, Glass, Short stem, Plain,45 mm dia.
Funnel, Glass, Short stem, Plain,100 null dia.
Funnel, Glass, Short stem, Plain,75 mm dia
Funnel, Buchner, 55 mm dia.
Funnel, Buchner, 70 mm dia.
Funnel, Polythene, 75 mm dia.
Page: 11
Page: 12
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Funnel, Stainless steel, 150 mm dia.
Funnel, Separating, 100 ml
Funnel, Separating. 250 ml
Glass tube, Borosilicate, 6 mm dia.
Glass tube, Borosilicate, 8 mm dia.
Glass tube. Borosilicate. 13 mm dia.
Glass rod, 4 mm dia.
Glass rod, 5 mm dia.
Glass rod. 10 mm dia.
Glass cloth
Glass T piece. 5 mm bore
Glass T piece, 6 mm bore
Glass T piece, 9 mm bore
Glass Y piece. 5 mm bore
Glass Y piece, 6 mm bore
Glass Y piece, 9 mm bore
Glass cutting file
Glass cutting knife
Glove. Protective, Disposable
Glove, Surgical, Green. 28 cm
Glove. Surgical, Green, 35 cm
Holder, Double burette, with holder
Label. 25 x 51 mm
Label, 38 x 76 mm
Lighter, Spark type, 150 mm
Litmus paper, Red
Litmus paper, Blue
Knife, Stainless steel, Flexible,
Magnet, Telescopic, 60 cm
Magnifying glass
Micro-slide, White, glass, 76 x 26 x 1 mm
Micro-cover glass, 22 x 24 x `mm
Mortar and Pestle, Agate, 75 mm
Mortar and Pestle Agate, 90 mm
Mortar and Pestle, Hard porcelain, 90 mm
Pipette, Automatic, Variable volume dispenser, 0.4 to 2 ml
Pipette, Automatic, Variable volume dispenser, 1 to 5 ml
Pipette, Graduated. Polypropylene, 1 ml
Pipette, Graduated, Straight, 1 ml
Pipette, Graduated Straight, 2 ml
Pipette, Graduated with Safety bulb, 1 ml

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Pipette, Graduated with Safety bulb, 10.ml
Pipette, Graduated with Safety bulb, 25.ml
Pipette, Volumetric, Bulb type, 1 ml
Pipette. Volumetric, Bulb type, 5 ml
Pipette. Volumetric, Bulb type, 10 ml
Pipette, Volumetric, Bulb type. 25 ml
Pipette, Volumetric, with safety bulb, 1 ml
Pipette. Volumetric, with safety bulb, 2 ml
Pipette, Volumetric, with safety bulb, 5 ml
Pipette. Volumetric, with safety bulb, 10 ml
Pipette, Volumetric, with safety bulb. 20 ml
Pipette, Micro end-to-end, 0.5l
Pipette, Micro end-to-end, 1 l
Pipette filter Universal model
Plate, Porcelain. Glaced, with 6 wells
Pump. Water jet type
Rack, Sterilising, for petri dish
Rack, Test tube, Stainless steel, Assorted
Rack, Thermometer, PVC
Rubber cone, GUKO, for gooch crucible
Rubber stopper. Assortment, 8/77 to 41/47 mm
Rubber teat, for pipettes & droppers, 4 mm, 1.5 ml
Rubber teat, for pipettes & droppers, 6 mm. 2.0 ml
Safety goggles, Perfecta
Safe visor, 320 K.PL
Scissors, 150 mm
Spatula, Nickel cut square & bent
Spatula, Stainless Steel, Micro
Spatula. Nickel Spoon end
Stand, Nessler cylinders
Stand, Rotating Polypropylene. 230 x 450 mm
Stand, Polished Stainless steel, 600 mm
Stand base, Polished. Stainless steel, 300 x 150 mm
Stirrer, Magnetic. with/without heater
Silicone stopcock grease. Tube
Stop watch
Support, Filtration funnel, PVC
Support ring, Stainless steel, Assorted
Syringe. Disposable with needle, 1 ml
Syringe, Disposable with needle, 5 ml
Syringe, Hypodermic, 2 ml
Page: 13
Page: 14
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4.6
1.
2.
3.
Syringe, Hypodermic,100 ml
Syringe, Gas tight with needle, 1 ml
Syringe, Gas tight with needle. 2 ml
Syringe, Gas tight with needle, 5 ml
Thermometer, Mercury in glass, -10 to +100 C
Thermometer, Mercury in glass. -10 to +250 C
Thermometer, Mercury in glass(Specl) -10 to +250 C
Thermometer, Mercury in glass, +20 to +230 F
Thermometer, Mercury in glass, 20 to 580 F
Thermometer, Mercury in glass, +20 to +760 F
Thermometer, Mercury in glass, -50 to +50 C
Thermometer, Mercury in Class. -100 to +100 C
Thermometer, Mercury in glass, 0 to 100 C
Thermometer, Mercury in glass. 0 to 2.00 C
Thermometer, Mercury in glass, 0 to 360 C
Thermometer, 3C range each. 19 to 101 C
Thermometer Special, 208 to 212 F
Thermometer with coller, -10 to 250 C
Tong, Nickel plated steel, 50 cm
Tong, Stainless steel with Teflon tip. 25 cm
Tong, Stainless steel, 25 cm
Tongs, Stainless steel, 40 cm
Tong, Stainless steel, for beaker, 25 cm
Tone, Stainless steel, for basin, 25 cm
Tong, Stainless steel, for flask, 25 cm
Tray, DURAN, for bottles, 377 x 210 mm (2L)
Tray, Polythene, Small
Tray, Polythene, Big
Tray, Stainless Steel, Small
Tray, Stainless Steel, Big
Triangle, Iron wire, 60 mm
Tripod, Stainless steel, 120 x 210 mm
Tube, Absorption, Straight, 15x 2 cm dia.
Tubing, Rubber, Red. 3 x 1 mm
Tubing, Rubber, Red, 5 x 1.5 mm
Tubing, Rubber, Red, 10 x 2 mm
Tubing, Rubber, Vacuum, 5 x 4 mm
Tubing for Bunsen burner, 60 cm
Tube, Glass, for dissolved oxygen sampling, 500 ml
Tube, Nessler reaction vessel. 60 ml
Tube, Test tube, Borosilicate, 130 x 16 mm dia
Tube, Test tube, Borosilicate. 150 x 25 mm dia
Tube, Test tube with stopper, 25 ml
Tube, Test tube with stopper, 50 ml
U Tube for Calcium chloride
Vials with plastic screw caps. Glass, 30 ml
Vials with plastic screw caps. Glass. 50 ml
Vials with plastic screw caps. Glass, l00ml
LABORATORY CHEMICALS
1,1,2-Trichlorotrifluoroethane
1,10 Phenanthroline
1-Amino-2-Naphtol-4-Sulphonic Acid

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2,4,6-Collidine(Trimethyl Pyridine)
2-Carboxyl-2-hydroxysulf. benzene (ZINCON)
3-Nitrophenol (m-Nitrophenol)
8 Hydroxyquinoline
Acetic Acid (Glacial)
Acetone
Aluminium Ammonium Sulphate
Ammonia Solution S.G. 0.91
Ammonium Acetate
Ammonium Chloride
Ammonium Molybdate
Ammonium Nitrate
Ammonium Oxalate
Ammonium Per Sulphate
Ammonium pyrrolidine dithiocarbamate (APDC)
Ammonium Sulphate
Ammonium Vanadate
Anion Exchange Resin ( Basic)
Antimony Potassium(+)Tartrate
Ascorbic Acid
Aurine Tricarboxylic Acid (Aluminon)
Barium Chloride
Barium Hydroxide
Bathophenthroline (4,7 diphenyl 1,10 phn.)
Benzene
Benzoic Acid (Thermochemical STD)
Boric Acid
Bromine Water
Bromocresol - Green
Bromocresol - Purple
Buffer Solution pH 10
Calcium Chloride
Calcium Hydroxide
Calcon carhoxyl acid (NANA indicator)
Carbon (Activated)
Carbon Tetrachloride
Caesium chloride (CsCl)
Citric Acid
Cobaltous Chloride
Copper Sulphate
Crystal Violet
Decon 90
Dettol
Diamino Ethane Tetra Acetic Acid (EDTA)
Dimethyl Glyoxime
DPD Comparator Tablets No.1
DPD Comparator Tablets No.3
EDTA disodium salt 0.1 M solution
Electrolyte solution (3 mol/l KCI) sat. with AgCl
Eriochrome Black - T (Mordant Black)
Ehthyl Alcohol ( Absolute )
Ferric III Chloride
Ferrous Ammonium Sulphate
Page: 15
Page: 16
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115.
Ferrous Sulphate
Filter Paper (Cellulose Nitrate, 0.45 )
Gelatin Powder
Glass Balls
Glucose ( Bacteriological)
Glycerol
Hexamine ( Hexamethyl Tetramine)
Hydrochloric acid 1M solution
Hydrochloric Acid S.G. 1.18
Hydrochloric acid Sp.gr 1.19 (Fuming)
Hydrofluoric Acid ( Pure )
Hydrogen Peroxide ( 30 % )
Hydroxylamine Hydrochloride
Indigo Carmine
internal filling soln. for ref. electrode R 502
Iodine
Iodine solution. 0.05M (0.1N), Ampoule for 500 ml
ISA/Ca (4 mol/L KCl) for Calcium
ISA/FK (5 mol/L NaNO 3) for Chloride, Copper etc.
ISA/Na (pH 11 buffer) for Sodium
ISE Standard, Calcium (CaCl2) 10 g/L
1SE Standard, Chloride (HCl) 10 g/L
ISE Standard, Copper (CuCl2) 10 gIL
ISE Standard, Fluoride (NaF) 10 g/L
ISE Standard, Nitrate (NaNO 3) 10 g/L
ISE Standard, Potassium (KCl) 10 g/L
ISE Standard, Sodium (NaCl) 10 g/l
Iso Imyl Alcohol
Iso Propyl Alcohol (2 Propanol)
Lanthanum Chloride 7 Hydrate
Lead Acetate Paper ( Books)
Magnesium Chloride
Magnesium Sulphate
Manganous Sulphate ( MnSO4.H2 O)
Mercuric Chloride
Mercuric Iodide
Mercuric Sulphate
Methanol (Methyl Alcohol)
Methyl Iso-Butyl Ketone
Methyl Orange
Methyl Red
Murexide (Ammonium Purpurate)
N-Hexane
Nesslers Reagent
Nitric Acid S.C. 1.42
Nitrite Tablet No.1
Nitrite Tablet No.2
Outer chamber filling soln. for ref. elect. R 502
Oxalic Acid
p-Dimethylaminobenzaldehyde
p-Naphthol Benzene
Palladium(II) Nitrate
Perchloric Acid
Phenolphthalein
Phosphoric Acid S.G. 1.75
Potassium Bromide

116.
117.
118.
119.
120.
121.
122.
123.
124.
125.
126.
127.
128.
129.
130.
131.
132.
133.
134.
135.
136.
137.
138.
139.
140.
141.
142.
143.
144.
145.
146.
147.
148.
149.
150.
151.
152.
153.
154.
155.
156.
157.
158.
159.
160.
161.
162.
163.
164.
165.
166.
167.
168.
169.
170.
171.
Potassium Chloride
Potassium Chromate
Potassium Dichromate
Potassium Dihydrogen Phosphate (KH2PO4)
Potassium Hydrogen Phthalate
Potassium Hydroxide ( Pellets )
Potassium Iodate
Potassium Iodide ( Iodate free )
Potassium Monohydrogen Phosphate (K2HP04)
Potassium Nitrate
Potassium Periodate, KI04
Potassium Permanganate
Potassium Pyro Sulphate
Potassium Sodium Carbonate
Potassium Sodium Tartrate (Rochelle Salt)
Potassium Sulphate
Pyrogallol ( C6H603)
Safranine
Silica Gel ( Self indicating, 2-4 mm
Silver Nitrate
Silver Sulphate
Sodium Acetate
Sodium Arsenite
Sodium Azide
Sodium Bicarbonate
Sodium Bisulphate
Sodium Bisulphite
Sodium borohydride, Spectrosol for AAS
Sodium Carbonate ( Anhydrous )
Sodium Chloride
Sodium Citrate (Tri Sod. Cit. Dihydrate)
Sodium Diethyl Dithio Carbamate
Sodium Dihydrogen Phosphate (NaH 2PO4. 2H20)
Sodium Hexa Meta Phosphate ((NaPO3)6)
Sodium Hydroxide (Pellets)
Sodium hydroxide 1M solution
Sodium Metabi Sulphite (Sod. Disulphite)
Sodium Monohydrogen Phosphate(Na2HPO4)
Sodium Nitrate
Sodium Nitrite
Sodium Nitrite extra pure
Sodium Poly Phosphate ((NaPO3)n)
Sodium Sulphate
Sodium Sulphide
Sodium Sulphite
Sodium Tetra Borate
Sodium Thio Suphate
Solvent S-316
Standard solution - Al (Aluminium), 1000 ppm
Standard solution - As (Arsenic), 1000 ppm
Standard solution - B (Boron), 1000 ppm
Standard solution - Ba (Barium). 1000 ppm
Standard solution - Be (Beryllium). 1000 ppm
Standard Solution - Ca
Standard solution - Cd (Cadmium), 1000 ppm
Standard solution - Cl 1000 ppm
Page: 17
Page: 18
172.
173.
174.
175.
176.
177.
178.
179.
180.
181.
182.
183.
184.
185.
186.
187.
188.
189.
190.
191.
192.
193.
194.
195.
196.
197.
198.
199.
200.
201.
202.
203.
204.
205.
206.
207.
208.
209.
210.
211.
212.
213.
214.
215.
216.
Standard Solution - Co
Standard solution - Cr, 1000 ppm
Standard Solution - Cu
Standard Solution - F
Standard Solution - Fe
Standard Solution - K
Standard Solution -Mg
Standard solution - Mn (Manganese), 1000 ppm
Standard Solution - Mo, 1000 ppm
Standard solution - Na
Standard Solution - Ni
Standard Solution - NO2
Standard Solution - NO3
Standard Solution - P (Phosphorous), 1000 ppm
Standard solution - Pb
Standard Solution - PO4
Standard Solution Sb (Animony), 1000 ppm
Standard Solution Se (Selenium), 1000 ppm
Standard solution - Si
Standard Solution - Sn(Tin), 1000 ppm
Standard solution - SO4
Standard Solution -Ti
Standard Solution - V
Standard Solution - Zn
Stannous Chloride (Tin II chloride)
Starch (Soluble)
Sulphamic Acid
Sulphosalicylic Acid (5, Sulphosalicy.acid)
Sulphuric acid 0.5M solution
Sulphuric Acid S.C. 1.84
Sulphurous acid (5% w/v S02 soln.)
Tartaric Acid
Thio Glycollic Acid
TISAB for Fluoride
TISAB for Nitrate
Toluene
TPTZ (2,4,6 Tris (2, pyridyl-s-triazine)
Tri Ethanolamine
Universal pH Indicator Solution
Universal pH Test Paper
Xylene
Xylenol Orange
Zinc ( Granulated)
Zinc Chloride
Zinc Sulphate
Notes:
1. All chemicals should be of analytical quality for chemical laboratory use.
2. Any of the chemical reagents not mentioned above and needed for the Power Plant
laboratory shall be provided by the Contractor.
3. Any other chemical, the supply of which the Contractor foresees for the laboratory, to
be provided in addition to the above mentioned list.
4.7
Page: 19
STANDARD ANALYTICAL REFERENCE BOOKS
The following standard analytical reference books shall be provided:

No.
Name of the Book
Author / Editor
Publisher
Guidelines For Drinking Water

Quality, Volume 1,
Recommendations
World Health
Organisation, Geneva

Quality, Volume 2, Health Criteria
and Other Supporting Information
World Health

Quality, Volume 3, Drinking Water
Quality Control in Small
Copmmunitiy Supplies
World Health
Standard Methods For The

Edited By:
Examination Of Water & Waste
Leonore S. Clesceri
water. Latest complete edition with
supplements, if any
Arnold E. Greenberg
Andre D. Eaton
American Public Health

Association, American
Water Works Association,
Water Pollution Control
Federation
Drinking Water Quality Problems & N.F. Gray

Solution Latest Edition
John Wiley & Son
Water Quality & Treatment

Handbook of Community Water
Supplies
F.W. Pontius
McGraw Hill
Degremont Water Treatment

Handbook
Ahalsted Press Book,

John Wiley & Sons
Introduction to Environmental
Engineering
M.L. Davis, D.A. Cornwell
McGraw Hill
Environmental Chemistry
S.E. Manahan
Lewis Publishers
10
Air Pollution Engineering
Noel De Nevers
McGraw Hill
11
Perrys Chemical Engineers

Handbook
R.H. Perry, Don Green
McGraw Hill
American Water Work

Association
CNE/015/2002
P2.18
WORKING DOCUMENT
Part P2.18 Waste Water Treatment Plant Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
PAGE
GENERAL ..................................................................................................................................... 1
SCOPE OF WORKS..................................................................................................................... 2
2.1
LAYOUT ........................................................................................................................................ 4
DESIGN AND CONSTRUCT ION REQUIREMENTS................................................................... 4
4.1
GENERAL ......................................................................................................................... 4
4.2
WASTE WATER COLLECTION PIPING......................................................................... 4
4.3
OIL REMOVAL SYSTEM ................................................................................................. 5
4.4
CHEMICAL WASTE WATER RETENTION PIT .............................................................. 5
4.5
CHEMICAL WASTE WATER TREATMENT TANK........................................................ 5
4.6
WASTE WATER COOLING AND MONITORING BASIN............................................... 5
4.7
PUMPS.............................................................................................................................. 6
4.8
ELECTRICAL SYSTEM.................................................................................................... 6

5.1
DEGREE OF REMOTE CONTROL AND AUTOMATION............................................... 6
5.2
P2_18waste_water_treatment_Working_Doc.doc
Page: 1
GENERAL
This specification covers the general technical requirements of the waste water treatment plant and
the associated equipment.
The systems specified herein shall serve all needs of Jebel Ali Power and Desalination Station L Phase I, and provide collection, treatment and final discharge of all types of waste water, including
oil/water separation of all oil contaminated drains and treatment of chemical waste water. .
The process waste water treatment plant shall comprise the following main plant components for
collection and treatment of the different drains.
One oily waste water collection and treatment system for:

-
Turbine area drains
Boiler area drains
Transformer area drains
Drains from other oil contaminated areas of the plant
Oily waste water from the oily waste water drainage pits of the various power plant areas shall
be collected in the oily water basin of the waste water treatment plant
One treatment system for chemical drains from:

-
Chemical dosing
Chlorination plant
Batteries area,
MSF equipment area,
Chemical storage areas,
Blending Plant areas,
etc.
The chemical waste water from the chemical waste water drain pits of the various power and
desalination plant areas shall be collected and directed to the chemical waste water retention
pit of the waste water treatment plant
One waste water cooling and monitoring basin.

The neutralised effluents from the neutralisation tank of the demineralised water plant and
other effluents from the various plant areas, which do not require special treatment shall be
collected and directed to the waste water cooling and monitoring basin of the waste water
treatment plant
The capacities of the specified systems shall be determined by the Contractor according to the
requirements of the Jebel Ali L, Phase I Power and Desalination Plant .
Turbine and compressor wash waters shall be collected during the washing process in a separate
wash water tank. Collected wash water shall be treated and properly disposed off. The Turbine and
compressor washing system is specified in Part P2.1 Gas Turbine Unit and Auxiliaries Including
Bypass Stack.
Page: 2
Regeneration effluents from the water demineralisation plant and effluents from MSF desalination
demister acid cleaning shall be collected and neutralised in the neutralisation tank of the
Demineralised Water Plant. The neutralised effluent shall be transferred to the waste water cooling
and monitoring basin. The neutralisation tank is specified in Part P2.15 Demineralised Water
Plant.
Effluents from initial boiler cleaning and conditioning (acid pickling) must not be treated in these
systems but they shall be collected and disposed of by the Contractor in an environmentally safe
manner.
SCOPE OF WORKS
2.1
SCOPE OF EQUIPMENT
Design, manufacture, delivery, test, erection, commissioning and handing over of the waste water
treatment system shall include but not be limited to the following:
Oily water treatment system for free and emulsified oils which shall include but not be limited
to the following:
-
Two (2) oily water basins, to take up oily water from transformer, generator and turbine
areas, etc., including transformer deluge water chamber, pre-separation chamber,
equalisation chamber, portable oil skimmer, and two (2 x 100 %) capacity oily water
delivery pumps from each oily water basin to the oil separating tank of mono type including
controls, annunciators, motor, valves, connecting pipework and accessories. The deluge
water chamber shall be of sufficient size to take up the maximum oil content of the
transformers plus the maximum estimated amount of fire fighting water (according to
NFPA)
piping from the oily waste water drainage lines at the various plant areas to the oily water
basins , including all necessary pumps, valves, pipe connections, corrosion protection, and
accessories
all accessories for oily water basins, including step irons, manholes, connecting piping,
level indication, control devices, corrosion protection, etc.
all necessary equipment for safe operation and monitoring of the system, electrical wiring,
etc.
One (1) oil separating tank with plate separators and oil skimmers
One (1) oil sludge tank
One (1) oil holding tank and
Two (2 x 100 %) portable oil and oily sludge transfer pumps
One (1) complete control system for the oily water treatment system including a graphic
display control panel and all necessary controls, indicators, annunciators, recorders, and other
devices required for the operation of the oily waste water treatment systems
Chemical waste water collection system including

-
Piping from the chemical waste water drain pits of the various plant areas to the chemical
waste water retention pit, made from chemical and sun radiation resistant material
One (1) Chemical waste water retention pit of sufficient size for collection of all chemical
drains from the plant areas, including necessary railings and operation platforms.
Page: 3
All accessories for the chemical waste water retention pit, including step irons, manholes,
connecting piping, chemical proof inside coating, corrosion protection, etc.
One (1) Chemical waste water treatment tank for treatment of chemical drains from chemical
dosing, chlorination plant, batteries area, etc., equipped with one (1) charging pump, one (1)
discharge pump, one (1) sludge pump, necessary valves and control equipment. The tank
shall be equipped for manual addition of chemicals
One (1) Mobile vacuum suction tank with pump system for occasional removal of oil or sludge
fractions from the waste water treatment systems for final disposal
One (1) Waste water cooling and monitoring basin for collection of all treated waste water
streams and cooling down of the hot water/steam cycle blowdown water before final discharge
to the cooling water outfall, with sufficient capacity to retain fire water in case of fire accidents,
including level and temperature indication, discharge shut off valve, connecting piping,
corrosion protection, connection and transfer piping between the auxiliary sea water header
and the waste water cooling and monitoring basin, including all necessary valves and
instrumentation.
Isolation valves for all tanks, pumps and other process equipment.
All pumps shall have minimum flow and/or over pressure protection as applicable.
All necessary valves, controls, and instrumentation including:

-
Selector switches and pushbuttons and
Indicating lights
Interconnecting tubing, piping, valves, fittings, and gauges between all furnished equipment
All necessary electrical equipment including wiring and tubing required
Motor drivers for furnished equipment
All materials such as bolts, nuts and gaskets for the installation of all items shall be furnished,
including all access platforms required to service and maintain equipment.
Civil works shall be in accordance with civil requirements specified in this Technical Specification.
Especially the protection of all basins, tanks and pits and sub surface installations shall be in
accordance with the latest soil protection standards (German WHG or equivalent).
The waste water treatment systems shall treat the plant liquid wastes and produce an effluent
suitable for discharge to marine environment as per Dubai environmental regulations. The main
parameters of the waste water treatment plant effluents shall be limited as follows:
Pollutants
Units
Value
Max. Temperature
60
Floatables
none
pH
69
Total suspended solids
ppm
15 (max)
Turbidity
NTU
75 (max)
Oil and Grease
ppm
Page: 4
All waste water treatment facilities specified herein shall be designed to enable compliance with
the waste water discharge standards to marine environment set by the Local Order 61/1991 of the
Dubai Municipality. The respective environmental standard values are listed in the Part G4
General Project Requirements of this Specification.
The Contractor is obliged to be fully aware and familiar by himself with power plant and with
locations and distances for all connections necessary and required by the proper operation.
LAYOUT
The locations of the waste water treatment systems are indicated on the Layout plan
No. CNE/015/2002-X-01-G-D-00025.
The oily waste water treatment system shall be located in the vicinity of the turbine and transformer
areas.
The chemical waste water retention pit, the chemical waste water treatment tank and the waste
water cooling and monitoring basin shall be located in the vicinity of the circulating water outfall
channel.
The waste water treatment system shall be located outdoors and designed for the environmental
conditions stated in Part G5 General Technical Requirements and P2.28.
The process flow of the waste water treatment plant is shown on the tender drawing Waste Water
Treatment Plant P&I Diagram No. CNE/015/2002-W-39-G-D-00052.
4
4.1
DESIGN AND CONSTRUCTION REQUIREMENTS

GENERAL
It shall be the responsibility of the Contractor to ensure that the equipment has been designed,
manufactured and tested in accordance with all engineering codes, standards and government
regulations (quality of waste water to be discharged).
The design shall be governed by the requirements of this Technical Specification and the other
specifications referred herein.
All joints shall be of welded construction, except at flanged equipment connections. All pipe flanges
and flanged fittings shall be designed and manufactured in accordance with DIN standards or
equivalent.
Atmospheric tanks shall be designed and fabricated in accordance with DIN standards or
equivalent.
4.2
WASTE WATER COLLECTION PIPING
Waste water collection piping shall be supplied for collection of all types of waste water from the
discharge lines of the various plant systems up to the inlet connections at the waste water
treatment facilities specified herein. The piping shall be made from suitable corrosion resistant
materials and equipped with all necessary valves, connections and instrumentation.
4.3
OIL REMOVAL SYSTEM
All drains possibly polluted by oil will be collected in the two oily water basins. With the support of a
portable oil skimmer the oil layer will be removed from the water and collected in the oil holding
tank.
Page: 5
From the oil holding tank the oil should be transferred to a tank truck for final disposal either by
gravity or two portable oil and oily sludge transfer pumps. The effluent from the oily waste water
collecting basin will be pumped by two (2 x 100 %) oily waste water transfer pumps to the oil
separating tank. The oil removed shall be led by gravity to the oil holding tank, the sludge shall be
transferred to the oil sludge tank and the effluent shall be led by two (2x100%) pumps to the oily
waste water cooling and monitoring basin.
The water effluent pre-separated in the oil interceptor facilities of the diesel oil pump station and
tank farm areas shall be transferred by 2 x 100 % transfer pumps to the oily water basin of the
waste water treatment plant.
The oil separation facilities shall be designed to enable compliance with the applicable Dubai
waste water discharge standards to the sea.
From the oil holding tank the oil should be transferred to a tank truck for final disposal by two (2 x
100 %) portable oil and oily sludge transfer pumps.
From the oil sludge tank the sludge should be transferred to a sludge vehicle for final disposal by
two (2 x 100 %) portable oil and oily sludge transfer pumps.
4.4
CHEMICAL WASTE WATER RETENTION PIT
All chemical drains from chemical dosing facilities of power plant and MSF evaporators,
chlorination plant, chemical stores, batteries, and other areas of the Jebel Ali L, Phase I Station
shall be collected in the chemical waste water retention pit. The chemical waste water retention pit
shall have sufficient capacity to retain all chemical waste water arising at the various plant areas
and shall be equipped with an overflow device to the waste water cooling and monitoring basin.
The chemical waste water collected in the pit shall be treated on demand in the chemical waste
water treatment tank.
4.5
CHEMICAL WASTE WATER TREATMENT TANK
All chemical drains collected in the chemical waste water retention pit shall be transferred on
demand by a charging pump (capacity 10 m/h) to the chemical waste water treatment tank. The
waste water treatment tank shall be of conical bottom type with four stands with an effective
capacity of 10 m. The tank shall be equipped for manual addition of acid, caustic and precipitation
agents in order to neutralise the waste water and to remove suspended solids by precipitation. A
mechanical agitation device shall be included for mixing of chemicals during treatment. After
sedimentation of suspended particles the clear phase will be discharged by a discharge pump
(capacity 10 m/h) to the waste water cooling and monitoring basin. The collected sludge shall be
discharged by one sludge pump (capacity 10 m/h) to a container with suitable provision for
transportation for final disposal. Provision shall be made by suitable control equipment to prevent
overcharging of the tank.
4.6
WASTE WATER COOLING AND MONITORING BASIN
One waste water cooling and monitoring basin shall be provided for collection of all treated waste
water, as well for cooling down of the hot steam/cycle blowdown water, before final discharge to
the cooling water outfall. Discharge pumps shall be provided if required. waste water samples for
environmental monitoring purposes shall be taken from the waste water cooling and monitoring
basin. The capacity of the basin shall be sufficient to retain fire water in case of accidents and shall
be equipped with a discharge shut off valve to avoid contamination of marine environment in case
of fire and other emergency situations associated with the release of substances hazardous to the
environment.
The hot water/steam cycle blowdown water shall be cooled down below 60 C by mixing with sea
water in the waste water cooling and monitoring basin. Corresponding supply connections, piping
and instrumentation shall be provided. The cooling sea water shall be taken from the auxiliary sea
Page: 6
water pump header and transferred to the waste water cooling and monitoring basin by suitable
piping. The mixing of cooling sea water to the waste water cooling and monitoring basin shall be
controlled according to the temperature measurement at the discharge line of the basin.
4.7
PUMPS
The Contractor shall provide centrifugal pumps in accordance Part G5 General Technical
Requirements.
The Contractor shall supply any necessary level switches and automatic flow-control valves to coordinate pump operations.
4.8
ELECTRICAL SYSTEM
General technical requirements are specified in Part G5.

DC power sources, if so required by the Contract's design, have to be provided.
Based on the final building layout of the Demineralisation Plant/Waste water Plant, the MCCs for
both areas may be combined in one piece and location, subjected to the approval of the Engineer.
The Instrumentation herein shall meet the requirements given in Part P2.27 Instrumentation &
Control and in Part G5 General Technical Requirements.
5.1
DEGREE OF REMOTE CONTROL AND AUTOMATION
A local control panel with mimic shall be furnished for the oily water treatment system and shall
display the controls, relays, other instruments, and associated wiring included in the Specification.
The panel will be located indoors in the water treatment building. The panel shall conform to the
requirements of I&C Specification. Remote control from the DCS operator stations in the CCR shall
be provided.
The Contractor shall supply as a minimum panel-mounted and locally mounted

instrumentation and controls that shall contain or perform the following functions:
1.
Automatic pump stop when low-low level is achieved in oil/water separator.
2.
Two position (start and stop) selector switches for all pumps.
3.
Automatic and manual control of oil/water separator pumps.
All measuring and control facilities shall be designed for fully automatic continuous operation.
All safety and protection functions for the plant and individual components shall run fully automatic
in any case without manual operation.
The design of the plant shall provide safe operation for easy cleaning, maintenance and repair. All
the plant and their automatic control shall be designed and implemented in such a way that a
power failure will not cause critical situation and plant shall be kept in a safe condition.
5.2
Active and passive interlocks shall be provided for combination of settings, which may lead to
malfunction, corrosion, or destruction of plant components. (e.g. protection against running dry of
parts of the plant).
Page: 7
All pumps shall be equipped with pressure gauges, locking valves and designed for minimum
amount recirculation operation.
The surfaces of all equipment, pipes and valves, etc. shall be corrosion protected in accordance
with Part G5.5 Corrosion Protection and Painting.
CNE/015/2002
P2.19
WORKING DOCUMENT
Part P2.19 Sewage Treatment Plant Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
PAGE
GENERAL ..................................................................................................................................... 1
SCOPE OF WORKS..................................................................................................................... 1
LAYOUT ........................................................................................................................................ 1
P2_19Sewage_Treatment_Working_Doc.doc
Page: 1
GENERAL
A complete sanitary waste treatment plant shall be provided to treat the sanitary wastes coming
from the sewage systems of the Jebel Ali Power L, Phase I Station. Suitable provisions shall be
made available to connect the sanitary wastes coming from the future Station L Phase II.
SCOPE OF WORKS
The Contractor shall supply a complete sewage treatment plant suitable to treat 100% of sanitary
waste water and sludge. All equipment and facilities necessary for a good and reliable operation of
the plant shall be provided.
The plant shall be equipped at least with the following but not limited to:
One (1) bar screen,
One (1) rotating screen complete with motor,
Two (2) hopper of screened material,
Two (2) submerged centrifugal pumps,
Two (2) aeration blowers,
One (1) air lift blower,
One (1) dosing system for sludge conditioning agent
One (1) filterpress for sludge dewatering
One (1) pit for dewatered sludge
Two (2) submerged pumps for the sludge (stand-alone pumps are acceptable in case pump
performance is equivalent),
Air lifting device,
Basins for retention/collection, aeration/sludge contact, de-nitrification,
sedimentation/clarification,
All additional facilities required for tertiary treatment to achieve effluent quality required for
irrigation re-use at plant area
Chemical dosing facilities for disinfection of discharge water,
Rotating sludge collector (Air lifting only is acceptable in case sludge collection can be provided
as required by the system. Decision about the selected system shall be made during design
stage.) and
Pipes, weirs, instrumentation
Ring lines shall be supplied for collection of sanitary sewage from the sewage sump pump
pressure lines of the various plant systems up to the inlet connections at the sewage treatment
plant facilities specified herein.
LAYOUT
The Sewage Treatment Plant shall be located between the East side of the sea water outfall
channel and the site boundary fence.
Page: 2
Part P2.19 Sewage Treatment Plant Working Doc
The location of the Sewage Treatment Plant is indicated on the General Layout Plan No.
CNE/015/2002/-X-01-G-D-00025.
The sanitary sewage coming from sanitary toilets and showers, etc. shall be discharged to a total
oxidation plant where the above effluents shall be reduced from organic matter to stable sediment.
The sewage treatment process shall include secondary as well as tertiary treatment.
The water discharged from this plant shall be conveyed to the cooling water outfall channel if not
used for irrigation. Suitable pumping and piping system shall be provided and connected to station
irrigation system.
The incoming water shall pass through the screening devices, pumped to the active sludge contact
basin equipped with an extended aeration device, treated by recirculation through the denitrification chamber and separated from the sewage sludge in a sedimentation/clarification basin.
Sedimented sludge shall be collected with a rotating sludge collector and partially recirculated
according the requirements of the biological treatment process.
The fraction of the sewage sludge, which will not be recirculated within the system, shall be
conditioned with a suitable precipitation agent (e.g. lime slurry, FeSO4, initial set of dosing
chemicals to be provided) and dewatered by means of a (chamber/membrane) filterpress to
achieve a residual content of dry matter of minimum 30 %. The dewatered sludge shall be
collected in a sludge pit and disposed of in regular intervals.
All additional facilities required for tertiary treatment shall be provided in order to achieve effluent
quality required for irrigation re-use within the plant area (suitable process to be offered, e.g.
dosing of Fe(II)SO4 for phosphate elimination or microfiltration).
Before discharge, the treated water shall be chlorinated for disinfection by dosing of hypochlorite
solution generated in the Sea Water Chlorination Plant (2 x 100 % forwarding pumps for
hypochlorite solution and the required piping, valves and instrumentation are included in the scope
of the Sea Water Chlorination Plant Part D2.10).
The surface water of the sedimentation basin shall be discharged to a treated sewage water
storage basin, from where the treated sewage water will be either pumped to Outfall or re-used for
irrigation purposes.
The plant shall have a treatment capacity of approximately 50 m3 per day and shall be capable of
operating continuously over long periods with minimum attention. Provisions shall be made and
sufficient space for installation to be reserved for future extension of the sewage treatment plant
along with the installation of Phase II of the L Station.
The plant shall be of compact design, preferably with several treatment pits in one pool (as far as
possible) for each phase of the treatment (arrival pit, aeration/sludge contact pit, de-nitrification
chamber, sedimentation/clarification pit, sludge pit).
The material of construction shall be selected considering the corrosion resistance required by the
handled fluid.
The sanitary waste water treatment plant outlet water to be re-used for irrigation purposes shall
meet the Dubai emission limit values for discharge of effluents and sludge to land, listed in
Part G4.
All waste water treatment facilities specified herein shall be designed to enable with the waste
water discharge standards to land set by the Local Order 61/1991 of the Dubai Municipality. The
respective environmental standard values are listed in the Part G4.3.2 Environmental Protection
Requirements of this Specification.
Page: 3
The Instrumentation herein shall meet the requirements given in Part P2.27 Instrumentation &
Control and in Part G5.3 General Technical Requirements.
The sanitary waste treatment plant shall be controlled from one local control panel.
A micro processor based programmable control system shall be provided to realise the automatic
control subsystem. Interface with the DCS shall be provided for alarm and indication on the
operator stations monitors in the CCR.
In case of trip of the running pump the stand by pump shall come into operation automatically.
Remote control from the DCS operator stations in the CCR shall be provided. FGC shall be
provided in the DCS.
Dosing rates for sludge conditioning agent shall be determined during commissioning and adjusted
manually.
All the necessary instruments for a correct and safe running of the plant shall be provided. All
equipment and instrumentation shall be fully tropicalised, vermin proof, painted and suitable for the
climatic conditions.
CNE/015/2002
P2.20
Sump Pumps
WORKING DOCUMENT
Part P2.20 Sump Pumps Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
PAGE
GENERAL ..................................................................................................................................... 1
SCOPE OF WORKS..................................................................................................................... 1
CHEMICAL DRAIN AND SEWAGE PUMPS............................................................................... 1
OIL DRAIN PUMPS...................................................................................................................... 1
P2_20Sump_pumps_Working_Doc.doc
Part. P2.20 Sump Pumps Working Doc.
Page: 1
GENERAL
The Contractor shall supply where required intermediate pumping stations, which shall be
designed to pump the required quantities of waste water to the treatment systems. In sewage
drains sewage and seawater can be mixed in any proportion for the Jebel Ali Power and
Desalination Station L, Phase I power and water co-generation facilities.
SCOPE OF WORKS
The scope of supply shall include all drainage pits, connection lines, trenches and 2 x 100% pumps
automatically operated for each sump and/or pit/basin necessary to form a complete system of
plant drainage.
Automatic control system shall consist of an arrangement whereby duty and standby pumps
operate alternatively on the basis of predetermined float level switches. Both pumps shall come
into operation when a predetermined level will be exceeded.
An alarm shall be provided with the appropriate back indication to indicate fault conditions such as
motor tripping, exceeding of duty high water level and electrical supply failure.
CHEMICAL DRAIN AND SEWAGE PUMPS
Chemical drain waste water can be of alkaline or acidic nature and can comprise different type of
contaminating compounds according to the operating situation.
A minimum of on duty and one standby pump shall be installed at each pumping station with all
associated valves, pipework, electrical and control equipment, access ladders, etc. The installation
shall be designed to operate automatically on the basis of float switches, which with the pumps
installed shall ensure efficient and economic operation of the complete installation. The wet well
and number of pumps shall be selected and designed to ensure that pumping is carried out
intermittently and not continuously. Pump installation and operation shall be strictly in accordance
with the manufacturers recommendations.
The pumps shall operate efficiently and shall have a non-overloading characteristic so that they will
not overload if the wet well becomes full. The duty point top water level on each station will be the
invert level of the lowest incoming sewer. The bottom duty point water level shall be the lowest
operating level of the pump proposed. Each pump installed shall be capable of efficiently pumping
the design capacity at duty point top water level.
The Contractor shall provide the installation complete with all pipes, valves, pumps, control and
electrical equipment in accordance with the requirements of this specification in appropriate pump
chambers including suitable water and dust proof cubicles all deigned and installed with due
regard to the climatic and operational conditions prevailing at the site.
OIL DRAIN PUMPS
Where required the Contractor shall supply and install, in suitably designed pumping stations, axial
flow pumps capable for handling oil contaminated water arising from plant drainage sources within
the site area.
Operation and control facilities shall be equal to those described for chemical drain pumps.
Oil contaminated water may comprise seawater or freshwater or a mixture of both contaminated by
oils of various specific gravity. Consequently the oily drain pumps preferably shall be of cast iron,
suitable rubber lined.
Page: 2
Part. P2.20 Sump Pumps Working Doc.
The pumps shall be capable of pumping over the full range of possible duties required and shall
pump efficiently over the normal operating range of design water levels in the sump pumps. The
pump operation shall be designed to minimise emulsification of the oil-contaminated water and the
design shall be with low operating velocities and low fluid accelerations. The Contractor shall
supply all pumps, pipes, valves, electrical and control equipment in accordance with the general
requirements of this specification.
CNE/015/2002
P2.21
Cranes and Hoists
WORKING DOCUMENT
Part P2.21 Cranes and Hoists Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
PAGE
GENERAL ..................................................................................................................................... 1
SCOPE OF WORKS..................................................................................................................... 1
2.1
GAS TURBINE HALL CRANE......................................................................................... 2
2.2
STEAM TURBINE HALL CRANE.................................................................................... 2
2.3
EMERGENCY DIESEL GENERATOR BUILDING CRAN E............................................ 2
2.4
STORE BUILDING CRANE ............................................................................................. 2
2.5
AIR COMPRESSOR AND FEEDWATER PUMP CRANES............................................ 2
2.6
ELECTRICAL OPERATED HOISTS................................................................................ 2
2.7
MANUAL OPERATED HOISTS....................................................................................... 2
3.1
DESIGN AND OPERATING CONDITIONS..................................................................... 3
3.2
DESIGN AND CALCULATION STANDARDS ................................................................ 3
3.3
MATERIAL STANDARDS................................................................................................ 5
3.4
GENERAL DESIGN PARTICULARS............................................................................... 5

3.4.1
General .......................................................................................................... 5
3.4.2
Trolley............................................................................................................ 6
3.4.3
Crane Bridge Structure................................................................................ 6
3.4.4
Crane Runway Rails ..................................................................................... 7
3.4.5
Crane Walkways, Ladders and Platforms ................................................. 7
3.4.6
Crane Control Cab........................................................................................ 7
3.4.7
Bridges Drive ................................................................................................ 8
3.4.8
Trolley Drive.................................................................................................. 8
3.4.9
Transmission Gear....................................................................................... 8
3.4.10
Trucks, Wheels and Axles........................................................................... 9
3.4.11
Hoists............................................................................................................. 9
3.4.12
Bearings ...................................................................................................... 10
3.4.13
Lubrication .................................................................................................. 10
3.4.14
Tool Box ...................................................................................................... 10
3.4.15
Ropes........................................................................................................... 10
INSTRUMENTATION CONTROL EQUIPMENT AND ELECTRICAL EQUIPMENT ............... 10

4.1
LIMIT SWITCHES........................................................................................................... 11
4.2
ELECTRICAL EQUIPMENT ........................................................................................... 11
OPERATION ............................................................................................................................... 12
PROTECTION AGAINST CORROSION.................................................................................... 12
SPECIAL EQUIPMENT AN D TOOLS........................................................................................ 13
P2_21cranes_hoists_Working_Doc.doc
Page: ii
PartP2.21 Cranes and Hoists Working Doc.
SPARE PARTS...........................................................................................................................13
PERFORMANCE GUARANTIES ...............................................................................................13
10 INSPECTION AND TESTS.........................................................................................................14
Page: 1
GENERAL
This specification covers the cranes and hoists as well as the associated equipment complete in
every respect as a minimum requirement and suitable for satisfactory operation of the plant.
SCOPE OF WORKS
The scope of equipment listed below is meant as minimum requirement. Included in the scope of
equipment are further lifting equipment for proper handling of all components with a weight of 50 kg
and more and which require maintenance and repair work. For suc h equipment the Contractor
shall provide monorails and/or hoisting eyes with suitable hoist equipment. According to specific
needs, the hoists can be permanently installed or can be removable. They can be electrically or
manually operated.
The main scope of supply shall consist of:
Pos. Location/ equipment
Type of cranes/hoists
Manual/ electrical operated;

controlled
Turbine hall, gas turbines
Double girder overhead Electrical; pendant switch

crane, main + aux. hoist
Turbine hall gas turbine

as required
EOT crane for upending

the rotor for unstacking
rotor disc
Turbine building, steam

turbine
Double girder overhead Electrical; pendant switch

crane, main + aux. hoist
Blackstart / Emergency
diesel generator building
Overhead cranes
Electrical; pendant switch
Workshop and store
Overhead cranes
Air compressor and boiler

feedwater pumps building
Overhead cranes
Fire fighting water pump

house
Overhead crane
Gas compressor room
Overhead crane
10
Gas Turbine compartments Hoists with trolleys
Electrically operated
11
Water treatment plant

pumphouse
Hoists with trolleys
12
Steam turbine ancillary

equipment
13
Condensate pumps
14
Others installations
15
Fire pumphouse
Hoist
Manual
Electrical Pendant switch
Page: 2
Pos. Location/ equipment
Type of cranes/hoists
Manual/ electrical operated;

controlled
16
Store house
Hoist
Manual
17
Steam turbine ancillary

equipment
Hoist
Manual
18
Other installations
Hoist
Manual
2.1
GAS TURBINE HALL CRANE
Gas turbine hall crane shall be a double girder bridge type and shall be provided with the main and
auxiliary hoist and control cabin. Crane shall be electrically operated. The lifting capacity of the
main hoist shall be able to handle the heaviest part of the GT generator safely. The crane shall be
cabin and pendant control. Radio frequency or infrared remote is not acceptable.
2.2
STEAM TURBINE HALL CRANE
Steam turbine hall crane shall be a double girder bridge type and shall be provided with main and
an auxiliary hoist and control cabin. Crane and crab shall be electrically operated. The lifting
capacity of the main hoist shall be able to handle the heaviest part of the turbine generator safely.
The crane shall be cabin and pendant control. Radio frequency or infrared remote is not
acceptable.
2.3
EMERGENCY DIESEL GENERATOR BUILDING CRANE
Emergency diesel generator building crane shall be a single girder type and shall be provided with
main hoist and pendant control unit. Crane shall be electrically operated.
2.4
STORE BUILDING CRANE
Storage building crane shall be double girder bridge type and shall be provided with the main hook
and pendant control unit. Crane and crab shall be electrically operated.
The crane shall be of 10 tons lifting capacity with a clear height to the hook of 7 m minimum.
2.5
AIR COMPRESSOR AND FEEDWATER PUMP CRANES
The crane shall be of the electrical operated double girder type and provided with main hoist and
pendant control unit.
2.6
ELECTRICAL OPERATED HOISTS
The hoists shall be of the motor operated type with motor trolley on monorail and shall be provided
with pedant control unit. Hoist shall be electrically operated.
2.7
MANUAL OPERATED HOISTS
The manual operated hoist shall be provided with manual chain drive for hoist and trolley on
monorail.
3
3.1
Page: 3
DESIGN AND OPERATING CONDITIONS
The cranes, hoists and lifting devices shall be used primarily for unloading, installation and
maintenance of the mechanical and electrical equipment.
Regarding the outer appearance, the cranes shall be pleasant from an aesthetic point of view, and
the mechanical and electrical equipment of the indoor arrangements shall be fully protected from
the influence of climatic conditions at the Site. The outdoor crane shall also be adequately
protected especially against sun radiation and prevailing winds besides other climatic conditions.
The crane drive and trolley arrangement shall be designed to require a minimum of space while
optimising 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 bridge drive and trolley drive. Electrical driven cranes, hoists and
lifting equipment shall have a nominal and a creep speed. All indoor cranes shall have driver
cabins and two lamps to illuminate the working area.
The cranes in the turbine hall and in the turbine building shall allow to lift the upper half of the
turbines and to lift up the rotor and transport it over another turbine in operation to the lay down
area. Over each generator one lifting devise shall be installed for lifting the upper half of the
bearings and parts of the excitation system. Cranes in the pump houses shall enable to remove the
pump motors and the complete pumps.
Crane hook approaches shall be of the minimum possible dimensions to ensure maximum
coverage of the plant area.
All lifting equipment shall be clearly marked in English and Arabic with the Safe Working Load
(SWL).
All motors on each crane shall be supplied through one contactor operated main switch, each
motor shall be protected by a protective device of approved manufacture. The protective devices
shall be arranged so that in the event of a fault developing on any motor, the main contactor will
open, isolating all motors and applying the electro-mechanical brakes.
Controlled lowering with safety of any load up to and including the test load in the event of
extended current supply failure shall be possible, and a brake release lever is to be provided, the
initial operation of which shall operate a switch making all crane circuits dead.
Hoisting motors shall also be fitted with a centrifugal type brake capable of restraining under all
conditions of load, including test loads, the lowering speed which shall not be grater than twice the
normal full load lifting speed. Auto brakes be provided on both traversing and travelling motors.
Each automatic brake shall be provided with local manual gear to enable the brake to be released.
Runway beams shall meet the General Technical Requirements specification (see Part G5). To the
greatest possible extent all outdoor cranes, hoists and trolleys shall have adequate protection
against exposure to and corrosion from the atmosphere.
3.2
DESIGN AND CALCULATION STANDARDS
Generally, for design, stress calculation, manufacture and installation, the following standards and
codes, apart from various other relevant standards and regulations, shall be applied:
Crane manufacturers association of America
American National Standards Institute
Page: 4
No 70 Specification for Electrical Overhead Travelling Cranes 3.3.3.
B30.2 Safety Code for Cranes, derricks and Hoists
B3.11 Load Ratings for Ball and Roller Bearings
American Institute of Steel Construction
DIN 4100
Welded Steel Structures
DIN 4114
Stress Calculation of Steel Structures
DIN 15018
Cranes, Steel Structures, Calculation and Design
DIN 15020
T1 Cranes, principles for steel structures, stress analysis
T2 Cranes, steel structures principles of construction
Lifting appliances, basic principles for rope reefing components
T1 Computation and design
T2 Maintenance in service
DIN 15030
Lifting equipment; acceptance testing of crane installations; principles
DIN 18800
Steel structures T1/ T7 weld ability proof
ANSI A10.5 Safety Requirements for Hoist Materials
American Welding Society
D1.1 Structural Welding Code
D14.1 Specification for Welding industrial and Mill Cranes
National Electrical Manufacturers Association (USA)
No. 112A Test Procedure for Polyphase Induction Motors and Generators
ANSI B30.20 Overhead and Gantry Cranes
ANSI A10.4 Safety Requirements for Workmens Hoist (Requirement of British Safety for five
Star Grading).
All the electrical equipment must comply with the latest relevant recommendation of the
International Electrotechnical Commission (IEC), British Standards Specifications (BSS) or other
equivalent/higher standards such as:
DIN 120 Calculation for Structural Steel Work of Cranes and Gantries.
DIN 15018 Krane-Stahltragwerke-Berechnungs-Grundsaetze
Accident Prevention Rules No. 1.8.3. Cranes
Association of Iron And Steel Engineers (USA).

If the Contractor wishes to base this Contract on codes and standards other than those specified,
he may do so provided that he submits with his Tender complete data with respect to the codes or
standards forming the basis of this Tender, and confirms in his Tender that such codes or
standards meet, as a minimum the specified codes and standards. The Contractor shall submit
with and as a part of Tender a tabulated list of the differences between the codes and standards
Page: 5
applied in his Tender and those specified herein, The decision to accept such alternative code or
standard shall entirely rest upon the Engineer/ Employer on the basis of this evaluation of, but not
limited to, the following:
Safety devices for the operating personnel shall be provided in accordance with the safety rules
and regulations.
The safety rules outlined in VBG 9 of the German "Verband der Berufsgenossenschaft" and VDI
2388 "Overhead Travelling Cranes in Buildings, Layout Data" or similar internationally recognised
codes shall be observed.
Unless otherwise specified, the lifting equipment shall be classified to DIN 15020 as follows:
-
For lifting capacity up to 10,000 kg (10 tons) "class 2 m", representing an average daily
working time of 2 to 4 hours and an equal share of small, medium, and heavy loads (normal
duty).
For lifting capacity larger than 10,000 kg (10 tons) "class 1Am", representing an average
daily working time of 2 to 4 hrs. and a small share of heavy load lifts (light duty).
The Contractor shall state the various load combinations and factors of safety taken as a basis for
calculation of the different components and equipment items of the cranes and hoists.
In addition, the various factors of safety for the different load combinations shall be stated.
Steel structures of lifting equipment shall be of welded construction, which can be assembled at
Site. All field connections and joints shall be bolted.
Automatic engaging brakes shall be provided for outdoor installed cranes and trolleys. The effect of
strong winds shall be adequately be considered.
For lubrication, inspection and maintenance, ladders, platforms and stairs treads shall be provided.
All walkways shall have non-slip chequered plate treads and/ or non-slip floor grating, and shall be
equipped with tubular handrails and skirting. Walkways, stairs and platforms for lifting equipment
shall be designed generally for a live load of 3,000 N/m.
For standard manual operated hoists, type test certificates are required.
3.3
MATERIAL STANDARDS
The material to be used for manufacturing the lifting equipment steel structures shall conform to
DIN 17100 or to the equivalent ASTM standards. However, the Contractor 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. For these structural steels, connecting bolts and welds, the allowable stresses given in
DIN 15018 shall apply.
The material and all equipment can be stress relieved, as required the specified code or standards,
if manufacturing and/or construction methods procedure undesirable locked-in stresses.
If alternate standards are accepted, the Contractor shall provide three (3) English language copies
of such alternative standards and submit them to the Engineers/Employer for use on the Project.
3.4
GENERAL DESIGN PARTICULARS
3.4.1 General
Nameplates stating the nominal load capacity in kilograms (kg) or tonnes (t) written in Arabic and
English 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.
Page: 6
The manufacturers name or trade mark shall appear on the plate together with manufacturers
serials or identification number and date of manufacture.
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.
The lifting capacity of the main hoist shall be handle the heaviest part of the equipment or the
complete equipment if required during maintenance and repair works.
All structural parts of the crane shall be designed to sustain the max. loads as requested by the
standard with due allowance for eccentricity of loading, without exceeding the unit stress of
materials hereinafter specified.
Live load of 240 kg/m2 shall be assumed for the design of walkways and platforms.
Collision forces between bumpers and stops shall be taken as the forces due to such collision with
the trolley or gantry travelling at full speed with the power off. Dead load only shall be considered
as contributing to the collision forces.
The mechanical parts of the crane shall be designed to have minimum safety factor of five (5)
when supporting the rated capacity load, based on the ultimate strength of the material used. Unit
stresses shall not exceed 90% of the material elastic limit for the loads due to the break down
torque of the hoist motors.
All couplings, drive wheels and gears shall be press fit and keyed to the shaft.
3.4.2 Trolley
The trolley frame shall be made of welded structural. After manufacture, the trolley frame shall be
stress-relieved.
Flexible bumpers shall be provided at the ends of the trolley frame 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 trolley from leaving the rails and to limit the maximum sag of the trolley to 20 (twenty)
millimetres 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.
3.4.3 Crane Bridge Structure

The crane bridge girders shall be made of structural steel of welded construction. Each girder shall
be designed to resist a half of a total lateral forces affecting bridge. Girder connections to the end
trucks shall be fixed by means of turned bolts and ample gusset plates to ensure proper alignment
and rigid structure. All field and joints shall be bolted. Lifting lugs or hanging holes shall be
provided to minimize paint damage during erection.
Welded joints shall be used for the main structure of the crane, bolted joints shall be avoided
wherever possible.
The travelling crane girders shall be welded in structural steel box sections, with wide flanged
beams, standard I beams or reinforced beams. Girders shall be symmetrical and line-of-sight
must be considered along with girder design, as well as suspended crane supports. Trellis girders
shall be prohibited.
Page: 7
The girders shall be designed to withstand all vertical loads and horizontal forces which may arise
under service conditions. The vertical deflection of the girders, caused by safe working load
(nominal load) and the weight of the crab in the central position shall not exceed 1/1000 of the
span.
The bridge girders shall be securely braced to the end of carriages to prevent cross-racking. There
must not be a possibility for travelling crane to fall from the gantry in the event of derailment. The
carriages of bogie type shall be equipped at each end with spring bumpers.
The crane bridges of the double girder cranes shall be provided with gangways fitted on the bridge
or the side of the crane.
3.4.4 Crane Runway Rails

Travelling crane runway rails shall be provided by the Contractor. Joints between rails on opposite
runway girders for the cranes shall be staggered with respect to each other and to the wheel base
of the cranes. All rails joints shall be welded. Rail joints shall not be located over the runway girder
splices. Provision of rail expansion shall be made at the end stop locations only.
Guiding of rails on the girders should be carried out with rail clamps for distance adjustment.
Welded clips are not allowed.
End stops shall be designed and located to limit the maximum crane travel. The end stops shall be
capable of stopping the travelling crane fully loaded and travelling at rated speed.
3.4.5 Crane Walkways, Ladders and Platforms

Electrical double girder overhead cranes shall be provided with walkways, platforms and guard
hand rails along the bridge rails and on the crab to facilitate cleaning/maintenance of the crane. An
escape walkway shall be provided over the entire length of long travel girder to the nearest escape
ladders.
The platform and walkways shall be designed to support any weight to be imposed upon them
during crane overhaul.
Ladders, platforms and steps shall be provided to permit access to crane flood lights and for
lubrication, inspection and maintenance. Operator platform shall have non-skid galvanised chequer
plate flooring and shall be provided with pipe handrails and toe-boards.
Details of the method of access together with access ladders, platforms, etc., shall be supplied.
Stairs and platform with walkways shall be provided, for operator cabin and crane top access from
the floor level.
3.4.6 Crane Control Cab

The crane cab for cranes provided with a control cab shall afford the operator unrestricted view of
the load and a clear view of the surroundings and full view of all crane activities. It must not limit
the cross travel of the crab. Provisions shall be made on platform to mount manually operated
master switches, main line disconnect switch, hydraulic break foot pedal and all necessary for the
protection of the operator. Control cab shall have a clear head room of at least two (2) meters.
The crane cab shall be equipped with at least the following:
a comfortable seat, with adjustable seat and backrest. Because of the high temperature,
the construction and materials should not induce uncomfortable body conditions.
an overhead lamp with a conveniently located switch.
controls which are arranged conveniently and logically to the drivers hands.
Page: 8
the crane controls are to be spring loaded so that on release they return to the off
position.
a master isolator control switch to open/close the main contactor operated by a removable
key, the key being removable only when in the off position.
a read-out of load on each hoist.
an emergency stop device to de-energies the main contactor in emergency.
a warning Klaxon foot switch.
a fire extinguisher of approved type.
an electrical operated fan with two or those speeds and arranged so that the crane operator
can swivel it to provide the most comfortable cooling ventilation.
a warning bell or horn with lamps to warn that the various motor limit switches have
operated.
a safe means of escape from the cab for the crane operator in the event of emergency or
extended power failure.
opening windows to allow for exterior window cleaning from within the cab.
the control cab shall be fully enclosed and provided with adequate air conditioning
equipment for operator comfort.
3.4.7 Bridges Drive

The driving mechanism shall be designed as two corner drives and so constructed to provide
steady travel, free from vibrations or racking in any part of the structure while travelling under any
load and speed. The control of the drive motors shall be designed to provide simultaneous starting
and stopping of both motors even with very high temperatures that will exist in those locations.
Automatic spring set, electrically released brakes having breaking capacity in either directions of
travel equal to at least 150% of full load torque of the drive motors and capable of holding the
crane stationary shall be provided. Automatic brakes shall become effective when the drive
controller is set in off position or when the main power is disconnected. Shoe type hydraulically
operated brakes, controlled from a foot pedal in the operators station and having a breaking
capacity in either direction equal to at least 150% of the full load torque of the drive motors, shall
be mounted on the drive motor pinion or extension shafts.
3.4.8 Trolley Drive

The trolley drive shall consist of oil bath lubricated gear case motor and shall be designed so that
the travel under all conditions will be steady and free from vibration or racking in any part. The
trolley shall be driven by means of a motor mounted on the trolley through gearing and shafting.
The motor shall be designed with inching controls. Couplings shall be provided at each side of the
gear reducer and ahead of the drive pinion. An automatic electric brake having a capacity not less
than 125 percent of the full load torque of the driving motor shall be provided on the trolley drive.
3.4.9 Transmission Gear

All gear including the drum gears and pinions shall be enclosed in oil tight gear boxes and shall be
easily removable.
All gearings must be machined cut from solid steel. All spur wheels shall be of cast or welded steel
and pinions shall be of solid steel forging integral with the shaft. The hardness range of gears and
pinions must be the same.
Page: 9
Gear boxes shall be made of cast steel or welded steel plates in two halves and shall be fitted with:
Inspection covers in the upper half of the casing, to permit inspection of both gear and
pinion teeth without removing the upper half casing
Lifting lugs
Baffle opening to prevent any build-up of pressure inside the casing
Oil level indicators
Drainage fittings
The gears shall be designed for automatic lubrication. Suitable drip pans made of steel plate 3 mm
thick shall be provided to collect oil and grease which may drop from operating parts. Gear box and
drip pans shall be provided with means for cleaning and draining without dismantling the
equipment. Dust covers shall be provided where necessary to protect sliding and rotating parts and
to prevent mixing of dust with lubricant.
All shafts shall be forged of alloy steel accurately finished to size the bearing and gearing
connections. Gears are to be pressed on and keyed to shafts.
The gear case and cross-shaft bearings shall be antifriction ball or roller type. The bearing housing
shall permit easy removal of the shaft. The bearing shall be provided with pressure lubrication and
designed to exclude dirt and prevent leakage of oil or grease. Other bearings shall be of the plain
adjustable can-type, lined with bronze or white metal
3.4.10 Trucks, Wheels and Axles

The end trucks shall be designed to distribute the load evenly between the wheels. Wheels shall
be of the rotating axle type. The trucks shall be heavily reinforced to provide rigid structure. Safety
lugs shall be provided to prevent a drop of more than I inch in case of the broken axle. Truck
sweeps shall be provided at each en of the trucks. Safety lugs shall be provided to prevent the
trucks leaving the rails. Truck bumpers shall be rigidly mounted in such a manner that the attaching
bolts are not in share. Runway stops will be provided at the limits of travel.
All wheels shall be double flanged, made of solid wrought or rolled steel wheel banks and
accurately turned or ground to true diameter. The thread width shall provide ample clearance
between wheels, flanges and railhead. Wheels shall be designed to carry the maximum rated load
under normal conditions without undue wear, and shall have roller type bearings with highpressure grease lubrication. The load shall be equally divided between the wheels on each side.
Wheels without flanges but with guide rollers will be also accepted.
3.4.11 Hoists
The trolley shall be equipped with a main hoist of the required rated capacity. The hoisting
mechanism shall include the motor, reduction gearing, drum, rope, hooks and blocks, so designed
and arranged that the load may be raised or lowered and carried along the bridge, and shall be
provided with limit switches to prevent damage to hoisting tackle or trolley frame through overraising or over-lowering of the hook block.
An eddy current control brake shall be provided on the hoist to prevent any lowering speed greater
than that corresponding to the controller setting. The eddy current load break shall have the
capacity to hold the full load, and shall be designed to function under full load without overheating.
In addition the hoist shall be equipped with the mechanical load break complying with rated for
150% of the torque.
Page: 10
3.4.12 Bearings
All bearings (except the lower block bearings) shall be of the ball or roller type, designed to permit
easy removal of the shaft. End truck and trolley wheel bearing shall be of the roller type and shall
be interchangeable. Shaft bearings shall be placed as close as possible to points of loading. All
bearings shall be easily replaceable. All bearing housings shall be of cast iron, or structural steel
construction.
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.
3.4.13 Lubrication
Oil bath lubrication shall be provided for all high speed gears and pinions. Low speed gears shall
be lubricated by means of soft grease. Bearings (except the lower block bearings) shall be
lubricated by means of oil bath of pressure lubrication. Suitable drip pans shall be provided to
collect oil and grease which may drop from operating parts. Drip pans shall be accessible for
drainage and cleaning. The lubricant used on the crane ropes shall not dip under condition that
exist in this location.
Suitable arrangements shall be provided to check box oil level. The lubrication of the cranes shall
be centralised as much as possible.
3.4.14 Tool Box

A steel box with hinged cover, for storing oil cans, grease gun, tools, grease and waste, shall be
permanently secured to crane bridge. All special tools required for repairs and maintenance as well
as oil cans, grease guns, lubrications charts, and crane operation, maintenance and repair
manuals shall be provided.
3.4.15 Ropes
The wire ropes for the hoists shall be of twist-free construction preferably with a fibre-core; the
wires should consist of hardened and tempered 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 of the sufficient length to provide two extra turns of each part on the drum with
additional adequate length for attaching to the drum.
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.
The coils and contacts of the magnetic control must be enclosed in metal cabinets. The
manufacturers shall supply detailed information about the materials used, such as contact life,
closing and opening time of the contacts, etc. The main contacts shall be able to operate without
Page: 11
excessive wear, overheating, sticking or any other malfunctioning. The insulating material shall be
class "A" for a temperature rise of 60C above the 60C ambient temperature.
The electrical control devices shall be installed in panels and steel cubicles mounted inside the
cabin which provide maximum safety to the crane operator and the maintenance staff. All controls
shall be conveniently grouped in the cabin to enable the operator to operate the crane from a point
where he can best watch all crane movements.
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 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.
4.1
LIMIT SWITCHES
The crane shall be equipped with the following enclosed limit switches of the closed-circuit type:
Block-actuated switches to limit upward travel of the load blocks.
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.
Lower hoist limit switch, gear or chain-driven from drum (on auxiliary hoists acceptable for
upper and lower hook position).
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.
4.2
ELECTRICAL EQUIPMENT
The power supply will be 380 V AC, 3-phase, 50 Hz. Besides the stipulations given in Part G5.2.
Motors
The motors to be provided shall be induction motors with adequate rating to cope with the load
involved.
The motors shall have class F insulation or better and shall be rated for service at an ambient
temperature of 60C. Motors of relatively low-speed shall be given preference.
Current Feed Cables for Trolley
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 (220 V, 20 A), which shall
be suitably located on the trolley for maintenance purposes.
Cables, Cable Conduits and Terminals
The Contractor shall supply all cables. They shall be laid in rigid, galvanised steel conduits with
screwed connections and draw-in boxes, which shall be suitably built into the crane structure. All
Page: 12
cables shall run to terminal strips for making the outer connections. The cables must not be
spliced.
Unless stipulated otherwise, stranded cables with PVC insulation or equivalent protection for at
least 600 Volts shall be used.
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 subjected to the approval of the Employer/Engineer.
Power Supply Line for the Crane
Power shall be fed to the crane by 4 - wire (3-phase plus grounding) rigid copper conductors of the
protected type located on the upstream wall of the relevant buildings. These conductors, complete
with insulating wall-mounting brackets and collectors mounted on the crane, shall be included in
the supply.
OPERATION
The cranes shall be operated from the ground level by pendents and from the cabins.
The following items shall be provided at convenient points:
An emergency push-button to stop all motions.
Complete instructions for operation, maintenance and lubrication of the crane be placed in a
suitable case with glazed front.
A 6 kg carbon-dioxide fire-extinguisher.
Actuating elements for the signal horn, which shall be mounted on the crane bridge. It shall be
possible to actuate the horn from the pendent and from four points of the relevant room.
Two battery-operated headphones with 40 m of connection cable for direct communication

between crane operator and the person giving instructions during difficult hoisting processes
(fitting generator and turbine shaft etc.).
PROTECTION AGAINST CORROSION
The Contractor must be fully aware of the serious corrosion problems existing at the power plant
site, therefore all site equipment shall be fully protected against corrosion. All condensate, however
formed, shall be properly and safely located
All parts of equipment shall be anti-corrosion protected, depending on the conditions of operation
of each equipment part. Selected way of protection shall be exactly executed with materials and
procedures which, depending on the operation conditions, provide efficient and durable system of
equipment anti-corrosion protection system.
The Contractor shall replace at his own cost and expense any piece of equipment found corroded
within warranty period.
Piece of equipment shall be found corroded if its rust degree falls within the range R2 and R3
according to DIN 53210. The warranty period shall be 5 years from the date of takeover.
Page: 13
SPECIAL EQUIPMENT AND TOOLS
The Contractor shall provide a list of recommended special equipment and tools including but not
limited to:
Two sets of special tools and gauges required for the normal maintenance of the cranes and
lifting equipment.
One set of special lifting and handling appliances required for normal maintenance.
Suitable storage rocks shall be provided for all portable lifting tackle.
The tools and appliances with appropriate storage racks, cabinets and boxes shall be provided.
Any special tools or appliances required solely for erection shall be provided by Contractor for his
own use and shall remain the property of the Contractor.
SPARE PARTS
The Contractor shall complete the recommended list of spare parts, consumables and shall submit
them at the time of tendering. The recommended spare parts list shall be sufficient for safe and
reliable operation for at least five years.
Major items of spare parts must be priced individually but very minor items can be grouped
together.
The Contractor shall segregate in the Schedule those "consumable" spares necessary for efficient
day to day maintenance of any items of Cranes and lifting Equipment and those "strategic" spares
which, in his opinion, the Employer should hold to minimise the outage of plant due to breakdown.
Each item shall be clearly marked and labelled on the outside of its packing with detailed
description and purpose and corresponding identification number.
Each item shall be separately packed against damage and sealed to prevent deterioration from
corrosion. The protection shall be sufficient for a minimum of five years storage in a dry place.
The Contractor shall provide as a part of the scope of this Contract all the wear and tear parts, all
the consumables required for the equipment as defined in Part G3.
The spare parts shall be placed in bins, racks, drawers, shelves, cabinets, etc. to be provided by
the Contractor.
PERFORMANCE GUARANTIES
Each Crane and lifting Equipment shall be Performance tested to demonstrate that the operation
complies with the Guaranteed Performance and to provide base data for the assessment of
Performance throughout the operating life of the equipment. The extent of and procedures for
performance tests shall be to the approval of the Engineer.
Unless otherwise specified in the Equipment Requirements the programme of performance test
shall include at least the following:
determination of performance
determination of overload
leak test (hydraulic test).
Page: 14
10 INSPECTION AND TESTS

See Part G5.6 Inspection and Testing.
CNE/015/2002
P2.22
WORKING DOCUMENT
Part P2.22 Workshop and Store Equipment Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
PAGE
SERVICE REQUIREMENTS........................................................................................................ 1
1.1
SCOPE OF SPECIFICATION........................................................................................... 1
1.2
SYSTEM DESCRIPTION.................................................................................................. 1
1.3
OPERATION REQUIREMENTS ...................................................................................... 1
SCOPE OF WORKS..................................................................................................................... 2
2.1
GENERAL ......................................................................................................................... 2
2.2
MECHANICAL WORKSHOP EQUIPMENT .................................................................... 2
2.3
ELECTRICAL WORKSHOP............................................................................................. 3
2.4
INSTRUMENTATION AND CONTROL WORKSHOP .................................................... 3
2.4.1
General requirements .................................................................................. 3
2.4.2
Scope of Supply ........................................................................................... 4
SPARE PARTS STORE............................................................................................................... 9

3.1
GENERAL ......................................................................................................................... 9
3.2
RIGHT SIDE SHELVING AREA (NEXT GOODS LIFT), GROUND FLOOR.................. 9
3.3
LEFT SIDE SHELVING AREA, GROUND FLOOR....................................................... 10
3.4
SPECIAL STORE 1, GROUND FLOOR (ELECTRICAL/ELECTRONIC PARTS)....... 11
3.5
LEFT SIDE SHELVING AREA, UPPER FLOOR .......................................................... 11
3.6
RIGHT SIDE SHELVING AREA, UPPER FLOOR........................................................ 11
3.7
SPECIAL STORE 2, UPPER FLOOR (ELECTRICAL /ELECTRONIC PARTS)........... 12
MOBILE EQUIPMENT ................................................................................................................ 12

4.1
MOBILE PICK-UP CRANE ............................................................................................ 12
4.2
DIESEL FORKLIFT ........................................................................................................ 12
4.3
ELECTRICAL FORK-LIFT ............................................................................................. 13
4.4
HAND LIFT CAR FOR PALLETS.................................................................................. 14
4.5
LARGE PLATFORM CAR .............................................................................................. 14
4.6
HANDCART FOR DRUMS............................................................................................. 15
4.7
HANDCART FOR CYLINDERS..................................................................................... 15
4.8
PLATFORM TROLLEYS................................................................................................ 15
4.9
PICK-UP TRUCK............................................................................................................ 15
4.10 LOW BED TAILOR......................................................................................................... 15
4.11 HYDROLECTRIC WORK PLATFORMS (SCISSOR TYPE)......................................... 16
4.12 SWEEPING MACHINE................................................................................................... 16
LIMITS OF WORK...................................................................................................................... 16
TESTS......................................................................................................................................... 16
GUARANTEES / REJECTION................................................................................................... 16
7.1
GUARANTEES............................................................................................................... 16
7.1.1
Rejection...................................................................................................... 16
P2_22Workshop_Store_Working_Doc.doc
1
1.1
Page: 1
SERVICE REQUIREMENTS
SCOPE OF SPECIFICATION
Within the power station one I & C workshop, one mechanical workshop and one store also for
spare parts will be built.
This specification deals with the equipment to be provided for the Instrument (I & C) workshop
located in the central Control Building, the mechanical workshop and the spare parts store. The
supply of equipment for the mechanical workshop adjacent to the spare parts store is included
separately.
1.2
SYSTEM DESCRIPTION
The mechanical workshop will be used for various works related mainly to mechanical and wooden
components as well as for painting. The spare parts store will be in continuous use for handling
spare parts and consumables.
1.3
OPERATION REQUIREMENTS
The equipment to be provided for the workshops under this Part shall be used for the following:
Maintenance Works in the I & C Workshop

Various equipment removed from the power plant will be brought into the workshop. There it
will be disassembled, cleaned, checked and repaired as well as repainted, if necessary. After
reassembling, it will be checked, released and transported back to the plant.
Maintenance Work in Power Plant

For this purpose tools, instruments and equipment will be kept in the workshops, which on
request will be distributed to the power plant, where it will be used to perform the relevant
work.
Repair Work, Modifications

Instruments, damaged or worn out, have to be repaired. Not only is disassembling, cleaning
and checking associated with this work, but also marking of work to be performed. Similar
work is required for modifications.
Manufacture of Parts
Parts, damaged or worn out and no more repairable, may be replaced by those manufactured
in the workshop. Thereby such manufacture will be limited to procedures which can be
performed under prevailing circumstances and to the scope of the workshop equipment
specified in Clause 2.2, 2.3 and 2.4 of this Part.
Parts Handling in the Spare Parts Store

The equipment to be supplied for the Spare Parts Store will be used to store received material
and to support appropriate handling. The storekeeper rooms will not be equipped under this
Chapter.
Page: 2
SCOPE OF WORKS
2.1
GENERAL
Tools and equipment shall be supplied, installed and set to work under the Contract as listed
below.
The sizes and other details of the tools and other items specified shall be regarded as approximate
only and the Contractor may supply, subject to the Employers/Engineer's approval, standard
equipment most nearly representing that detailed.
It is the intention that the machine tools specified in this Chapter shall enable the station
maintenance staff to carry out all major repairs, overhaul, production of certain spare parts, testing
and inspection of the plant installed. The Contractor is therefore required to recommend any
alteration or additions necessary to enable maintenance work to be carried out in the workshop
with these tools. All additional tools or equipment recommended by the Contractor shall be quoted
separately for the consideration of the Employer as specified in Part G3.2 under Mandatory Special
Equipment and Tools.
For equipment to be installed the Contractor shall provide all foundations, wherever necessary.
The Contractor shall install this equipment. He shall carry out grouting and any other necessary
work. Prior to TOC the Contractor's specialist has to demonstrate the performance of each piece of
equipment for 2 hours' operation as far as suitable. All consumed material, if taken from contracted
supplies, shall be refilled thereafter prior to TOC as specified in Part G4.
For all equipment needing electrical power, the contractor shall provide and install all electrical
interconnections, controls, etc., including all cabling, which shall be terminated at one local power
and control board (LPCB), which he has to supply and to install and connect to the main electrical
supply system. All cables shall be placed in heavy-duty conduits, designed as per API standard
and acceptable according to relevant NFPA requirement. The Contractor shall provide all plans
and all the material for placing them prior to finishing of the floor. Special attention shall be paid to
appropriate load distribution on single phases and to step loads caused by start of welding
procedures, etc., to avoid undue voltage drop and fluctuations. The single-line diagram of the
workshop and the spare parts store after being approved by the Employer/Engineer shall be
printed on DIN A2-sheet and placed inside a wooden box with glass window, glass thickness, 4
mm. This box shall be placed on the wall inside the supervisor's office.
For all equipment which will be permanently installed and which is not mounted on a trolley, etc.,
the Contractor shall provide racks, steel boxes, etc., heavy duty cupboards, and closed storage
racks as specified, suitable for the purpose and lockable also, if not specifically mentioned in the
following and subject to approval by the Engineer.
For all consumables which the Contractor has to provide for a two-year defect liability period, he
shall provide containers, boxes, etc., and appropriate racks.
For all rooms for which the Contractor shall install or only supply equipment, he shall prepare a
detailed layout plan, subject to approval.
2.2
MECHANICAL WORKSHOP EQUIPMENT
Quantity
Description
Sufficient
nos.
Work benches with standard vices.
1 no.
Standard pedestal grinder and tool grinder
2 nos.
table mounted drilling machines
3 nos.
Electric welding machines
2 nos.
Inert gas (Tig) welding machines
1 no.
Electrode oven to store electrodes
3 nos.
Oxyacetylene sets
1 set
Water jet cleaner
1 set
Mobile steam cleaner
2 sets
Portable petroleum baths
5 sets
240/12V lighting transformer with hand lamps
Page: 3
Adequate storage racks for tools and consumables will be required in the tool room at work shop.
2.3
ELECTRICAL WORKSHOP
No delivery of equipment for the electrical workshop shall be considered under the scope of this
Part.
(Some equipment to be used by the Electrical maintenance will be delivered as loose item as
specified in Part G3.2 under Mandatory Special Equipment and Tools.)
2.4
INSTRUMENTATION AND CONTROL WORKSHOP
2.4.1 General requirements

I&C Workshop necessary to perform all required tasks to maintain, repair and test properly
instrumentation and control equipment of the whole plant and ancillaries shall be supplied.
The workshop equipment shall be of a standard sturdy and well-known design and manufacture,
and subject to the Employer/Engineer's approval.
The Contractor shall also be responsible for the arrangement, installation of instrument workshop
equipment, on-site connection and distribution of auxiliary power supplies, including air distribution
system, compressed air utility connections, proper earthing etc.
In case Contractor finds the specified equipment performance data inappropriate for the given
service, he shall provide the equipment of the appropriate performance.
All portable equipment shall be supplied with carrying case, exchangeable batteries and charger
from the equipment manufacturer (if available).
2 (two) sets of new rechargeable batteries shall be delivered for each portable equipment.
The handing over of I&C workshop equipment shall be done in one lot and accompanied by
function check and demonstration of operation and all functions done by the Contractor in
presence of Employer/Engineer. Equipment failed shall be returned to the Contractor for further
action and repeated handing over.
For all equipment 2-year guarantee shall be performed.
For the whole Workshop installation erection check is required.
Page: 4
The necessary operational manuals are to be delivered in English language in one original and
one copy compiled in hardcover files. All labels and inscriptions on the I&C Workshop items are to
be in English language.
2.4.2 Scope of Supply

All items shall be delivered in addition to any other tools/ maintenance equipment, etc., specified
elsewhere. All equipment shall be complete in every respect with cases edge protectors, cable kits,
chargers, batteries, spare fuses and other accessories as available from manufacturer. Lithium
batteries or better shall be considered, if recommended by the manufacturer.
2.4.2.1 Workbenches
2.4.2.1.1 Regular Workbenches
The regular workbenches shall be of heavy-duty quality with dimensions of approx. 1.8x0.8x0.8 m
with console for sockets. Each workbench shall be equipped with a row of 3 sockets for the power
source of 220 AC. The workbenches will be equipped with drawers.
Four (4) workbenches shall be provided.
2.4.2.1.2 Instrument Workbench

Instrument workbench with a vertical top section for the installation of the instruments listed below
shall be provided. The dimensions of the instrument workbenches shall be at least as specified for
the regular workbenches and shall be suitable for a logical distribution of instruments on the
vertical section and for the loose distribution of test instruments and tested devices on the
horizontal surface.
The instrument board console shall be composed of sheet steel with a minimum thickness of 2.5
mm and shall be totally closed.
Connections to the installed instruments shall be fixed at the front of the instrument board for
prompt access. Earthing arrangement for the Workbench and for measurements shall be provided.
The following equipment shall be integrated into the vertical section of the workbenches:
Quantity
Description
2 pcs
DC power supply laboratory-type unit with controlled and adjustable current and
voltage output 0 - 50 V, 0 - 25 A
1 pc
DC power supply unit with adjustable and controlled voltage output: 220 V,
approximately 1 kW
1 pc
AC power supply unit with adjustable current and voltage output: for 0 - 240 V, 0 10 A
1 set
Stabilised power supply unit 231V DC/1500 VA, ferroresonant type or similar static
type with sinusoidal waveform, the voltage adjustable between 5%.
2 sets
1 set
24 V DC relays with 2 sets of switch-over contacts with front banana sockets for
the supply and for contacts
Timer relay(s) with front banana sockets for contacts and with front adjusting knob
(s). The time shall be adjustable between:
0.5 sec. - 30 sec.
10 sec. - 5 min
1 min. - 1 hr
Quantity
Page: 5
Description
4 pcs
Power supply sockets for normal AC
4 pcs
Power supply sockets for stabilised AC
Two (2) instrument workbenches shall be provided.
2.4.2.1.3 Pneumatic Workbenches

Pneumatic workbench with a vertical top section for the installation of the devices as listed below
shall be provided. The dimensions of the workbenches shall be at least as specified for the regular
workbenches and shall be suitable for a logical distribution of devices on the vertical section and
for the loose distribution of test instruments and tested devices on the horizontal surface.
The instrument board console shall be composed of sheet steel with a minimum thickness of 2.5
mm and shall be totally closed.
Connections to the installed instruments shall be fixed at the front of the instrument board for
prompt access. Earthing arrangement for the Workbench and for measurements shall be provided.
The following equipment shall be integrated into the vertical section of the workbenches:
Quantity
Description
2 sets
Instrument air filter and regulator for flush-mounting with pressure adjusting knobs,
precision pressure gauge, diameter 160 mm, range 0 - 1.6 bar, accuracy +- 0.3%, and
front air connections
2 pcs
Precision regulating valves with fine adjustment for control air supply with front air
connections
2 sets
Three-way valves for control air with front air connections
1 set
Flush-mounted precision pressure gauges, diameter 160 mm, accuracy 0.3%,

ranges 0 - 1.6 bar, 0 - 2.6 bar, 1 - 60.0 bar,1 - 250.0 bar with front air connections
Flexible pneumatic and hydraulic pipes/hoses with appropriate end connections for
necessary interconnecting of items
Power supply sockets
25 pcs
4 pcs
Two (2) pneumatic workbenches shall be provided.
2.4.2.2 Loose Instruments

Quantity
2 pc
Description
Digital hand held multimeters for AC/DC, frequency, ohms, diode tests, etc., 4 -
digit, wide bandwidth with auto-ranging. Similar to Fluke 87 III. (To be used for
calibration purposes)
Page: 6
Quantity
Description
DC Ranges
0 - 1000 V
0 4000 A
0 - 10 A
AC Ranges
0.1 % + 1 digit
1.0 % + 2 digits
0.2 % + 2 digits
lowest range 400 mV

lowest range 400 A
lowest range 40 mA
0 - 1000 V
0 - 10 A
0 - 20 kHz
Capacity
1.0 % + 2 digits at 50 Hz
1.0 % + 2 digits
0.005 % + 1 digit
lowest range 400 mV

lowest range 40 mA
lowest range 200 Hz
0 - 5 F
Resistance
1 % + 3 digits
lowest range
5 nF
5 pcs
0 - 40 Mohm 0.2 % + 1 digit

lowest range 400
Digital hand-held multimeters, 3-1/2 digit display, for DC/AC voltage and current
measurements, resistance, capacitance and frequenc y measurements, continuity
checking, etc. with temperature probe
1 pc
Frequency meter/timer/counter, 8 digit display for

frequency 0 - 100 MHz
period 10 us - 105 s
ratio 0.1 Hz-100 Hz
1 pc
Pulse/function generator, range 1 Hz to 20 MHz with digital display
1 pc
Multifrequency LCR meter, resolution 5 1/2 digit, 0.1% basic accuracy, with
autoranging
1 set
Set of precision resistance decades, 10 boxes, covering ranges from 0.1 ohm to
10 kohm
1pc
Portable pneumatic line recorder of standard chart size, 2 channel with variable speed
setting 20 - 220 mm/h, accuracy 1.0%, range 0.2 - 1.0 bar, suitable for 220 V AC
power supply
1 pc
Portable 4 line recorder with variable speed setting 20 - 220 mm/h, accuracy 0.5%,
with switchable input ranges 0 - 20 mA, 0 - 10 V, 0 - 10 mV, 0 - 50 mV
Portable 6 points recorder with at least 3 speeds, chart width 200 mm, suitable for
0/4 -20 mA, 5 voltages ranges for DC.
1 pc
1 pc
Double channel digital storage oscilloscope, minimum bandwidth 0-100 MHz

(-3 dB), 2 channels with memory for 4 waves, with RS 232 (or similar) interface, cable
and user program for PC with one set of measuring heads
2 pcs
Hand-held Graphical Display Meter (DSO-meter) with big size display for waveform
representation (industrial frequencies). Further features:
Storage capacity for at least 8 curves
Max. sampling rate at least 20 MS/s
Band with 100 kHz
Horizontal time base from 5 s/div, auto trigger
128 x 128 Matrix LCD at least
RS 232 (or similar) interface, cable and user program for PC
Additional DMM operation (Digital MultiMeter)
Quantity
Page: 7
Description
2 pcs
Clip-on Ammeter
2 sets
Relay tester
2 sets
Variable transformer (variac), single phase, 231 V +10%/1000 VA
1 pc
Variable transformer (variac), three phase, 400V + 10%/5000 VA
2 pcs
DC power supply laboratory-type unit with controlled and adjustable current and
voltage output 0 - 50 V, 0 - 25 A
1 pc
Synchronoscope
2 pcs
231 V AC Extension cables with multiple sockets and switch
5 pcs
Measuring cables of different lengths and colour, complete with banana plugs
50 pcs
Single and multiple (for IC's) cable clips hook and pin types, banana plugs, etc., as
required
1 set
Thermocouple/RTD simulation equipment (mV, ohm) for different types of

thermocouples and RTD's
5 pcs
Direct temperature indicating meter suitable for direct measurement of different types
of thermocouples and resistance thermometers with additional hand-held
thermoprobes for temperature measurements from -20 to + 600 deg C
5 pcs
Temperature baths with cooling coil with control for medium and high temperature
testing
1 set
Current and voltage sources 0 - 20 mA/0 - 10V, accuracy 0.3%
5 pcs
Soldering iron sets with 220 V AC power supply, galvanic separation, temperature
stabilised tips sets, holders, etc. for each workbench
5 sets
Stationary solder remover with vacuum pump, pipes, tips, etc. for each workbench
2 set
Precision pressure gauges, accuracy 0.6%, in portable boxes, pressure ranges in bar 1 - 0, -1 - 10, 0 - 1, 0 - 1.6, - 4, 0 - 10, 0 - 16, 0 - 25, 0 - 40, 0 - 60, 0 - 100, 0 - 160
1 set
Manometers suitable for very low and low pressure measurements
1 set
Portable pressure source for low pressure and vacuum (pneumatic measuring box)
2 set
Calibration pressure pump 0-20 bar
1 pc
Deadweight testers covering the ranges used in the Plant, at least one for 1 to 50 bar
and one for 20 to 250 bar.
1 set
pH tester
1 set
BACHARACH combustion testing kit, comprising CO2 indicator 20 %, smoke test

pump, digital thermometer, CO2 indicator 10 %, CO detector, inclined manometer
etc.
1 set
Portable gas detector with test gas bottle
1 set
Anemometer
Page: 8
Quantity
Description
1 pc
Portable sound level (dBA) meter
1 set
Barometer
1 pc
Vernier caliper, 250 mm
2 pcs
Micrometers, 25 mm
2 pcs
Stop watch
2 pcs
Torches complete with batteries
5 pcs
Speedometer (RPM), optical/digital
1 pc
Megger insulation tester
2 pc
Circuit continuity testers with buzzers and light indication
5 pcs
Sets of standard instrument technician tools in appropriate cases/bags comprising

screw drivers, spanners, players, voltage testers, cable isolating tools and other
electrician and instrument fitter tools
5 sets
Thermochrome-chalks for measuring of temperature of metallic surface, range 65 670 0C, consisting of 18 chalks for different temperatures.
2 sets
Lighting/ reflecting mirror tool
1 set
Bench drilling machine, min. up to 12 mm drill diameter, with 3 sets of drill bits,
mounted on one of the regular workbenches
1 set
Portable drilling machine, min. up to 10 mm drill diameter, with 3 sets of drill bits
2 sets
Mini drilling machine set with set of bits for precision works
1 set
Coil winding machine for winding wires up to 1.5 mm diameter wit accessories
2 set
Watchmaker lathe, medium size with complete set of tools and accessories
2 sets
Watchmaker tools, ploughs, forceps, etc.
1 set
Standard rotatable vice, heavy duty, mounted on each of the regular workbenches
one for each

workbench
Storage metal cabinets for electronic equipment with shelves, shelters, boxes, etc. min.
dimensions (W x D x H) 0.8 x 1.8 x 0.6 m
3 pcs
Whiteboard (wall fixed) with 3 sets of pens in different colours and eraser
one for each

workbench
Heavy duty chairs for the workbenches
one for each

workbench
Light sources/ lamps adapted to the workbenches
2 sets
Vacuum cleaners, industrial type
3
3.1
Page: 9
SPARE PARTS STORE

GENERAL
The purpose of this store is to accept packed and unpacked spare parts and consumables.
Unpacked parts are understood to be airtight sealed, avoiding corrosion under prevailing weather
conditions.
The following specified equipment is related and limited to the shelving areas in the Spare Parts
Store only. The Contractor shall provide a complete lay out and all static calculations. The systems
to be provided shall be of the build-up type using slotted supports, open steel planks, parts with
perforated sections etc of pre-galvanised cold-milled mild steel with standard galvanised finishing
except where otherwise stated. BS-standard 4358 or equivalent standard shall be applied. All
products shall comply with SEMA Storage and Materials Manufacturers Association, UK; or the
Rack Manufacturer's Association, USA; or German RAL-RG 613/614, Quality Requirements;
having the Agreement Certificate and the GS-Certificate. A roster-type system shall be used with
bolting only. All rack systems shall have safety railing/support systems for accepting, holding and
fixing ladders and minimum height 3m.
All the load capacity of the racks and machinery shall be marked by printing/engraving.
3.2
RIGHT SIDE SHELVING AREA (NEXT GOODS LIFT), GROUND FLOOR
This area shall be used for storing heavy parts and long parts like pipes. The installation shall
consist of all steel type pallet racking and "long pieces" racking.
The pallet racking shall be designed for accepting standard UIC 435-2 pallets, dimensions
800x1200mm, loading capacity 2000 kg/m. Always four (4) pallets shall be placed vertically above
each other. Accordingly one pallet is placed at the ground floor with sufficient gap between the
floor and pallet for floor working and cleaning and the other three on three levels of racks, distance
between each rack one (1) meter. Wire mash shall be arranges towards the wall and the sides of
the panel shall be covered. Column guards shall be provided.
Horizontally the above-described pallets shall be arranged in rows. This arrangement of pallets
shall be placed either on walls or against each other forming double lines facing with the rear sides
to each other.
Each pallet shall be placed into the rack by forklift so that a depth of approx. 1.25 meters and a
width of approx. 0.9 meters are used up. Accordingly the racks shall be equipped with suitable
pallet support boxes and inside column protective guards.
Between double-line rakings and in front of wall-located racks a travelling space for the forklift of
2.5 meters shall be arranged. In front of double rows a travelling space of 3 meters shall be
considered.
All individual racking systems standing at walls or in double lining shall have every one (1) or every
two (2) meters, one vertical support with diagonal bracing, the number depending on the
acceptable ground floor loading. At each end and after each six (6) horizontally located pallets one
support shall be extended to a height of four (4) meters. This is also true for all vertical supports at
the end of each rack. Furthermore each rack shall have in longitudinal and horizontal direction a
sufficient stiffness, to accept horizontal forces equal to 0.01 g acceleration of the completely loaded
rack in all directions, thereby allowing between rack and adjacent wall still a clearance of 50 mm.
Racks located at walls shall be located at a distance of 0.1 m form the walls and shall have a rear
wall system consisting of a 0.4 m high strong support which limits the pallet to be placed on the
relevant place. Above this support a heavy-duty wire mesh shall be arranged to close the pallet
area toward the wall. This is true for the ground level, including all levels except for the most upper
Page: 10
level, where only the support is required. This complete arrangement shall also be provided for one
line of a double-line system.
All individual racking systems shall have two (2) steel type marking signboards, size 120x100 mm,
complete with clipping device and painted, ready to accept a numbering system. Also they have on
all sides, which extend into access ways heavy-duty spring-loaded column guards, size
250x250x310 mm, painted in strips yellow/black.
Except as otherwise stated all racking shall be of galvanised steel structures complete with all
standard equipment and mounted and assembled as to final layout plan. All horizontal beams shall
be sufficiently stiff with box type cross sections, minimum size 50.8x115 mm.
The complete rack system shall be of the bolted type arrangement, whereby welding is not
permitted, with possibility to select at time of installation or at a later date a different height for the
first and second floor racking, but the uppermost one shall be considered due to its elevation of 3
meters as firm, because the relevant fork-lifts are specified accordingly.
The racking for long pieces shall have six (6) levels, being double-sided, complete with horizontal
and vertical diagonal bracing, etc. The lowest level supports shall be used as footing. All other
outriggers shall have an individual bearing capacity of min. 450 kg weight. The height of the upper
most outrigger shall be not less than 2.2 meters. Supports shall be placed at a distance of 1.5
meters. For design, materials, supplementary equipment etc., the same shall apply as for the
above-specified racking systems for pallets.
The supply for this room shall be as above specified, including:
single-line pallet rackings,
double-line pallet racking systems
One (1) long piece racking, double sided, having a length of min. ten (10) meters,
complete set of pallets filling up all spaces in the above mentioned racks, type UIC-435-2,
four-way type, 800x1200 mm, design accepted by international pallet pool,
One (1) ladder, aluminium type for inspection with width 0.4 meter and safety hook system
suitable to be used with safety racking/support system,
One (1) set of minimum ten (10) warning indication labels assembled on galvanised steel
plates, size min. 400x600 mm including "No Smoking," "Fire Hazard" and direction to
emergency escape.
3.3
LEFT SIDE SHELVING AREA, GROUND FLOOR
The specification as per Clause 3.2 applies, except that the long piece racking is deleted and that
the following supply, one (1) complete packing/unpacking system shall be provided consisting of:
One (1) table, size 850 x 1,500 x 750 mm, with steel support structure and 50 mm thick table
plate out of laminated wood.
Packing equipment consisting of one or more separate board/rack systems, housing and
completely equipped with:
Two (2) electronic pulse producers, type polyester 100 GE
One (1) welding tongs, type polyester 40 D
One (1) welding tongs, type 24 DS
One (1) welding tongs, type polyester 15 D
One (1) continuous welding tools, type polyester 350 SM
Polyethylene - tube foil, colourless, transparent, consisting of:
Two (2) vacuum cleaners, heavy-duty industrial type.
3.4
Page: 11
SPECIAL STORE 1, GROUND FLOOR (ELECTRICAL/ELECTRONIC PARTS)
Clause 3.2 shall apply, except that the racks shall have 8 levels and the steel-type base plates
shall have a size of 457x990 mm and a bearing capacity of min. 200 kg. Each sixth base plate
shall be equipped with two (2) vertical separating walls, 0.2m height. Each fourth base plate shall
be equipped with 4 polypropylene-type material boxes 3400 x 215 x 200 mm, each box having one
colour, i.e. yellow, blue, red or black.
The supplies shall include:
Two (2) ladder type trolley of standard size of 6 x 12 m
single-line racking system as specified above to be located next all walls with steel-type base
plates and related equipment.
One (1) ladder
One (1) set warning labels as per Clause 3.2
One (1) table, size 850x1500x750mm, with steel support structure and 50 mm thick table plate
out of laminated wood.
3.5
LEFT SIDE SHELVING AREA, UPPER FLOOR
This room shall be used to store boxes filled with spare parts and unpacked parts.
The installation shall consist of all-steel type, all base-plate equipped racking systems and vertical
holding systems.
The racking system shall have a total height of three (3) meters and six levels, containing steeltype base plates, each base plate having min. dimensions of 650 mm depth and 990 mm length,
and loading capacity of min. 650 kg. The vertical structures at the end of each system shall be
closed by steel panels and colour painted, colour subject to selection by the Employer. For all other
requirements, those of Clause 3.2 shall also apply here.
One (1) vertical free-standing holding system shall consist of six single-sided free-standing vertical
holding platforms, approx. 927 x 445 x 2057 mm, complete steel type, slotted with an assorted set
of 60 hooks, two (2) racks 457 x 120 x 50 mm and six boxes, 65 mm height. This system shall be
located with it's backside facing the filter storage area.
One (1) complete packing/unpacking system same as specified in Clause 3.3
For the filter storage area only warning labels as above specified in Clause 3.2 are to be supplied.
3.6
RIGHT SIDE SHELVING AREA, UPPER FLOOR
The installation shall consist of all-steel type, all base-plate equipped racking systems and vertical
holding systems as specified in Clause 3.5.
The supplies shall include:
Page: 12
single-line racking system to be located next walls with steel-type base plates as per Clause
3.5.
double-line racking systems with steel-type base plates as per Clause 3.5.
One (1) ladder
One (1) set warning labels
One (1) vacuum cleaner, heavy-duty industrial type
3.7
SPECIAL STORE 2, UPPER FLOOR (ELECTRICAL/ELECTRONIC PARTS)
The installation shall be the same as specified in Clause 3.4.
MOBILE EQUIPMENT
The manufacturers of all the mobile equipment shall well reputed, of a popular brand and shall
have a local agency in U.A.E..
4.1
MOBILE PICK-UP CRANE
One mobile Pick-up crane shall be supplied.

The capacity for a radius of 6 m shall be 4.5 tons and for 10m, 2 tons.
The total length of the crane shall not exceed 10.5m.
Characteristics:
Four (4) pneumatic wheels
Water-cooled 6-cylinder, 4-stroke engine
Hydraulic telescopic boom, two sections movable
Hydrostatic power steering
Servo assistance brakes
Full-flow hydraulic filter
Adjustable seat
Sun-protection roof
3600 continuous swing
Safety devices, such as hoist and load-lowering limit switches, overload cut-out, locking
valves, etc.
Working speed infinitely variable
4.2
DIESEL FORKLIFT
Number Specified:
two (2)
Technical data:
Design
As per DIN 15 138 T1/T2
Page: 13
Capacity (ton)
1.6 and 3.0
rated lift height (mm)
3000
Lifting speed under load (m/s)
0.46
travelling speed under load (m/s)
Fork size, min. (mm) approx.
1000 x 1000
Tilt forward (deg)
Tires
4/pneumatic
Forks spacing, min/max (mm)
as per manufacturers standard
Coupling for platform cars
provided
Characteristics:
Stability as per DIN 15138 T1/T2
Water-cooled 4 cylinder diesel engine, min. output 25 kW with 250 hour service interval
Completely automatic transmission with hydrodynamic torque converter
Load guard with sum protection
Adjustable seat
Hydrostatic power steering
Full flow hydraulic filter
Dual-element air cleaner
Solid state instruments, including counter for operating time and locking device
Forks to allow handling of pallets, pool-type, as per UIC-435-2
4.3
ELECTRICAL FORK-LIFT
Number specified:
One (1)
Technical Data:
Capacity (ton)
Rated lift height (mm)
3000
Lifting speed under load (m/s)
0.3
Travelling speed under load (m/s)
Fork size (mm) approx.
1000 x 1000
Tires
4/solid, material
Size, electrical motor (kW) min.
Voltage (V), min
24
Battery capacity, type PZS, capacity (Ah) min.
200
Page: 14
Battery charger installed
Yes
Battery controller installed
Yes
Characteristics:
Stability as per DIN 15160 T1/T2
Electric motor capable of operating continuously:
for one (1) hour
Electro hydraulic lifting and moving
yes
Electronic impulse control, allowing jerk-free

lifting, moving, acceleration and braking
Solid state instruments, including counter for

operating time and locking device
4.4
yes
yes
Forks for the 1.6 ton fork-lift shall allow handling

of pallets, pool-type as per UIC-435-2
yes
Coupling for platform cars shall be included
yes
HAND LIFT CAR FOR PALLETS
Number specified:
Two (2)
Technical Data (for all numbers):
Capacity (ton)
1.6
Wheels, number/material
4/nylon
Lifting, lowering
Hydraulic, hand operated
Lifting arrangement
For pallets, pool type as per UIC-435-2
Lifting height of pallet

bottom (mm) approx.
100
Steering, moving
Manual
Colour
Yellow
4.5
LARGE PLATFORM CAR
Number specified:
One (1)
Capacity (ton)
0.3
Size of platform (mm)
1000x700
Wheels size (mm) min.
180
Two wheels on swivel joints
Yes
Operation
Manual
Page: 15
Platform
Laminated wood 25 mm covered with

suitable protective layer
Vertical safety board
At one side; board material pushing

level same as platform
Frame
Steel pipe
Painting
Grey
4.6
HANDCART FOR DRUMS
Number specified:
Two (2)
Capacity (ton)
Wheels, solid rubber,

no./size (mm)
4.7
0.25
2/250
HANDCART FOR CYLINDERS
Number specified:
Two (2)
Technical Data:
4.8
Capacity (ton)
0.25
PLATFORM TROLLEYS
Number specified:
Two (2)
Technical Data:
Capacity (ton)
2 for one trolley
Capacity (ton)
3 for one trolley
4.9
PICK-UP TRUCK
Number specified:
One (1)
Net loading capacity (ton)
0.5
Engine
Diesel
Loading area
Open with reinforced loading area
4.10 LOW BED TAILOR

Number specified:
Two (2)
Net loading capacity (ton)
10
Size of platform
6 x 10
Page: 16
Optional: for GT / ST
Number specified:
One (1)
4.11 HYDROLECTRIC WORK PLATFORMS (SCISSOR TYPE)

Number specified:
Two (2)
4.12 SWEEPING MACHINE

Number specified:
One (1)
LIMITS OF WORK
All work related to the workshop is limited to installations in the workshop, to the supplies as
particularly specified here and generally required as per this Part, demonstration of the guaranteed
performance and performance of relevant guarantees. Regarding the Spare Parts Store, the same
is true, except that the installations are limited to the storing areas. The mobile equipment shall,
after checking of adherence to specification and testing, be handed over the Employer/Engineer.
TESTS
7
7.1
GUARANTEES / REJECTION
GUARANTEES
The Contractor guarantees the suitability of equipment for the intended use as well as the
characteristics and data with zero deviation as required by the applicable codes and/or standards
and as stated in the specification except as stated in the list of deviations.
7.1.1 Rejection
If the Contractor fails to demonstrate the guaranteed operating ranges and capacities, the itemised
contract price for the equipment in question shall be reduced by two percent (2%) for each percentreduced operating range and capacity.
If the Contractor fails to demonstrate at least ninety percent (90%) of the guaranteed operating
range and capacity of one particular piece of equipment, although he was granted reasonable time
for corrections, which time shall not exceed thirty (30) days, this equipment shall be rejected.
CNE/015/2002
P2.23
Station Fire Fighting and Fire Detection Systems
WORKING DOCUMENT
Part P2.23 Station Fire Fighting and Fire Detection Systems Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
PAGE
GENERAL ..................................................................................................................................... 1
SCOPE OF WORKS..................................................................................................................... 1
2.1
CONSTRUCTION REQUIREMENTS............................................................................... 5
2.1.1
General .......................................................................................................... 5
2.1.2
Fire Zones...................................................................................................... 5
2.1.3
Stairs and Escape Routes........................................................................... 6
2.2
FIRE FIGHTING PUMP INSTALLATIONS...................................................................... 6

2.2.1
Fire Fighting Pumps..................................................................................... 6
2.2.2
Seawater Fire Fighting Pump...................................................................... 7
2.3
OUTSIDE PROTECTION.................................................................................................. 8
2.3.1
Underground Fire Service Main.................................................................. 8
2.3.2
Outdoor Hydrants......................................................................................... 9
2.3.3
Hose Cabinets for Outdoor Hydrants ........................................................ 9
2.4
STANDPIPE AND HOSE SYSTEMS............................................................................... 9

2.4.1
Indoor Hydrants.......................................................................................... 10
2.5
SPRINKLER SYSTEMS................................................................................................. 10
2.6
WATER SPRAY FIXED SYSTEMS............................................................................... 10
2.7
FOAM-WATER SPRAY SYSTEMS............................................................................... 11
2.8
FIXED LOW EXPANSION FOAM SYSTEMS................................................................ 11
2.9
TANK SHELL COOLING SYSTEMS............................................................................. 12
2.10
FIRE AND GAS DETECTION AND ALARM SYSTEM ................................................. 12

2.10.1
Fire and Gas Alarm Panels (FGAP) .......................................................... 14
2.10.2
Manual Fire Alarm Stations ....................................................................... 15
2.10.3
Automatic Fire and Gas Detectors........................................................... 15
2.10.4
Audible Alarms ........................................................................................... 16
2.10.5
Visible Alarms ............................................................................................. 16
2.10.6
Manual Release Push Buttons.................................................................. 16
2.10.7
Cabling......................................................................................................... 16
2.11
FIRE EXTINGUISHERS.................................................................................................. 17
2.11.1
Mobile Fire Extinguishers ......................................................................... 17
2.11.2
Portable Fire Extinguishers...................................................................... 17
2.11.3
Fire Blankets............................................................................................... 17
CO2 SYSTEMS............................................................................................................................ 17
HUMAN SAFE INERT GAS SYSTEMS..................................................................................... 18
P2_23FF_Fire_Detection_Working_Doc.doc
Page: 1
GENERAL
This specification covers all fire fighting installations, supplement by a fire and gas detection and
alarm system, complete in every respect and suitable for satisfactory operation to offer protection
for all installations of this L Station Phase I where needed.
SCOPE OF WORKS
The scope of supply comprises design, manufacturing, testing, delivery, erection and
commissioning as well as all required documentation for the equipment as specified and
additionally such equipment as is deemed necessary for safe and reliable operation of the different
systems.
Fire fighting water shall be taken from the potable water reservoir, in which a minimum of 1,500m
water shall be available at any time for fire fighting purposes only to cover the demand of water
required for fighting the maximum risk for a duration of hundred and twenty (120) minutes. After
this period and in emergency cases, seawater shall be taken from the sea water intake structure .
The fire fighting pumps shall be sized to cover the water demand for fighting the maximum risk of
the power plant, determined by foaming the tank inside of one (1) fuel oil storage tank on fire, plus
parallel operation of the tank shell cooling systems for the tank on fire (roof and tank shell) and the
adjacent tanks (half tank shells), plus parallel operation of yard hydrants, as required by the
relevant NFPA codes and standards.
One (1) electric motor driven fire fighting pump and one (1) diesel engine driven standby fire
fighting pump, each pump with a capacity of approx. 600 m/h at approx. 10 bar shall take suction
from all compartments of the potable water reservoir and supply fire fighting water into a fire
service main. This fire service main shall be laid in underground, made of polyethylene PE 100 and
designed as a ring system to supply fire fighting water to outdoor hydrants, indoor hose stations,
sprinkler systems, water spray fixed systems, foam systems and tank shell cooling systems.
For emergency cases and as backup system one (1) electric motor driven seawater fire fighting
pump and one (1) diesel engine driven standby seawater fire fighting pump, each pump with a
capacity of approx. 600 m/h at approx. 10 bar shall take suction from the sea water intake
structure. Package P contractor shall supply all equipment related to fire fighting pumps and input
data for the civil works to the Contractor of Package D. Pumps could be installed at one of the
pump bays of Package D, e.g. Closed Cooling Water and Chlorination System Pumps (No
additional stop logs should be required).
Under normal stand-by conditions, the fire service main, the hydrants, the hose stations and the
fire fighting systems shall be pressurised by a water/air pressure vessel, charged by two (2) air
compressors.
Two (2) x 100% electric jockey pumps shall be provided with a duty standby selection facility in
order to make up leakages and cover the demand for one (1) indoor hydrant without the need to
start the fire fighting pumps for such a small consumption.
All fire fighting and detection equipment are subject to approval by the Civil Defence Authority.
All water based extinguishing systems shall be connected for drainage to the plant drainage
system.
The systems shall be complete and functional in every respect, mentioned or not in this
specification.
The scope of equipment shall mainly consist but shall not be limited to the following:
Fire fighting pumps
Page: 2
Seawater fire fighting pumps
Underground fire service main
Hydrants and hose cabinets
Standpipes and hose systems
Sprinkler systems
Water spray fixed systems
Foam-water spray systems
Fixed low expansion foam systems
Tank shell cooling systems
CO2 systems
Human safe inert gas systems
Fire and gas detection and alarm system
Mobile and portable fire extinguishers
Installation material like supports, hangers, sleeves, clamps, gaskets, seals, bulk heads, fire
stops, electrical cables etc. for the complete fire protection system
Spare parts and special tools
The fire fighting installations and detection systems to be installed are indicated in the following
table:
SURVEY OF FIRE PROTECTION SYSTEMS TO BE INSTALLED
The fire fighting installations and fire detection system to be provided are indicated in the following
table as a minimum. The Contractor shall however, include any areas / items not listed in the table
in order to cover the entire Power Plant (all packages) for the Engineers / Employers approval.
BUILDING/AREA/
EQUIPMENT T O
BE PROTECTED
FIRE FIGHTING
INSTALLATIONS
DETECTION SYSTEMS
Steam Turbine Building
Water indoor hydrants
Smoke detectors. Automatic fire

alarm system and manual fire
alarm stations.
Gas Turbine and Steam

Turbine Lube Oil tanks and
system and Hydraulic oil tank
and systems.
Automatic foam/water spray

fixed system
Linear heat detectors and UV/IR

flame detectors. Automatic fire
alarm system
Generators
Automatic water spray fixed

system for generators
Steam Turbine / Generator

bearings

system
Linear heat detectors. Automatic

fire alarm system.
Gas Turbine Building
Water Indoor hydrants

alarm stations
Page: 3
BUILDING/AREA/
EQUIPMENT T O
BE PROTECTED
FIRE FIGHTING
INSTALLATIONS
DETECTION SYSTEMS
Gas Turbine Units
Automatic fixed total flooding

system using CO2.
Linear heat detectors. UV/IR

flame detectors, gas detectors.
Automatic fire & gas alarm
system.
Fuel Oil and Fuel Gas Skid

and power control centres
(PPCs)
Fuel oil storage tanks
Low expansion foam systems Linear heat detectors Inside the

into the tanks and automatic
tanks Automatic fire alarm
water spray fixed system for
system.
tank shell cooling.
Fuel oil pump house
Automatic foam/water spray

fixed system
Gas receiving station, gas

Explosion proof design and
compressors and gas storage equipment. Portable
extinguishers.
Smoke detectors, UV/IR flame

detectors. Automatic fire alarm
system and manual fire alarm
stations
Ex-proof smoke and gas
detectors and Ex-proof manual
fire alarm stations. Automatic fire
& gas alarm system.
Seawater pump area
Hydrants. Mobile 30 kg CO2 Smoke detectors. Automatic fire

extinguishers and portable
alarm stations
5 kg CO2 extinguishers for the
switchgears.
Potable water pump station
Hydrants

alarm stations
Fire fighting pump houses
Automatic sprinkler system
Smoke detectors, linear heat

stations
Chlorination Building
Manual water spray system

and indoor hydrants
Smoke detectors, Linear heat

stations
Chemical Stores

system and indoor hydrants.
Smoke detectors Linear heat

stations
Demineralisation Plant
Indoor hydrants
Smoke detectors Automatic fire

alarm stations
Workshops, Stores,
Laboratories, etc.
Automatic sprinkler systems

and indoor hydrants
Smoke detectors, linear heat

stations
Page: 4
BUILDING/AREA/
EQUIPMENT T O
BE PROTECTED
FIRE FIGHTING
INSTALLATIONS
DETECTION SYSTEMS
Administration Building
Building fully sprinklered and

indoor hydrants

alarm stations
Central Control Building and

its Switchgear Building
Indoor hydrants for the control Smoke detectors Automatic fire

room, automatic water spray alarm system and manual fire
fixed system for the cable
alarm stations
basement and fixed total
flooding human safe inert gas
system for the switchgears
400 kV Switchgear Building

All Oil Filled Transformers as
well as Dry Type
Transformers
Mobile 30 kg CO2
5 kg CO2 -extinguishers.

alarm stations

systems
Sprinkler head heat detectors.

Automatic fire alarm system.
Emergency Black Start Diesel Automatic foam/water spray

UV/IR detectors, smoke
Generators
fixed system and mobile 50 kg detectors, Automatic fire alarm
dry-powder extinguisher
stations
Local Control, Computer,
Electronic And Switchgear
Rooms
Mobile 30 kg CO2
5 kg CO2

alarm system.
Extinguishers
Cable Floors, Shafts and
Tunnels

systems
Smoke detectors for ventilated

cable floors and tunnels. Linear
heat detectors for non-ventilated
cable floors and tunnels.
Automatic fire alarm system.
Ventilation Systems
Automatic sprinkler system
Duct smoke detectors. Automatic

fire alarm system
All other Buildings and Areas

including Desalination Plant
and Blending Plant Area
Outdoor hydrants and hose

cabinets
Manual fire alarm stations
HRSG and SFB

systems
UV/IR detectors, gas detectors,

Automatic fire alarm system and
manual fire alarm stations
Auxiliary Boilers

systems
UV/IR detectors, gas detectors,

Automatic fire alarm system and
manual fire alarm stations
2.1
Page: 5
CONSTRUCTION REQUIREMENTS
2.1.1 General
Generally, the design, installation and tests shall be accomplished in accordance with the latest
state of art in the field of fire protection, fire and gas detection and alarm system engineering and
shall comply with the NFPA-Codes and Standards or with the DIN, VDE and VdS Forms and
Standards as well as all relevant local rules and regulations. .
The equipment/material to be supplied for the fire fighting, detection and alarm installations shall
be approved by one of the following authorities:
Civil Defence Authority of Dubai, CDA
Factory Mutual, FM
Underwriter's Laboratory, UL.
Verband der Schadenversicherer, VdS
Each major component of protective fire fighting equipment shall be marked in the local language
and in English in accordance with NFPA recommendations. Each and every valve in every system
shall be identified with a metal tag, bearing a white enamelled number on a red field, secured to
the valve wheel or body. All details of this requirement shall be subject to prior approval.
The fire fighting installations must, in any case, be ready for operation before commissioning the
turbine/generator units.
The design of buildings, civil constructions and all fire protection installations shall also confirm to
local regulations, latest edition and amendments, and are subject to acceptance by the local
authority having jurisdiction.
2.1.2 Fire Zones

The entire Power Plant (covering all packages) shall be sub-divided into various fire zones as
applicable and shall submit the documents for the Engineers / Employers approval. Each building
shall be subdivided and separated by fire resistant walls/ceilings/doors providing a fire resistance
for a minimum of ninety (90) minutes.
The following areas shall form an independent fire zone:
Each floor, except for stairways and elevator shafts
Each staircase, which is defined as emergency exit and escape route
Each control room, electronic room and computer room
Each switchgear room
Each cable floor, cable shaft and cable tunnel
Each battery room
Each air conditioning room
Each storage room.
Each turbine oil tank room
Each fire fighting pump room
Page: 6
All electrical cables or pipes running through openings of fire resistant walls and ceilings must be
properly sealed with approved material.
Outdoor cable trenches shall have fire cut-offs of approved material in distances not over 100 m.
Air-conditioning and ventilation ducts penetrating fire walls or ceilings shall be provided with fire
dampers. The fire dampers shall be equipped with magnetic release via smoke detectors,
controlled by the fire detection and fire alarm system, limit switches for central indications and
electrically actuated re-opening system. In addition, fire dampers shall be provided with a release
via a fusible link.
Fire zones shall have adequately designed smoke outlets.
Hazardous areas shall be identified and suitable equipment shall be selected for the use in such
areas.
Fire safety signs and safety instructions in the Arabic and English language shall be provided for all
zones and wall mounted at easily noticeable locations.
2.1.3 Stairs and Escape Routes

Stairwells shall be constructed fire-resistant in all directions in a manner to serve as escape routes.
For means of egress, the applicable local codes and requirements shall be considered.
2.2
FIRE FIGHTING PUMP INSTALLATIONS
The fire fighting pumps shall be designed, installed and tested in accordance with NFPA 20, latest
edition.
2.2.1 Fire Fighting Pumps

The fire fighting pumps shall take suction from each section of the potable water reservoir, in which
the minimum of water according to NFPA requirements shall be available at any time for fire
fighting purposes only.
The fire fighting pumps shall supply the fire fighting water into a fire service main to outdoor
hydrants, indoor hose stations, sprinkler systems, water spray fixed systems, foam systems and
tank shell cooling systems.
The pump installations shall be located next to the potable water reservoir in a separated fire
fighting pump house, which shall be of fire resistant construction, accessible from the outside and
consist mainly of the following equipment:
One (1) electric motor driven fire fighting pump unit, approx. 600 m/h (1x100%)
One (1) diesel engine driven stand-by fire fighting pump unit, approx. 600 m/h (1x100%)
Two (2) electric motor driven jockey pump units, each pump of approx. 30 m/h, (2x100%).
Duty / stand-by facility shall be provided with automatic start of the standby pump upon failure
of the duty pump.
One (1) water/air-pressure vessel of ample size
Two (2) air compressors (2x100%).
The delivery pressure of the fire fighting pumps shall by such that the operating pressure at the
most remote outdoor hydrant or indoor hose station shall not be below five (5) bars while the
largest water based extinguishing system is under operation.
Page: 7
The fire fighting pumps shall be of the horizontal split-case type. Each pump shall have its own
controller and the pump units shall be complete with all accessories as per NFPA-requirements.
The materials for pumps, pipes, valves, etc. shall be suitable for the use of potable water.
The pumps shall start automatically upon pressure drop in the discharge main at different and
adjustable set points.
Remote start of the fire fighting pumps from the central control room shall also be possible. For
each fire and jockey pump, the following remote indications shall be displayed in the central control
room:
Pump in stand-by condition
Pump in operation
Pump failed discharge.
For the fire fighting pumps, adequate minimum flow devices are required to allow also a reduced
consumption for only one (1) outdoor hydrant.
All valves, gages, test lines, flowmeters, etc. as well as fire hose connections at the fire fighting
pump room outside shall be provided as per NFPA 20, latest edition.
The diesel oil storage tank for the diesel engine shall have a capacity for eight (8) hours continuous
operation at full load. The storage tank shall be located inside the fire fighting pump room. A filling
connection with a locally mounted semi-rotary hand pump shall be provided. Fill and vent lines
shall be extended to outdoors.
2.2.2 Seawater Fire Fighting Pump

The seawater fire fighting pumps shall be designed, installed and tested in accordance to all
relevant NFPA codes and standards.
The pump installations shall be located next to the sea water intake structure in a separated fire
fighting pump house, which shall be of fire resistant construction, accessible from the outside and
consist mainly of the following equipment:
One (1) electric motor driven seawater fire fighting pump unit, approx. 600 m/h (1x100%)
One (1) diesel engine driven stand-by seawater fire fighting pump unit, approx. 600 m/h
(1x100%) The fire pump shall be of the vertical shaft turbine-type with a right angle gear
One (1) set of stationary crane for the seawater fire fighting pumps
The pump shall each take suction from the sea water intake structure and supply seawater as fire
fighting water to the discharge header of the fire fighting pumps.
The Seawater fire fighting pumps shall have identical characteristics to the pumps described in
Clause 2.2.1. The delivery pressure of the fire fighting pumps shall by such that the operating
pressure at the most remote outdoor hydrant or indoor hose station shall not be below five (5) bars
while the largest water based extinguishing system is under operation.
The pump shall have its own controller and the pump unit shall be complete with all accessories
as per NFPA-requirements. The materials for the pump, pipes, valves, etc., suitable for the use of
seawater, shall be the same as specified for the Main Seawater Pumps.
The diesel oil storage tank for the diesel engine shall have a capacity for eight (8) hours continuous
operation at full load. The storage tank shall be located at the seawater fire fighting pump station
nearby the Seawater Fire Fighting Pumps. A filling connection with a locally mounted semi-rotary
hand pump shall be provided.
Page: 8
The pumps shall start automatically upon pressure drop in the discharge main at different and
adjustable set points.
Remote start of the seawater fire fighting pumps from the central control room shall also be
possible. For each pump, the following remote indications shall be displayed in the central control
room:
Pump in stand-by condition
Pump in operation
Pump failed discharge
All valves, gages, testlines, flowmeters, etc. shall be provided as per all relevant NFPA codes and
standards.
2.3
OUTSIDE PROTECTION
The outside protection shall be designed, installed and tested in accordance with NFPA No. 24,
latest edition.
2.3.1 Underground Fire Service Main

An underground fire service main shall be designed in form of supply rings around and throughout
the entire power station and desalination plant complex to serve outdoor hydrants, standpipes and
extinguishing systems. All excavation, installation and backfilling works for the underground main
shall be included and specified requirements hereto shall be considered.
The underground mains shall be filled with potable water and constantly pressurised by the fire
fighting pump installations.
Two (2) delivery points shall be provided for the water supply from the fire fighting pump station
into the underground mains. The various supply rings shall be sectionalised with post indicator
gate-valves.
Generally, all post indicators and outdoor hydrants shall be protected with crash barriers against
mechanical damages.
The underground mains shall be made of polyethylene PE 100, SDR 11, according DIN 8074 /
8075 or the equivalent ISO-Standards and designed as follows:
Working pressure
10 bar
Test pressure
16 bar
Nominal diameter of underground main, minimum
DN 200
Branches to outdoor hydrants
DN 150
Branches to standpipes and extinguishing systems, minimum
DN 100
The pipes shall be preferably butt-welded using heating elements. Welded fittings may also be
used as required.
The pipework shall be complete with all supports, fittings, reducers, bends, T-pieces, flanges to
hydrants, valves and branch connections, etc. required for the complete and reliable operation of
the systems.
Branch connections from the underground polyethylene pipework to standpipes and extinguishing
systems made of carbon steel shall be flanged approx. 300-500 mm above ground.
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The design, construction, installation, pipe laying, welding, testing, commissioning, etc. for the
underground mains shall be strictly in accordance with the manufacturers requirements,
instructions and recommendations.
2.3.2 Outdoor Hydrants

Outdoor hydrants shall be of the self draining dry barrel type with two (2) upper outlets DN 65
(21/2") and one (1) lower outlet DN 100 (4) for hose connections and designed as follows:
Working pressure
8 - 10 bar
Design pressure
16 bar
Diameter of connection to underground main
DN 150
Each outlet shall have an instantaneous coupling with cap and chain and the coupling system must
be compatible with the same system as already used at site for the existing Stations.
A hydrant valve DN 65 (21/2 ") shall be installed at each individual outlet between the hydrant barrel
and the instantaneous coupling.
Between each hydrant barrel and the underground main, a hydrant connection valve DN 150 shall
be provided as illustrated in NFPA 24, Appendix A.
Outdoor hydrants shall be provided in all areas of buildings and equipment relevant to be protected
and the distances between hydrants shall not exceed 75 meters.
2.3.3 Hose Cabinets for Outdoor Hydrants

Next to each outdoor hydrant, a weather resistant, proper ventilated and red painted hose cabinet
shall be provided, containing the following equipment:
Two (2) fire hoses DN 65 (21/2"), 20 m length, with instantaneous couplings and hose straps
Four (4) fire hoses DN 50 (2), 30 m length, with instantaneous couplings and hose straps
Two (2) jet/spray nozzles DN 50 (2), with instantaneous couplings
One (1) dividing breeching DN 65 (21/2") / DN 50 (2) - 65 (21/2") - DN 50 (2)
One (1) fire axe
One (1) crowbar
Extra hydrant wrench
Brackets for all the equipment
The instantaneous couplings must be compatible with the couplings of the outdoor hydrants.
The hose cabinets shall be constructed of stainless steel (1.2 mm thickness) or be made of
laminated glass reinforced plastic provided with marine plywood reinforcement as necessary.
The fire hoses with couplings shall be of the highest quality, the hose reels shall be equal to or
better than DURALINE Type III.
2.4
STANDPIPE AND HOSE SYSTEMS
The standpipe and hose systems shall be designed, installed and tested as Class II systems in
accordance with NFPA No. 14, latest edition.
Page: 10
The standpipe systems shall be of the wet pipe type and water pressure maintained at all times.
The pipes shall be of seamless steel and hot-dipped zinc coated (galvanised).
2.4.1 Indoor Hydrants

Indoor hydrants for instant intervention shall be provided for all buildings as listed under the Survey
of Fire Protection Systems in such a number that all portions of each floor can be reached by a
hose stream.
Each indoor hydrant shall be enclosed in a metallic wall mounted cabinet. Each cabinet shall be
painted red and contain the following:
One (1) suitable landing valve with reducer, instantaneous coupling and fire hose readily
attached.
One (1) swivelling hose reel with a 30 m length, DN 25 (1) non collapsible fire hose with
jet/spray nozzle with tail piece readily attached.
The fire hoses with couplings shall be of the highest quality, the hose reels shall be equal to or
better than DURALINE Type III.
2.5
SPRINKLER SYSTEMS
The sprinkler systems shall designed, installed and tested in accordance with NFPA 13, latest
edition.
Only automatic sprinkler systems of the wet pipe type shall be provided. Pipes or tubes shall be of
seamless steel.
The piping systems shall be provided with flushing and inspectors test connections, allowing a flow
equivalent to one sprinkler head discharge.
All valves in connections to water supplies shall be approved indicating valves with a reliable
position indication.
Approved pressure gauges shall be installed in sprinkler risers, above and below each check
valve. A mechanical alarm (water-motor gong) shall be provided for each sprinkler system.
Alarm check valves shall be provided with reliable flow indicators, preferably vane-type waterflow
indicators shall be used.
Water flow alarms shall be annunciated at the central fire alarm control panel and relevant local
annunciator panels.
All sprinkler valve stations shall be skid mounted and pre-assembled in the manufacturers
premises.
2.6
WATER SPRAY FIXED SYSTEMS
The water spray fixed systems shall be designed, installed and tested in accordance with NFPA
No. 15, latest edition.
Complete systems shall be provided with all components required for automatic operation,
normally released via the fire detection and fire alarm system. Manual release must also be
possible.
All pipework normally empty and downstream the deluge valves shall be made of seamless steel
and hot-dipped zinc coated (galvanised). The threaded ends of galvanised pipes, after installation,
shall be properly protected against corrosion.
Page: 11
Open spray nozzles shall be protected with plastic caps to prevent plugging and corrosion.
The systems shall be designed to discharge effective water spray from all nozzles within
30 seconds following operation of the detection system.
All deluge valve stations shall be skid mounted and pre-assembled in the manufacturers premises.
Adequate drainage for the area to be protected shall be arranged for safe disposal of escaping
flammable liquids and to prevent the spread of fire.
2.7
FOAM-WATER SPRAY SYSTEMS
The foam-water spray systems shall be designed, installed and tested in accordance with NFPA
16, latest edition.
normally released via the fire detection and fire alarm system. Manual release must also be
possible.
The foam produced shall extinguish fires of the type produced by the handled fuels and oils.
Foam concentrate shall be stored in a suitable tank with level indication.
The foam concentrate must be suitable to withstand the minimum and maximum ambient
temperatures for min. two (2) years.
Foam concentrate supply to the proportioners shall be preferably by the pressure-proportioning
tank method with or without diaphragm.
All foam concentrate pipework shall be made of stainless steel.
All pipework normally empty and downstream the deluge valves shall be made of seamless steel
and hot-dipped zinc coated (galvanised). The treaded ends of galvanised pipes, after installation,
shall be properly protected against corrosion.
Open spray nozzles shall be protected with plastic caps to prevent plugging and corrosion.
Provisions shall be made for flushing the systems with clean water after use.
All deluge valve stations shall be skid mounted and pre-assembled in the manufacturers premises.
Adequate drainage for the area to be protected shall be arranged for safe disposal of escaping
flammable liquids and to prevent the spread of fire.
2.8
FIXED LOW EXPANSION FOAM SYSTEMS
Fixed low expansion foam systems shall be designed, installed and tested in accordance with
NFPA 11, latest edition, except stated otherwise hereinafter.
normally manual released.
Foam shall be supplied into each fuel oil storage tank by several type II foam discharge outlets.
The foam applied shall extinguish fires of the type produced by the handled fuels.
Foam concentrate shall be stored in the foam station in a suitable tank with level indication.
The quantity of stored foam concentrate shall be suitable for foaming the largest fuel oil tank inside
for a duration of min. forty-five (45) minutes.
Reserve supply of foam concentrate shall be stored at the premises.
Page: 12
The foam concentrate must be suitable to withstand the minimum and maximum ambient
temperatures for min. two (2) years.
Foam concentrate supply to the proportioner(s) shall be preferably by the balanced pressure
proportioning method using foam concentrate pump(s).
The foam concentrate pump(s) shall be AC motor driven and all electrical equipment shall be
connected to the emergency power supply system.
All foam concentrate pipework shall be made of stainless steel.
The valves for the foam distribution pipework to tanks shall be grouped as a valve station inside or
next to the foam station.
The valves shall be properly labelled and the valve station shall be protected against weather and
heat radiation.
Under normal stand-by conditions, the supply main up to the valve station shall be filled and
pressurised with potable water.
All pipework normally empty and downstream the valve station shall be protected against
corrosion.
Provisions shall be made for flushing the foam systems with clean water after use.
2.9
TANK SHELL COOLING SYSTEMS
Tank shell cooling systems shall be designed, installed and tested in accordance with DIN 14495,
latest edition.
normally manual released.
For each fuel oil storage tank, minimum two (2) ring pipes with spray nozzles shall be provided for
cooling the tank roof and shell in case of fire.
The ring pipes shall be sectionalised in portions of half rings in order to optimise the water demand.
The section valves shall be properly labelled and located at the valve station for the foam systems.
All pipework normally empty and downstream the valve station shall be protected against
corrosion. Open spray nozzles shall be protected with plastic caps to prevent plugging and
corrosion.
2.10 FIRE AND GAS DETECTION AND ALARM S YSTEM

Distributed digital fire and gas detection and alarm system shall be designed, engineered,
manufactured, factory tested, delivered to site, installed commissioned and put in reliable operation
with all necessary equipment, accessories, batteries and cabling in accordance with VDE 0833,
DIN 14675, V.D.S. form 2095 standards or NFPA standard, latest edition. A complete system shall
be provided with all components required for automatic operation.
The distributed digital fire and gas detection and alarm system shall comprise of distributed digital
fire and gas alarm panels (FGAPs) and fire and gas detection system for each protected area. The
fire and gas alarm system shall be digital microprocessor based system with on-line diagnostic
system and analogue addressable detection system. The system shall be capable to locate the
faulty detector and shall be capable to distinguish between false condition of fire and true condition
of fire. Each of the FGAP shall be designed redundant with redundant CPUs and fault tolerant
such that a single fault/failure will not cause a trip to the unit and/or will not invalidate the protection
system. It shall also be designed fail-safe in such a manner that any kind of failures in the system
will not release the extinguishing agent. The power supply modules inside the FGAP shall be
Page: 13
provided redundant. Hence, the power supply to the FGAP shall be redundant from the redundant
UPS 220V AC sources through a manual changeover switch, which shall be provided for this
purpose. 24V DC back-up battery shall be provided inside each FGAP. The battery shall have
sufficient capacity for 24 hours system operation plus 5 minutes operation of the audible and
visible alarm devices in accordance with NFPA standard. Each of the gas detection system and fire
detection system of each protected area shall be designed and built in three separate loops
passing through the protected area and shall be connected to the FGAP of each protected area at
two separate inputs for each loop. At least two detectors of the same kind shall be connected to
each loop at each location of the protected area to make a redundant configuration for each
location. The operation of detector/detectors on any one loop at a protected area shall initiate a
Level 1 audible and visual alarm of fire. The operation of fire detectors on 2-out-of-3 loops at the
protected area shall initiate a Level 2 alarm of fire and the following actions:
Trip of the protected unit.
Trip of ventilation systems and operation of fire dampers to seal openings.
Automatic shut-off of the fuel gas and fuel oil if applicable.
Automatic release of the extinguishing agent within the protected area.
The aforementioned actions shall be actuated and controlled by the FGAP of the protected area.
Alarm level 1 and alarm level 2 shall be annunciated with the appropriate message in the FGAP, in
the VDUs of the main central fire alarm operator stations in CCR and in the VDUs of the repeater
operator stations. It shall also be displayed in the DCS monitors in CCR. Any other actions deemed
necessary at the discretion of the Employer/Engineer and not specified above shall also be
included.
Alarm horns, rotating flashlights, call points, detectors and all other necessary equipment/devices
shall be provided. The linear heat detectors, smoke detectors, UV/lR detectors and gas detectors
shall be of analogue addressable type of the latest proven technology to the approval of the
Employer/Engineer. Type and model of detectors and other equipment/devices, their quantity and
location shall be subject to the Employer/Engineers approval.
Gas detection and alarm system shall be provided with the same make and type of system as of
the fire detection and alarm system. Both gas and fire detection and alarm systems shall be
provided in the same FGAP of the protected area whenever gas detection is applicable. The gas
detection system shall also be designed and built in three loops same as of the fire detection
system as described above. Level 1 shall be for alarm at 25% LEL. Level 2 alarm shall be at 60%
LEL. If tripping action is required such as for the gas turbine unit, the tripping action shall be at
level 2 and as a result of 2-out-of-3 voting logic from two loops at the same location. Level 2 shall
not release the extinguishing agent.
The whole fire and gas detection and alarm system of the entire plant shall be one unified system
of the same make and type and shall be sub-contracted as a whole to a single reputable company
subject to the Employer/Engineers approval. Different contracts and/or different suppliers will not
be acceptable.
The main functions of the system shall be as follows:
The actuation of any fire or gas detection device shall be audible and visible displayed on a
central fire alarm control panel and audible and visible alarms shall be initiated in the
appropriate fire zone of actuated detection
The system shall differ whether the alarm was initiated by an automatic detection device or by
a manual fire alarm station
Page: 14
Audible alarms may be silenced by pushing a silence button on the central fire alarm control
panel. Any subsequent actuation of a detection device shall again sound the audible alarm
Fixed fire fighting systems, designed for automatic operation, shall be released
Operation of fixed fire fighting systems, whether automatically or manually released, shall be
indicated on the central fire alarm control panel
Fire doors, fire dampers, air handling units or any other equipment or devices shall be released
or shut down as required
The fire alarm system shall be equipped with wire break and short circuit supervision for each
detection line. Short circuit, wire break or any other system troubles shall be indicated on the
central fire alarm control panel
After restoration of the alarm detection device to its normal condition, the system shall be returned
to normal stand-by condition.
For central system supervision, programming or configuration, two VDU based workstations shall
be installed in the central control room. The scope shall also include complete installations with
operator desk, printer, operator chair, etc. according to the manufacturers standard.
Area group alarm signals for fire and gas alarm and system troubles shall be connected to the
DCS system for monitoring and logging.
The fire and gas alarm system shall also be interfaced by zone alarms with the fire brigade.
The fire and gas detection and alarm system shall mainly consist of the following equipment.
2.10.1 Fire and Gas Alarm Panels (FGAP)

The Fire and Gas Alarm Panels (FGAP) shall be digital microprocessor based system and shall be
designed and manufactured fault tolerant and redundant. Each FGAP shall have its own VDU and
alarm printer. All the FGAPs in the whole plant shall communicate with two redundant central
computerised operator stations to be located in CCR at the shift supervisor desk. All information
such as status and alarms from all the FGAP shall be displayed in the monitors of these operator
stations. A third similar operator station shall be provided as a repeater station to be located at the
fire brigade station at G Power Station. The operator stations in CCR shall have serial interface
link to the DCS for status and alarm display in the DCS monitors. All functions of detection, alarm,
control, protection and release of the extinguishing agent shall be performed by the FGAP of each
unit/protected area separately. The Scope of Works of the FGAPs shall comprise but shall not be
limited to the following:
Each GTG unit shall have two (2) separate FGAPs. One FGAP for the GTG enclosures and the
other FGAP for the GTG related equipment and auxiliaries such as electrical equipment room,
switchgear, transformers, battery rooms, etc.
Each HRSG unit and with its supplementary firing system shall have its own FGAP.
Each Auxiliary Boiler unit shall have its own FGAP.
Each BPST unit shall have its own FGAP.
Each fuel gas station with fuel gas compressors shall be provided with its own FGAP.
Fuel oil tanks and fuel oil pump house shall have its own FGAP.
Each desalination unit shall have its own FGAP.
Page: 15
Blending plant building shall have its own FGAP which shall also include fire detection and
alarm system of seawater pump house, potable water pumps area, chlorination plant and water
treatment plant, laboratory.
Switchgears and control building shall have its own FGAP.
Store buildings shall have its own FGAP
The 400 kV switchgear and control building shall have its own FGAP.
Emergency and Black Start Diesel Generators units shall have their own FGAP.
Admin Building shall have its own FGAP
Two (2) operator stations shall be provided in the CCR for the overall monitoring status and alarm
display of all the FGAPs and all fire fighting system equipment.
One (1) repeater operator station shall be provided at the fire brigade station at G Power Station.
Fault or failure in the main operator stations in CCR shall not affect the repeater operator station,
which shall remain in service.
Power supply to the operator stations shall be from UPS. Existing UPS power system of the fire
brigade G station may be used up to a limited load for the supply of the repeater operator station.
If the repeater operator station requires a higher load, an independent UPS system shall be
provided.
Local annunciator mimic panels shall be installed at the main entrance of each major building,
complex or area providing detailed LED - annunciation of each detection, alarm and release
function for all relevant floor levels of this building, complex or area.
The local annunciator mimic panels shall be made of engraved stainless steel and be housed in a
wall-mounted, red painted steel cabinet with glass front. A visible alarm device outside the
entrance shall be activated if an alarm occurs.
Any other FGAP and equipment not mentioned above but deemed to be necessary at the
discretion of the Employer/Engineer shall also be provided.
2.10.2 Manual Fire Alarm Stations

Manual fire alarm stations shall be of the break glass push button operated type and individual
addressable and displayable on the central fire alarm control panel if activated.
The boxes shall be painted red with white or black lettering in the local language and in English.
When operating the manual station, the pushed button shall remain down and the alarm contacts
closed until the station is reset by opening the front, replacing the break-glass and closing the front
again.
Inside buildings, manual fire alarm stations shall be located on floors and at building exits following
the normal exit paths. At least one manual station shall be provided on each floor or exit.
For outdoor areas, the manual fire alarm stations shall be wall- or post-mounted, designed
according to protection class IP 54 and located in distances not exceeding 100 m, preferably at
yard hydrant locations.
2.10.3 Automatic Fire and Gas Detectors

Automatic detectors shall be of the fixed temperature and/or rate-of-rise heat detectors, optical
smoke and/or ionisation smoke detectors, ultraviolet and/or infrared flame detectors as well as gas
detectors, suitable to detect the properties of the used fuel gas.
Page: 16
Selection of kind of detectors is subject to approval.

Rate-of-rise heat detectors shall be designed for a sensibility of 5C/min. temperature rise and a
fixed initiation temperature of +57C +/-3C.
Ionisation smoke detectors shall be of the dual chamber type, with a radioactivity radiation of less
than 1.0 micro-Curie.
As far as possible, ionisation smoke detectors shall not be used in order to avoid handling with
radioactive parts.
In addition to the fixed mounted gas detectors to be installed, portable gas detectors shall be
provided suitable for the use in various hazardous areas.
Each automatic detector shall be addressable. Actuation of any detector shall be displayed
individually on the central fire alarm control panel.
Each automatic detector shall have a continuous condition supervision by using pulsing, trend
evaluating or equivalent system techniques.
The detector spacing on smooth surfaces shall not exceed the distance recommended by the
approving authorities. In areas, where irregularities occur, the detector spacing shall be reduced in
such a way as to obtain approved spacing.
Detectors generally shall be connected in groups to the central fire alarm control panel. The
number of detectors installed on any one signalling line shall be limited as recommended by the
manufacturer. Signalling lines shall be designed as loop connections, unless otherwise approved.
2.10.4 Audible Alarms

Sirens shall be installed inside all buildings. They shall have a minimum noise level of 110 dB(A) at
a distance of 1 m and shall be different in sound from other sirens, if any, installed in the area for
other purposes.
2.10.5 Visible Alarms

Red flash lights shall be installed inside the buildings and outside at main entrances. The lights
shall have a frequency of 60 or 90 flashes per minute with an ample light energy.
2.10.6 Manual Release Push Buttons

Push buttons for manual release of fixed extinguishing systems shall be designed as specified
above for manual fire alarm stations, however, coloured in yellow or blue.
2.10.7 Cabling
Signalling and release lines shall be designed as ring- or bus-systems, marked as "fire alarm
cable" and be laid in conduits. Minimum wire size shall be 0.8 mm. Further requirements for
cabling and wiring as specified shall be considered.
Cables to all detectors, remote alarms, fire fighting equipment and equipment indicators shall be of
the Mineral Insulated Copper Covered (MICC) type. However, for applications of continuous
operating temperature lower than 70 C. and with dry extinguishing systems other types can be
accepted provided that they are suitable for the environment of application and subject to the
Employer/Engineers approval. All fire system cabling shall be fully segregated and run on
separate routes to other cables and the conductors shall be continuously electrically monitored.
Page: 17
2.11 FIRE EXTINGUISHERS

The extinguishers shall be designed, installed and tested in accordance with NFPA No. 10, latest
edition and shall fulfilling local requirements.
2.11.1 Mobile Fire Extinguishers

Mobile fire extinguishers with 50 kg dry powder shall be provided and located in the machine halls
and the emergency black start diesel and at all locations required by the relevant local rules and
regulations.
Mobile fire extinguishers with 30 kg CO2. shall be provided and located in the machine halls, the
control and switchgear building and the 400 kV switchgear building.
The fire extinguishers shall be mounted on hand carts and furnished with a 6 m hose each.
2.11.2 Portable Fire Extinguishers

Portable 6 or 9 kg dry powder fire extinguishers shall be installed in all buildings and at all locations
required by the relevant local rules and regulations.
The fire extinguishers shall be wall-mounted and arranged at easily visible and accessible places
following the normal exit paths.
Numbers and locations of extinguishers shall be satisfactory to local authorities and are subject to
approval.
The maximum travelling distance to an extinguisher shall not exceed 25 m.
The portable fire extinguishers shall be fitted with pressure indicators.
The fire extinguishers must be provided as early as possible, however, at least on commencement
of the commissioning preparations.
After completion, random functional tests as of 5 % of the supplied portable extinguishers shall be
performed in connection with the training programs including refillment of the used extinguishers.
The colour code for the portable fire extinguishers is as follows:
Dry chemical powder:
Blue
Foam type:
Pale Cream
Vaporising Liquid:
Red
Alternative to Halon
Carbon dioxide:
Black
2.11.3 Fire Blankets

Fire blankets and further rescue equipment shall be provided as required.
CO2 SYSTEMS
The CO2 fire extinguishing systems for protection by total flooding shall comply with the
requirements of NFPA Code NO. 12 or BS 5306 Part 4.
A unitised system each protecting only one risk shall be provided, a centralised system is not
acceptable.
Page: 18
The CO2 systems shall be capable of being actuated either automatically or manually. The system
shall be capable of a manually released second discharge to the same concentration as the first
without alteration to pipework or the provision of new gas containers.
The automatic CO2 release signal shall originate from voltage free changeover contacts associated
with Local Fire Panel. The system shall incorporate a gas release delay feature variable within the
range of 0 30 seconds.
Manual release of the CO2 system shall be by a Release Unit located at the entry to the protected
enclosure. When operated, the unit shall either release the first discharge of CO 2 if not already
released automatically, or release a second discharge. The manual release of the CO 2 system
shall initiate a Level 2 Alarm of Fire on the Local Fire Panel for the Fire Safety Zone protected by
the CO2 system by voltage-free changeover contacts.
The Manual Release Unit shall be of the type requiring two distinct and separate actions for their
operation (e.g. break glass and pull handle) and shall be coloured yellow. On or adjacent to the
unit shall be the wording CO2 Fire Extinguishing System Manual Release.
Each system shall be provided with a Lock-off Unit located adjacent to the main entrance to the
protected area. The unit shall include a lock and key arrangement to ensure that the door into the
protected area may not be opened without the CO2 system being locked off first. The key for
locking off the CO2 system shall be the same as the key for entering the protected area and when
the CO2 system is operational, the key shall be retained in the Lock-off Unit. It shall be necessary
to lock-off the system and remove the key before access can be gained to the protected area. It
shall not be possible to remove the key from the door lock unless the door is closed.
Visual system status indication shall be provided adjacent to the lock-off unit and shall incorporate
the following:
CO2 FIRE EXTINGUISHING SYSTEM ON DO NOT ENTER (Amber)
CO2 SYSTEM LOCKED OFF SAFE TO ENTER (Green)
DANGER CO2 GAS DO NOT ENTER (Red)
The illuminated indications shall be readable under all natural and artificial lighting conditions in the
location. At least two lamps or other luminaries per indication shall be provided. Each of the visual
indications shall be provided with a pair of voltage-free changeover contacts to facilitate repeat
indication to the Local Fire Panel for that Fire Safety Zone.
A CO2 Discharge sounder having a sound output of 100 dB(A) at 1 metre and a sound distinctive
from any other in the location shall be provided in the protected area to warn personnel of the CO2
gas discharge. The sounders shall be initiated as soon as the CO2 release signal has been
received from the Local Fire Panel. Flashing beacons shall also be provided in noisy areas.
Power supplies for the CO2 system shall be taken from the same power supply as the Local Fire
Panel, which automatically initiates the operation of the CO2 system.
All CO2 protected areas shall have breathing apparatus sets installed to enable immediate
availability for the purpose of rescue.
HUMAN SAFE INERT GAS SYSTEMS
A human safe inert gas fire extinguishing system for protection by total flooding shall comply with
the relevant requirements of NFPA codes and relevant local rules and regulations. The system
shall introduce to a room a proper mixture of gases (e.g. Argonite, Fm 200, Inergen, etc.) that still
allow a person to breathe in a reduced oxygen atmosphere.
Page: 19
A unitised system each protecting only one risk shall be provided, a centralised system is not
acceptable.
The human safe inert gas system shall be capable of being actuated either automatically or
manually. The system shall be capable of a manually released second discharge to the same
concentration as the first without alteration to pipework or the provision of new gas containers.
The automatic inert gas release signal shall originate from voltage free changeover contacts
associated with Local Fire Panel. The system shall incorporate a gas release delay feature variable
within the range of 0 30 seconds.
Manual release of the human safe inert gas system shall be by a Release Unit located at the entry
to the protected enclosure. When operated, the unit shall either release the first discharge of
human safe inert gas if not already released automatically, or release a second discharge. The
manual release of the human safe inert gas system shall initiate a Level 2 Alarm of Fire on the
Local Fire Panel for the Fire Safety Zone protected by the inert gas system by voltage-free
changeover contacts.
The Manual Release Unit shall be of the type requiring two distinct and separate actions for their
operation (e.g. break glass and pull handle) and shall be coloured yellow. On or adjacent to the
unit shall be the wording Inert Gas Fire Extinguishing System Manual Release.
Visual system status indication shall be provided adjacent to the main entrance to the protected
area and shall incorporate the following:
DANGER INERT GAS DO NOT ENTER (Red)
The illuminated indications shall be readable under all natural and artificial lighting conditions in the
location. At least two lamps or other luminaries per indication shall be provided. Each of the visual
indications shall be provided with a pair of voltage-free changeover contacts to facilitate repeat
indication to the Local Fire Panel for that Fire Safety Zone.
A Human Safe Inert Gas Discharge sounder having a sound output of 100 dB(A) at 1 metre and
a sound distinctive from any other in the location shall be provided in the protected area to warn
personnel of the inert gas discharge. The sounders shall be initiated as soon as the inert gas
release signal has been received from the Local Fire Panel. Flashing beacons shall also be
provided in noisy areas.
Power supplies for the human safe inert gas system shall be taken from the same power supply as
the Local Fire Panel, which automatically initiates the operation of the human safe inert gas
system.
CNE/015/2002
P2.24
Heating, Ventilation and Air Conditioning
WORKING DOCUMENT
Part P2.24 - Heating, Ventilation and Air Conditioning Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
PAGE
GENERAL ........................................................................................................................... 1
SCOPE OF WORKS ........................................................................................................... 1
CODES AND STANDARDS ............................................................................................... 4
DESIGN REQUIREMENTS................................................................................................. 4
4.1
GENERAL ............................................................................................................... 4
4.2
INDOOR DESIGN CONDIT IONS............................................................................ 6
4.2.1
AC System Types................................................................................ 6
4.2.2
Air Conditioning/Cooling Systems ................................................... 9
4.2.3
Heat Transfer Coefficients............................................................... 10
4.2.4
Sound Pressure Level...................................................................... 11
4.3
REFRIGERATION EQUIPM ENT .......................................................................... 12
4.4
CENTRIFUGAL TYPE CHILLERS....................................................................... 14
4.5
SCREW TYPE CHILLERS.................................................................................... 15
4.6
RECIPROCATING TYPE CHILLER ..................................................................... 17
4.7
PACKAGE AIR COOLED ROOF TOP DX-UNITS.............................................. 19
4.8
GENERAL REQUIREMENTS FOR AIR COOLED CONDENSERS................... 19
4.9
REFRIGERATION PLANT - WATER COOLED CONDENSER
(ALTERNATIVE) ................................................................................................... 20
4.10 AIR-HANDLING UNITS........................................................................................ 21
4.11 COOLER / EVAPORATOR FOR CHILLERS....................................................... 24
4.12 COOLING COILS FOR DX UNITS....................................................................... 24
4.13 ELECTRIC AIR HEATING COILS........................................................................ 25
4.14 AIR FILTERS......................................................................................................... 26
4.14.1
General............................................................................................... 26
4.14.2
Return Air filters................................................................................ 27
4.14.3
Fresh Air Filters ................................................................................ 27
4.14.4
Panel Filters....................................................................................... 27
4.14.5
Bag Filters.......................................................................................... 28
4.15 SAND SEPARATION UNIT .................................................................................. 28
4.16 DRIP ELIMINATORS ............................................................................................ 28
4.17 FANS ..................................................................................................................... 28
4.17.1
Centrifugal Fans................................................................................ 28
4.17.2
Axial Fans .......................................................................................... 30
4.17.3
Propeller Fans................................................................................... 30
4.17.4
Roof Mounted Exhaust Fans ........................................................... 31
4.17.5
Acid-Resistant Fans ......................................................................... 31
4.17.6
Domestic Extractors......................................................................... 31
4.17.7
Domestic Kitchen Extractors .......................................................... 32
4.17.8
Multifunction Natural Roof Ventilators........................................... 32
4.18 CHILLED WATER PIPEWORK............................................................................ 32
4.19 SOUND-RESISTANT AIRTIGHT ACCESS DOORS FOR AIR CHAMBERS..... 36
4.20 LOUVERS AND DAMPERS ................................................................................. 36
4.20.1
Weather-Proof Louvers.................................................................... 36
4.20.2
Multi-Leaf Dampers........................................................................... 37
4.20.3
Adjustable Dampers......................................................................... 37
4.20.4
Backdraught Dampers ..................................................................... 37
4.20.5
Fire Dampers..................................................................................... 38
4.21 VIBRATION ISOLATION, FOUNDATIONS ......................................................... 38
4.22 REGISTERS GRILLES AN D DIFFUSERS .......................................................... 39
4.22.1
General............................................................................................... 39
P2_24HVAC_Working_Doc.doc
Page: ii
4.23
4.24
4.25

4.22.2
Registers............................................................................................ 39
4.22.3
Ceiling Diffusers ............................................................................... 40
4.22.4
Sectional Diffusers........................................................................... 40
4.22.5
Linear Diffusers................................................................................. 41
4.22.6
Supply and Return Grilles................................................................ 41
4.22.7
Disc Valves........................................................................................ 42
4.22.8
Overflow Grilles ................................................................................ 42
4.22.9
Plenum Boxes................................................................................... 42
4.22.10
Spin Type Ceiling Diffuser............................................................... 42
4.22.11
Grease Intercepting Grille ................................................................ 42
DUCTWORK AND ACCESSORIES..................................................................... 43
4.23.1
Ductwork............................................................................................ 43
4.23.2
Supports for Ductwork..................................................................... 46
4.23.3
Flexible Ducts.................................................................................... 47
INSULATION OF DUCTWORK............................................................................ 48
4.24.1
General............................................................................................... 48
4.24.2
Thermal Insulation ............................................................................ 48
4.24.3
Insulation for Air-Conditioning Ductwork...................................... 49
4.24.4
Insulation for Ductwork of Ventilation Systems ........................... 49
4.24.5
Acoustical Insulation........................................................................ 49
4.24.6
Fire-Proof Insulation......................................................................... 49
ACCESS DOORS AND SOUND ATTENUATORS.............................................. 50
4.25.1
Inspection Covers and Access Doors............................................ 50
4.25.2
Sound Attenuators............................................................................ 50
4.25.3
Cross Talk Silencer........................................................................... 50
INSTRUMENTATION AND CONTROL............................................................................ 50

5.1
GENERAL ............................................................................................................. 50
5.2
BUILDING MANAGEMENT SYSTEM.................................................................. 53
ELECTRIC INSTALLATIONS........................................................................................... 54
SPARE PARTS AND TOOLS........................................................................................... 54
Page: 1
GENERAL
The works covered under this specification shall include the whole heating, ventilating and airconditioning (HVAC) systems for all buildings, areas, etc. of the whole L Station Phase I Plant,
as well as all details, accessories, electrical and other associated services, etc. required for the
complete installation to operate safe, reliably and properly.
Chilled water system shall be used for Administration Building and Central Control & Switchgear
Building.
No window units or wall mounted units shall be foreseen. All system shall be of the Package
Type.
2
SCOPE OF WORKS
The scope of work shall cover the complete engineering, preparation of construction drawings,
shop drawings, obtaining approvals, procurement, manufacture, testing, transport, storage at
Site, keeping under custody, erection, installation, commissioning, tests on completion and
handing over in accordance with the requirements of the Contract and handling of the airconditioning and ventilation plants including motor control boards, switchgear, automatic control
and associated cabling according to the requirements of the Contract documents for the
Packages P (Power Plant), D (Desalination) and S (400 kV Sub-Station).
All equipment and/or accessories not specifically mentioned in this Specification, but which are
necessary for a safe, reliable and proper operation of the whole plant as well as service or
maintenance of the systems, shall be deemed to be included in the package. The Contractor
shall provide and execute such works as a part of the Contract and shall not be entitled to any
extra payment on the account.
The Contractor is liable to furnish evidence that his design/construct package will be complete
and will comply with the technical Specifications as set out herein in order to achieve complete
operational systems.
Air-conditioning and ventilation systems shall be completely provided including the performance
testing according to the following requirements:
Air-conditioning systems including air-handling units (AHU) with all components like air
filters, cooling and heating coils, humidifiers, accessories and flexible duct connections.
Chilled water systems
Complete roof top, DX-package units including air cooled condensing unit, air handling unit
with Direct Expansion (DX) cooling coil, refrigerant pipe lines, heating coils, humidifiers, air
filters, accessories and insulation.
Ventilation systems including air supply fans, return air fans and exhaust fans with back
draft dampers and ductwork.
Smoke fans for staircases, etc.
Outside louvers and sand filters.
Potable water supply and chemical conditioning system for the chilled water plants as well
as water taps with hose couplings for cleaning of air-conditioning plant and equipment.
Page: 2
Drainage piping system and waterproofing including insulation.

-
The Contractor shall supply, install and connect all necessary drainage and
waterproofing of the air-conditioning, ventilation and chilled-water plants in corrosion
resistant material, e.g. stainless steel 304.
Dielectric fittings of approved make shall be used on all connections between ferrous
and non-ferrous pipes.
All drain pans of air-coolers and drip eliminators shall be connected to the down pipes.
Ductwork including all dampers, extractors, vanes, diffusers, grilles, etc.
Heat insulation, sound insulation, vapour insulation and fire proof insulation.
Airtight, watertight and fire prove penetrations through roofs, floors, walls, casings,
housings, etc.
Vibration insulated attachments, suspensions, connections, installations and foundations.
Airtight equipment and components.
Appropriate fire detectors for automatic operation of e.g. dampers, if required.
Fire dampers for all wall and floor penetrations. It shall be possible to operate the fire
dampers i.e. closing and opening of the dampers from the building management
system/workstations.
Provision of all necessary auxiliary constructions such as supports, brackets, traverses,

mounting frames, anchor plates and airtight doors gaskets, fasteners.
Access and inspection doors or removable covers in suspended ceilings for all concealed
installed dampers, air heater, fans and sensing elements.
Provision of guard grills, stairs, ladders, service platforms, gratings, scaffolding and railings
for inspection, operating, servicing, repair, maintenance and for the security of the staff.
Electrically operated lifting devices to replace roofing area equipment, electrical hoists, etc.
Protective coats of paint and coating against corrosion and other damage including top
coats and finishing coats according to relevant specifications.
Lighting in all chambers and installation shafts for inspection and revision.
Earth conductors and earth connections for all metal parts of the air-conditioning and
ventilation systems.
Lightning arrestors and conductors and connections for all metal parts of the exhaust fans
installed in the open air on the roof etc.
Electrical sockets for maintenance works and water jet pumps for cleaning of condensers,
etc.
Inside and outside cleaning of all ducts, pipes, equipment and of all A/C-plant rooms and
chambers, including proper flushing of all pipes until the water requirements are reached.
Page: 3
Provision of calibrated instruments for provisional and final tests on Site, such as:
3
Thermo - and hygrographs for simultaneous measuring and recording of outside and
room-air conditions,
Electronic temperature recorder with quick-response and digital indication,
Aspiration-psychrometer including one bottle of distilled water.
Propeller anemometer.
Multimeter.
Sonometer with built-in A-evaluation filter.
24
Smoke cartridges including rubber hose and ball pump.
Sufficient number of spare fuses, controllers and switchgear, as well as spare

diodes, lamps, over-current relays and measuring fluid for pressure gauges at air
filters.
Setting, adjusting, balancing and measuring of all components and systems.
All equipment and material shall be subjected to work tests according to the standards and
good engineering practice or as may be decided by the Employer/Engineer.
Pressure and tightness test of the entire refrigeration, air-conditioning and ventilation plants
and elimination of all faults and damage.
Starting-up, initial operation and performance test by qualified personnel of the original
equipment manufacturer or licensed representative.
Elimination of all faults and damage during the Defects Liability Period including inspection,
services, cleaning and maintenance of all parts of the plants.
Performance of a general revision (and tests, if required) at the end of the Defects Liability
Period to ensure a trouble-free operation.
All necessary spare parts, special tools and tackles, measuring equipment, working and
substitute materials such as filter media, refrigerants, special detergents, oil and grease,
corrosion inhibitor, filter-drier cartridges, indicator liquid, fusible links, detonator safety
insets, etc. for an uninterrupted trouble-free operation in accordance with the original
equipment manufacturer recommendations.
Provision of all necessary documents for review and approval by the Employer/Engineer
before beginning some performance of work or preliminary tests for provisional acceptance
like calculations, determination of dimensions, drawings of construction details, certificates,
equipment samples, installation and stock plans, switch and control diagrams, airflow
diagrams, equipment selecting sheets, equipment schedule, motor lists, measuring point
and instrument lists, measuring tables, test records, cable, wiring and terminal lists,
technical data sheets of all parts of the plants and characteristics curves, working, operating
and servicing manuals, lubrication schedules, spare part lists, etc.
Training of operating staff as well as servicing and maintaining of the plants until the end of
the Defect Liability Period.
The provision of works shall not be limited to the above mentioned parts. All performance not
particularly specified but essential and required to meet the latest technical experiences and
standards shall be included.
Page: 4
3

CODES AND STANDARDS
All systems and equipment forming parts of the work shall be designed and constructed
according to the latest relevant and International recognised codes and standards, as DIN, AFI,
ASME, BS, IEC, VDE, VDI, UVV, VDMA, SMACNA, ARI, ANSI, NFPA, EPA or as listed in the
ASHRAE HANDBOOKS, latest editions. All local codes and requirements of the Authority
having jurisdiction shall apply to the execution of works.
If the Contractor offers material or equipment which conforms to standards other than those
published by the above mentioned bodies, or other standards not specified, full details of the
proposed standards and the variation from above mentioned standards, in so far as they affect
the design or performance of the equipment, shall be submitted with the Tender.
In such a case, the Contractor shall provide the Employer/Engineer with two (2) sets (official,
complete, unabridged and in the English language) of all relevant standard specifications
according to which the equipment is manufactured.
For cooling-load calculation the ASHRAE, latest method, or as per CARRIER E-20 II design
program, latest edition, shall be used.
4
DESIGN REQUIREMENTS
4.1
GENERAL
Refer to Part G4 General Project Requirements and Part G5 General Technical

Requirements.
The Contractor shall install all HVAC systems as required. Performance shall be in strict
accordance to the latest standards recommended by American Society of Heating, Refrigerating
and Air-Conditioning Engineers, Inc. (ASHRAE) and to the best engineering knowledge.
Contractor shall be aware of the figures and assumptions made by the Employer/Engineer to
estimate the cooling loads given. However, accurate quantities of heat dissipated from the
various equipment installed in the buildings as well as the overall coefficient values of heat
transfer U for walls, roofs and glass shall be calculated and the resulting cooling loads
required to satisfy the conditions stipulated in this Part shall be adopted.
Design, calculation, construction drawings, shop drawings, equipment selections and data of all
HVAC-systems shall be submitted to the Employer/Engineer for his review and approval, before
the Contractor may begin with any fabrication, construction or erection. It is clearly understood
that any material or equipment installed without the approval of the Employer/Engineer shall be
removed and replaced by an approved equipment free of charge. The selected supplier of air
conditioning equipment shall be well represented in the Gulf area so that services and spares
can easily be provided. In case of air-conditioned building with an exterior air system, cooling
coils shall be designed in function of the indoor and outdoor conditions.
The following design criteria shall be considered for design of the HVAC-systems:
For conditioned area the minimum air rate shall be based on 60 m3/h per person, or 10% of
total supply-air volume, or total exhaust air plus pressurisation requirements, whichever is
greater. For ventilated areas, air rate shall be considered as minimum 10 air changes/hour.
The HVAC system shall be designed for continuous operation under all prevailing climatic
and ambient conditions The cooling capacity of the HVAC system shall be at least 10%
higher than the cooling requirement for the relevant rooms and buildings.
All rooms shall be kept under a slight positive pressure to avoid infiltration of outside air to
the building.
Page: 5
Re-heaters shall be provided where necessary.
All staircases shall be designed as smoke-proof towers in order to guarantee a safe regress.
Therefore, a slight positive pressure shall be provided by means of forced-draught, supplyair units on low level and exhaust-outlet dampers and louvres on high level.
The smoke control system by HVAC-systems shall not only be initiated by fire-alarm panel,
but also by local override switches on each floor.
Each smoke-control system shall be designed for 10 changes of outside air per hour but not
less than 18.000 m 3/h.
Separate exhaust systems shall be provided for the required rooms, which shall be kept
under a slight negative pressure condition, e.g. when dangerous or disadvantageous gases
and odours may occur.
Supply air shall be served on low level only, where heavy gases may occur.
In general, the outlets for exhaust systems shall be located on high level and shall be
equipped with diffusers, grilles or valves, as required.
Wherever heavy gases may occur, the intakes for exhaust system shall be located on high
level and also on low level in order to take 50% of exhaust flow rate from underneath the
ceiling and 50% from lower level.
Cross-flow system serving all area and corners of the ventilated room shall be provided for
battery room and pump room.
Wherever combustion gases, vapour of fumes may occur, only explosion proof enclosed
motors and non-sparking materials shall be used for exhaust fans (in particular for battery
rooms).
Wherever aggressive gases may occur only corrosion resistant material shall be used for
exhaust systems as e.g. from such materials as polypropylene, or non-corroding stainless
steel (in particular for battery room).
Only vertical air-discharge outlets (jet-nozzle type) shall be provided for roof exhaust
system.
Air outlet and intake louvres shall be equipped with a rear built-in insect screen.
Outside air intakes shall be provided in outer walls and installed not less than 3m above
ground.
Every ductwork exposed to some mechanical plant room, such as machine halls etc. shall
be made of heavy reinforced and strong construction only.
Every duct work shall be designed, tested and constructed with regard to and in
consideration of the maximum foreseeable pressure condition, such as caused by full-load
operation of fans against closed dampers, etc. The same criteria shall be applied to the
design, testing and construction of the air-handling units.
Each air-handling unit and exhaust fan shall be interlocked with and shut down by the
appertaining smoke detectors, via fire alarm panel.
Air-handling units, supply-air fans, exhaust-air fans, etc. shall be located in A/C and
ventilation-plant room. The A/C and ventilation rooms shall be designed as separate fire
zones.
Page: 6
Every ductwork shall be equipped with a sufficient lot of access doors of an adequate size
for easy inspection and cleaning of the duct insides.
All A/C plant rooms shall be air-conditioned in order to avoid condensation effects and
corrosion.
Where corrosion may occur, appropriate non-corrosive materials and assembly methods
including isolation of dissimilar metals against galvanic interaction shall be used. Resistance
to corrosion must be achieved by use of the appropriate base materials and coatings, but
only applied when specifically permitted by the Specification. All equipment casings shall be
of sea water resistant Aluminium alloy.
All system components shall be matched and balanced to achieve compatibility of

equipment for satisfactory operation and performance throughout the entire operating
conditions and control range.
All equipment shall be designed for marine environment.
No return air shall be taken back into the system from battery room, or from any polluted
rooms.
The supply air temperature to rooms and areas to be air-conditioned should not be less than
18C of the room temperature
The ventilation shall be adequately sized to ensure that the GIS-Switchgear building and the
turbine buildings are slightly pressurised (20-30 Pa).
Additional extract fans shall be provided for toilets of air conditioned buildings and a
minimum of 10 air changes per hour shall be provided. It shall be ensured that air
conditioned air can enter the toilets.
4.2
INDOOR DESIGN CONDIT IONS
The indoor conditions given in the tables hereafter shall be considered for design, testing and
construction of the air-conditioning and ventilating systems and shall be guaranteed by the
Contractor.
4.2.1
AC System Types
General
The following tables are provided with symbols indicating the classification of ventilation and airconditioning systems.
Symbols
V-I
Mechanical ventilation supply
V-II
Mechanical ventilation exhaust
V-III
Mechanical ventilation supply and exhaust
AC-I
Air conditioning
Type of System and related Design Data of Room Conditions for Ventilation Systems:
Room
Electrical/mechanical
equipment rooms
Temperature
C
Type of Systems
System
Requirements
Not more than + 5 K

above maximum
V-III
100% Stand-by
Page: 7
Type of System and related Design Data of Room Conditions for Ventilation Systems:
Room
Temperature
C
Type of Systems
System
Requirements
ambient temperature
Demineralisation
Plant
ditto
V-III
100% Stand-by
providing the capacity for
Phase I and II
Waste Water Treatment
Ditto
V-III
100% Stand-by
SW chlorination plant room
Ditto
V-III
100% Stand-by
Providing the capacity for
Phase I and II
Ventilation fan rooms
ditto
V-I
100% Stand-by
Mechanical equipment
ditto
V-III
100% Stand-by
Rooms
Washrooms (toilets)
ditto
V-II
100% Stand-by
Store (Main Store Hall)
ditto
V-II
100% Stand-by
400 kV Substationditto
V-III
100% Stand-by
Switchgear Building
Turbine Generator Halls
ditto
V-III
100% Stand-by
Chemical Stores
ditto
V-II
100% Stand-by
Heat Treatment, Sand
ditto
V-III
100% Stand-by
Blasting, Air Compressor
Buildings
Type of System and related Design Data of Room Conditions for Air Conditioning Systems:
ROOM
Computer Room
Substation Control Room
Central Control Room
and other Control Rooms
Electronic Equipment
Sampling and Analysing
Sanitary
Meeting Rooms
Laboratory
Offices, Prayer Room and
connected Corridors
Administration Building,
except toilets and kitchen
Mechanical Workshop
Air-conditioning
Equipment Room
Battery Rooms
SYSTEM
AC-I
AC-I
AC-I
TEMPERA HUMIDITY
TURE
C
%
23 1
50-60
23 2
50-60
23 2
50-60
NOISE
LEVEL
dB (A)
50
45
45
SYSTEM
REQUIREMENTS
100% Stand-by
100% Stand-by
100% Stand-by
AC-I
AC-I
AC-I
AC-I
AC-I
AC-I
23 2
23 2
23 2
23 2
23 2
23 2
50-60
50-60
50-60
50-60
50-60
50-60
50
60
45
45
45
100% Stand-by
100% Stand-by
100% Stand-by
100% Stand-by
100% Stand-by
100% Stand-by
AC-I
23 2
50-60
45
100% Stand-by
AC-I
AC-I
28 2
26 2
< 65
< 65
60
60
100% Stand-by
100% Stand-by
AC-I
26 2
50-60
50
100% Stand-by *
Page: 8
ROOM

SYSTEM
TEMPERA HUMIDITY
TURE
C
%
26 2
50-60
NOISE
LEVEL
dB (A)
50
SYSTEM
REQUIREMENTS
Switchgear Rooms for

AC-I
100% Stand-by
LV/MV, cable floors /
cable basements
Telecommunication
AC-I
26 2
50-60
50
100% Stand-by
Room
Relay Rooms
AC-I
26 2
50-60
50
100% Stand-by
Rooms other than Main
AC-I
26 2
50-60
50
100% Stand-by
Store Hall in the Stores
(refer also to P2.28)
Note: 100 % stand-by means that all equipment needed for the HVAC system shall be provided
redundant. Exceptions: Air ducts and to the extend possible, water pipe works
*
To remove acidic air and hydrogen gas. Intake air shall be filtered & all fans and
equipment shall be explosion and acid proof.
Air Distribution
The air-distribution systems shall be generally low-velocity air re-circulating systems with
constant outside air rates at minimum and maximum outside conditions. During the transition
period outside air shall be used for cooling purposes at appropriate outside temperatures.
The maximum air velocities in different applications shall be as follows:
Room, Equipment
Maximum air velocity m/s
Air-conditioned rooms
0.25
Through filters
2.5
Through coils
2.5
In main air ducts
5.0 7.0
In main ventilation ducts in turbine halls
5.0 8.0
In branch ducts in turbine halls
2.0 5.0
For final design of the above-mentioned airflow velocities, the induction effects of the airdistribution and the maximum allowable sound pressure level shall be considered too.
Ventilation Systems
Complete ventilation systems shall be provided for the areas as stipulated. Depending on the
type of system (V-I, V-II, V-III), supply-air fan, exhaust-air fan or both, air-handling units,
necessary duct work with grills, automatic -control system with switchboard, air-intake and
exhaust-air louvers or exhaust-air hoods shall be included.
Where necessary, appropriate fire detectors, fire dampers and sound attenuators have to be
provided. Air-intake louvres for battery rooms have to be provided with air filters.
All systems designed to remove internal heat from machinery, lighting, etc., shall be based on
an outdoor temperature of 50C. In absence of excessive internal heat, the systems shall be
designed on an appropriate air-change rate.
The ventilation system in rooms containing a flammable or explosive material shall be
automatically cut out under fire conditions. Ventilation systems in other rooms with automatic
Page: 9
fire-extinguishing systems shall be tripped and/or controlled in the local-control panel and maincontrol panel in the Central Control Room of the fire-fighting system.
All exhaust systems shall be generally low velocity up to approximately 8 m/s.
All toilets, janitor rooms, wash rooms, locker rooms, stores and tea kitchens shall be ventilated
by transferred air from adjacent areas and exhaust fans.
Battery rooms shall be ventilated by transferred air from adjacent areas and exhaust system
including grilles, duct works and exhaust fans made of acid resistant synthetic material (PVC).
Transformer bays, if applicable shall be ventilated naturally through louvres in the doors or
walls.
Exhaust systems shall be designed based on the following minimum air change rates (ACR) per
hour:
Electrolyser rooms
Battery rooms
12/6
ACR
ACR
Toilets
12/6
ACR
Washrooms
12/6
ACR
Shower cabins
30/15
ACR
Kitchens
30
ACR
Canteens
6/3
ACR
Laboratories
8/4
ACR
Fume hoods
6,000 m 3/h per metre
Pump rooms
12/6
ACR
Tank rooms
ACR
Filling rooms
12/6
ACR
Dosing rooms
ACR
Storage rooms
ACR
Emergency showers
12/6
ACR
Air-compressor rooms
12/6
ACR
Sampling stations
12/6
ACR
Neutralisation rooms
ACR
Cable floors
12/6
ACR
Water-treatment plants
12/6
ACR
Chlorination and chlorine-drum storage room
20
ACR
Air-blower rooms
12/6
ACR
4.2.2
Air Conditioning/Cooling Systems
Complete air-conditioning systems shall be provided for the areas as stipulated.

The system shall comprise:
Air-handling unit
Page: 10
Ductwork, control dampers, air grills and fixtures
Sound attenuator, fire dampers
Outside and exhaust-air louvres
Control system and switchboard
The verification of air quantities has to be based on a cooling-load calculation considering

external and internal-heat gain and the room design condition as stated.
When necessary, electric steam humidification shall be applied in order to control the relative air
humidity in the rooms.
A standby capacity of 100% of the air-conditioning system shall apply for all areas:
The AC systems shall be designed to utilise the required outside-air cooling at an appropriate
outside temperature and to maintain an indoor positive pressure of not greater than 49 Pa.
The air-conditioning system shall be designed to the rules of Fire Services Requirements for
Buildings. The ducting system shall be equipped with fire dampers and thermal or electrothermal links. All the thermal insulation shall be incombustible and a fire-retardant product.
For buildings with automatic gas-extinguishing system, the fire dampers, smoke-extraction
dampers and smoke-extraction fans of the air-conditioning system shall be controlled in the
local control panel and the remote fire-control panel or centre. When the fire alarm is initiated,
all the relevant/respective fire dampers shall be closed and the air-conditioning unit and related
exhaust unit shall be stopped instantly.
Automatic-control system and control panel shall be provided for the air-conditioning system.
Audio-warning alarms and visible indication system of the air-conditioning systems shall be
installed in the central control room and the local control panel. Local control panel and powersupply isolator for the air-conditioning system shall be provided.
4.2.3
Heat Transfer Coefficients
The following heat transfer coefficients values are recommended to use for cooling load
calculation. These values shall be the minimum requirement. The Contractor shall calculate the
actual heat transfer coefficients with the building material used.
External walls at least
0.75 W/mK
Roofs at least
0.45 W/mK
External walls shall be double skin with thermal insulation between the skins.
Insulation with k 0.04 W/mK
0.45 W/mK
Internal walls
2.3 W/mK
Intermediate floor, ceiling
3.4 W/mK
Partition
3.4 W/mK
Internal aluminium door, 40 mm
4.5 W/mK
Internal galvanised steel door, 40 mm
4.5 W/mK
Intermediate wooden door, 40 mm
2.2 W/mK
External galvanised steel door
5.88 W/mK
External glass door
6.4 W/mK
Window double glass
4.0 W/mK
Page: 11
Generally a lighting level of 33 W/m2 shall be considered.

4.2.4
Sound Pressure Level
For the purpose of noise protection for personnel and public, all mechanical systems and
components design shall not exceed the maximum permissible noise level as shown in the
following table considering the maximum possible daily exposure time of workers during
maintenance operation.
The sound pressure level shall be measured and recorded according to DIN 45633, Evaluation
Curve A. It will be measured at one meter distance from each point of the installed equipment.
Maximum Permissible Sound Level (dBA)
Daily Exposure Time
A-eighted, Slow Response
16 hours
85
8 hours
90
6 hours
92
4 hours
95
3 hours
97
2 hours
100
1.5 hours
102
1 hour
105
30 minutes
110
15 minutes or less
115
Sometimes a worker may be exposed to several noise environments of different levels a day. In
such a case, the combined effect is considered safe if
C1 C 2 C 3
Cn
+
+
+ ...... +
<1
T1 T 2 T 3
Tn
Where Cn is the total exposure time at a certain sound level and Tn the maximum allowed daily
exposure time as defined above.
The far noise level under base rating operation of all units shall not exceed 55 dB(A) at a
distance of 120 meter at a height of 1.5 meter above ground level from the building or
equipment boundary in the Contractors scope of supply.
The maximum sound pressure level in the rooms shall be as follows:
Room
Sound Pressure Level [dB(A)]
Control Rooms
45
Offices
45
Electrical rooms
50
Mechanical rooms
80
Page: 12
4.3
REFRIGERATION EQUIPM ENT
General
The refrigeration employed to the system shall comply to the Montreal Protocol (e.g. R134a). All
the components shall be designed for refrigerated employed and shall be suitable for the
discharge high pressure common to air cooled condenser application.
All of the principal parts of any refrigerating machine shall be the standard products of a
reputable refrigerating machine manufacturer. Minor accessories, piping, etc., not produced by
the manufacturer shall be strictly in accordance with the refrigerating machine manufacturers
standard practice and specific recommendations. All equipment shall operate within the
manufacturers standard range of recommended speeds and guaranteed capacities as
indicated by the manufacturers latest catalogue information.
Each refrigerating machine shall be supplied with one full charge of refrigerant and lubricating
oil. All losses of refrigerant or oil occurring prior to acceptance of the equipment, or occurring as
a result of defects for which the Contractor is responsible under the guarantee, shall be made
up by the Contractor free of charge to the Employer.
The Contractor shall furnish and deliver one extra complete charge of lubricating oil and
refrigerant in sealed containers in addition to that placed in the system. No refrigerant shall be
charged until the equipment has been tested as hereinafter specified and approved by the
Employer/Engineer.
All heavy parts (30 kg or over) that must be removed for inspection, cleaning or repair, such as
motors, gear boxes, cylinder heads, casing tops, condenser and cooler heads, etc. , shall be
provided with lifting eyes or lugs. Electrical hoists for lifting of equipment to carry out
maintenance works as well as for lifting spare equipment onto the roof of buildings shall be
provided for permanently use. Except for removable heads on coolers, insulation for
refrigerating machine may be factory applied in lieu of field applied as required hereinafter
under the Thermal Insulation clause. Any damage to insulation after or before final Employer
acceptance, shall be sufficient cause for the Contractor to replace the entire section damaged.
Insulation shall not be patched.
The Contractor will submit for the Employer/Engineer a detailed proposal for the control system
for approval before any orders for equipment are placed.
Refrigeration Plant Accessories
All major items of plant shall be dried at the factory and filled with a holding charge of refrigerant
or inert gas; all openings shall be sealed. During erection, care shall be taken to prevent the
entry of moisture. A flanged dehydrator shall be fitted in the refrigerant pipework and so
arranged that the drier cartridge can be replaced when the refrigerant circuit is charged. In
addition to the suction gas, and lubricating oil strainers fitted in the compressor, a liquid line
strainer shall be fitted to protect the expansion valve or float valve; where any pressure
regulating device is fitted in the suction line it, shall be protected by a strainer. Where an
evaporator pressure regulating device is fitted, an additional gauge to indicate evaporator
pressure shall be provided and shall be complete with means of isolation.
Each chiller shall be provided with the following items:
Manual shut-off valves on the compressor suction and discharge
Compressor suction and discharge pressure gauges
Oil pressure gauge
Oil sight glass
Low oil pressure cut out
High and low gas pressure cut-out of controls with manual reset
Thermostatic expansion valve externally equalised
Shut-off valve, charging valve and sight glass shall be provided on the liquid line
Check valve on compressor discharge
Liquid line solenoid valve
Refrigerant filter drier
Discharge gas muffler
Pressure relief device
Head pressure control by cycling condenser fans on outdoor units only
Timer to prevent excessive compressor cycling
Evaporator freeze-up protection thermostat
Control thermostat operating step controller providing capacity modulation
All motors shall have built-in thermal overload protection.
Page: 13
A weatherproof control panel shall be provided to house all starters, gauges and controls. The
panel shall contain all necessary terminal strips to facilitate external wiring.
The following safety devices and interlocks shall be incorporated into the water chilling plant
systems:
Mercury in glass thermometers and pressure gauges shall be provided on individual inlet
and outlet pipework connections to the water circuit of the evaporator.
The chilled water pump starters shall be interlocked through an auxiliary contact with the
compressor and wired in series with the compressor safety controls.
A paddle type flow-switch shall be fitted in the chilled water circuit for non-flow cut-out of the
compressor.
Refrigerant Circuits
All refrigerant circuits shall be assembled, tested and charged with refrigerant at the
manufacturers works.
Refrigerant pipework at site shall be avoided as far as possible.
All refrigerant pipework shall be of refrigerant quality, soft copper tube with socketed fittings and
soldered joints to the size recommended by the equipment manufacturer. Particular attention
shall be paid to cleanliness during erection, all pipe ends being sealed and all fittings, valves
etc. shall be kept in their individual wrapping until actually required.
Flexible connections shall be fitted at each compressor. These shall be corrugated flexible
bronze tube, armoured with phosphor bronze and braiding of the same bore as the line in which
they are fitted and suitable for the stated test pressure.
Page: 14
A liquid-line sight glass, thermostatic expansion valve, drier and strainer shall be fitted in the
main liquid-line to each evaporator.
All refrigerant pipework shall be supported continuously on cable trays or similar. Individual
items of equipment, such as driers, solenoid valves shall be independently supported.
Pipework shall be designed and run so that any oil in the compressor discharge refrigerant,
which passed through the oil separator (where fitted), is carried through the system and
returned. At any point where a large quantity of oil may accumulate, an oil separator and a
means of returning the oil to the compressor shall be provided.
Valves required for compressor, liquid receivers etc. shall be of either diaphragm or bellows
type or shall be packed valves complete with a back seating and a seal cap.
4.4
CENTRIFUGAL TYPE CHILLERS
The air cooled centrifugal liquid chiller shall be completely assembled with all refrigerant piping
and internal wiring, ready for field installation. The unit shall be pressure tested, evacuated and
fully charged with refrigerant R134a and includes an initial oil charge. After assembly, an
operational test shall be performed with water flowing through the cooler to check that each
refrigeration circuit operates correctly. The unit structure shall be heavy-gauche, galvanised
steel, coated with backed-on enamel. Base rails shall be of formed double thickness, painted
galvanised plate steel.
Each chilling unit shall be mounted on the vibration isolators under all feet. Isolators shall be
proportioned for the loads at all points and all isolators for one unit shall be mounted on a
floating concrete base extending under the entire unit and isolating the building construction
from any vibrations.
Compressor
The compressor shall be a single stage centrifugal type powered by an open drive electrical
motor. The housing shall be fully accessible with vertical circular joints, with the complete
operating assembly removable from the compressor and scroll housing. Compressor castings
shall be designed for the highest working pressure and hydrostatically tested in accordance with
the design standard. The rotor assembly shall consist of a heat-treated alloy steel drive shaft
and impeller shaft with a cast aluminum, fully shrouded impeller. The impeller shall be designed
for balanced thrust, dynamically balanced and overspeed tested for smooth, vibration-free
operation. Insert-type journal and thrust bearings shall be fabricated of aluminium alloy,
precision bored and axially grooved.
Internal single helical gears with crowned teeth shall be designed so that more than one tooth is
in contact all the times to provide even distribution of compressor load and quiet operation.
Each gear shall be individually mounted in its own journal and thrust bearings to isolate it from
impeller and motor forces. The shaft seal shall be a spring loaded carbon ring with precision
lapped collar cooled by oil during operation. A gravity-fed oil reservoir shall be build into the top
of the compressor to provide lubrication during coastdawn in the event of a power failure.
Capacity Control
Capacity control shall be achieved by use of pre-rotation vanes to provide fully modulating
control from full load to minimum load. Pre-rotation vane position shall be automatically
controlled by an external electric actuator to maintain constant leaving chilled water
temperature.
Compressor Motor
The compressor motor shall be an open squirrel cage induction motor. The open motor shall be
provided with a D-flange, bolted to the cast iron adapter mounted on the compressor to allow
Page: 15
the motor to be rigidly coupled to the compressor to provide factory alignment of motor and
compressor shafts. Motor drive shaft shall be directly connected to the compressor shaft with a
flexible disk coupling. The coupling shall be off all metal construction with no wearing parts and
no lubrication requirements.
Lubrication
Lubrication oil shall be force-fed to all bearings, gears and rotating surfaces by an oil pump
which operates prior to start-up, continuously during operation and during coast down. An oil
reservoir, separate from the compressor shall contain a submersible oil pump and immersiontype oil heater, thermostatically controlled to remove refrigerant from the oil. Oil shall be filtered
in an externally mounted 0.5 m replaceable cartridge oil filter equipped with service valves. Oil
cooling shall be via a refrigerant cooled oil cooler, with all piping factory installed. Both the
refrigerant and the oil side of the oil cooler shall be provided with service valves. An automatic
oil return system to recover any oil that may have migrated to the evaporator shall be provided.
Oil piping shall be completely factory installed and tested. The lube oil system shall be designed
in such a way that sufficient oil is supplied during coast down and in the event of power failure.
Power and Control Panel
The unit shall be supplied complete with a microcomputer control center in a locked enclosure,
factory-mounted, wired and tested. The control center includes a 40 character alpha-numeric
display showing all system parameters with numeric data in S.I. units.
Digital programming of essential set points through a color coded keypad includes:
Leaving chilled water temperature
Percent current limit
Pull down demand limiting
Seven-day time clock for starting and stopping chiller
Remote reset temperature range.
4.5
SCREW TYPE CHILLERS
The air cooled screw liquid chiller shall be completely assembled with all refrigerant piping and
internal wiring, ready for field installation. The unit shall be pressure tested, evacuated and fully
charged with refrigerant R134a and includes an initial oil charge. After assembly, an operational
test shall be performed with water flowing through the cooler to check that each refrigeration
circuit operates correctly. The unit structure shall be heavy-gauche, galvanised steel, coated
with backed-on enamel. Base rails shall be of formed double thickness, painted galvanised
plate steel.
Compressor
The rotary twin-screw compressor shall be engineered and constructed to meet the exacting
requirements of the industrial refrigerating market. It utilise the latest technology to provide the
most reliable and energy efficient compressor available at all operating conditions. The
compressor shall be driven by an electrical motor via a gear speed control for increased
capacity and improved volumetric efficiency. The compressor housing shall be made of cast
Page: 16
iron, precision machined to provide minimal clearance for the rotors. The design pressure shall
be in compliance with the chiller as well as the cooling medium conditions.
The rotors shall be manufactured from forged steel and use asymmetric profiles. The
compressor shall incorporate a complete anti-friction bearing design for reduced power and
increased reliability. Four separate, cylindrical, rollerbearings handle radial loads. Angularcontact ball bearings handle axial loads. Together they shall maintain accurate rotor positioning
at all pressure rations thereby minimising leakage and maintaining efficiency.
Capacity Control
Capacity control shall be achieved by use of a slide valve which provides fully modulating
capacity control from 100% to 15% off chiller full load. The slide valve shall be actuated by oil
pressure controlled by external solenoid valves.
Compressor Motor
The compressor motor shall preferably be an open squirrel cage induction type motor. The
motor stator is of epoxy bonded core construction with glass-served windings, and insulation for
maximum durability. The terminal boxes are rain-tight. Heat sensing thermistors are an integral
part of the motor for reliability protection.
Lubrication
The compressor shall have a closed coupled oil separator with no moving parts to minimize oil
carry-over for optimum heat exchanger efficiency. Impingement, direction change, and low
velocity provide effective separation over a wide range of operating conditions. The main oil
reservoir shall be located in the oil separator. The compressor also shall have an oil reservoir
located at the rotor bearings to provide lubrication during start-up, coastdown and in the event
of power failure. During operation, system pressure differential provides proper oil flow without
the need of an oil pump.
An immersion oil heater shall be located in the oil separator reservoir and compressor. It shall
be temperature-actuated to effectively remove refrigerant from the oil during shutdown. Power
wiring shall be provided to the control center. An external, replaceable-cartridge oil filter shall be
provided with manual isolation stop-valves.
Oil cooling, when required, shall be provided by liquid injection into the compressor and
discharge temperatures for all conditions. The control centre provides consistent oil temperature
at all times to assure proper oil viscosity independent of system conditions.
Economizer
An economizer shall be included in each refrigerant circuit to enhance the overall system
performance. The refrigerant to refrigerant plate type economiser shall be constructed of acid
resistant stainless steel. The heat exchangers shall be designed according to the requirements
of the system. The temperature limits are -195C to +185C.
Refrigerant Circuit
Independent refrigerant circuits will be furnished on each unit. All unit piping is ACR copper,
with brazed joints. The liquid line includes:
a shutoff valve with charging port
sight glass with moisture indicator
thermal expansion valve
solenoid valve
Page: 17
filter-drier.

All controls and motor starting equipment necessary for unit operation shall be factory wired and
function tested. Components shall be mounted on galvanised steel back plates and enclosed in
the relevant power or control compartment of the galvanised steel enclosure. On the main
control panel door a further door, with perspex viewing window shall be located on the exterior
of the control compartment door to house the microcomputer keypad and display. All doors shall
be hinged and lockable and include door stays. The control panel shall be designed to IP 65 for
outdoor weather protection and finished in zinc phosphate pre-treated bake enamel.
Each power compartment shall contain:
Star/delta compressor starting contactors, if required
Fan fuses
Control interface relays
Incoming mains terminal block per compressor
Incoming mains bus bars
Control circuit (220/230 V) serving compressor solenoids
Compressor heaters
Compressor and fan contactor coil with residual current circuit breaker.
The 24 V compartment contains:
auto/off switch mounted on the door
microprocessor board
power supply board
keypad
display mounted under a perspex door.
Anti-freeze protection (Thermostat) shall be considered for cooler (Heat exchanger).

4.6
RECIPROCATING TYPE CHILLER
Reciprocating type chillers shall be completely assembled with all interconnecting refrigerant
piping and internal wiring for field installation.
The unit shall be pressure tested, evacuated and includes nitrogen holding charge and initial oil
charge.
The unit base frame shall be of heavy gauge, galvanised steel, with backed on enamel.
Page: 18
Compressor
The chiller shall be an accessible, semi-hermetic, reciprocating compressors. All rotating parts
shall be statically and dynamically balanced.
The compressor motors shall preferably be of an open squirrel cage *** overload protection in
each phase. The terminal boxes shall be to IP 54 for indoor and IP65 for outdoor. Starting can
be done by part winding or star/delta connectors.
The compressor housing shall be cast iron, and contains: removable cylinder heads with
internal muffling, suction and discharge service valves, crankcase sight glass and heater, oil
and suction strainers, and internal relief valves.
The crankshaft shall be ductile (nodular) iron, drilled for positive oil distribution, with integral
counterweights for balancing. The main bearings shall be insert type, steel backed babbitt. The
thrust bearing shall be bronze.
Cylinder assemblies: suction and discharge valves are high-quality, nonflexing, stainless steel.
The pistons shall be aluminium alloy with two piston rings. The connection rods shall be
aluminium alloy with integral bearing surfaces on both ends. Cylinder liners shall be removable.
The lubrication shall be forced-fed by reversible oil pump to all crankshaft and bearing surfaces
through a fine mesh stainless steel strainer.
Capacity control shall be provided by solenoid actuated, capacity control valves, which are
controlled by the microprocessor centre. Gas flow shall be sufficient at all times to cool the
motor.
Each compressor shall be mounted on isolator pads to reduce vibration transmission to
structure.
Semi-hermetic compressors shall include the following features:
All parts of the electric motor shall be proof against contact with halocarbon refrigerant and
the lubricating oils associated with halocarbon refrigeration systems.
The oil pump shall operate equally well under either direction or rotation.
Where the motor rotor is overhung, a support bearing of adequate width shall be provided.
Additional motor protection shall be provided against failure or partial failure of the gas
cooling system.
Refrigerant Circuit
Independent refrigerant circuits shall be furnished on each unit. All unit piping shall be ACR
copper, with brazed joints and insulated with flexible, closed cell, foam.
All controls and motor starting equipment necessary for full unit operation shall be factory wired
and function tested. Components shall be mounted on galvanised steel back plates and
enclosed in the relevant power, pressure or control compartment of the galvanised steel
enclosure. A separate door shall be provided for the pressure control section. On the main
control panel door a further door, with perspex viewing window shall be located on the exterior
of the control compartment door to house the microcomputer keypad and display. All doors shall
be hinged and lockable and include door stays. The control panel shall be designed to IP 54
indoor and IP65 outdoor and finished in zinc phosphate pre-treated bake enamel.
Page: 19
Each power compartment contains: part winding or star/delta compressor starting contactors;
fan fuses; control interface relays; incoming mains terminal block per compressor; incoming
mains bus bars; control circuit serving compressor solenoids, compressor heaters, compressor
and fan contactor coil with residual current circuit breaker.
The 24 V pressure compartment contains: compressor low, high and oil pressure transducers
plus manual high pressure cut out. Auto/off switch and key reset emergency stop button
mounted on door.
4.7
PACKAGE AIR COOLED ROOF TOP DX-UNITS
The units shall be factory assembled, piped, internally wired, fully refrigerant charged, suitable
for outdoor installation and designed to deliver the required cooling capacity at 50 C dry bulb
(DB).
Refrigerator circuit with refrigerant filling (e.g. R134a), refrigerant drier and capillary tube
injections; complete including fully wired control gear in control box. Mounting facility for airbrake contractor, air cleaner, thermostat and time delay relay.
The unit casing shall be constructed from galvanised steel sheets, zinc-phosphated, with a
stoved-enamel finish. All access panels and the unit casing shall be provided with thermal and
acoustic insulation. All moving components such as compressors and condenser fans and
motors shall be anti-vibration mounted to minimise the transmission of vibration and noise.
The access panels and the main unit casing shall be attached to a sturdy chassis.
Compressor
Generally, semi-hermetically sealed reciprocating compressors including electric crankcase
heater shall be fitted with internal and external shock absorbers to minimise vibration and noise
transmission. The compressor of bigger units shall be fitted with a discharge line silencer and
charged with the required quantity of oil for adequate lubrication circulated by means of an
internal oil pump.
Internal overload protection located in the motor windings shall be provided.
Control Panels
The control panels with locked doors shall contain all circuits including relays, freeze protection
controls, interlocks for inherent motor protectors, crankcase heaters, liquid line solenoid valves,
discharge, suction and oil pressure gauges and gauge valves.
All control and power wiring to motors shall be interconnected. Refrigerant controls shall be
separated from the power circuit for safety. Units shall be factory equipped with electrically
operated device loading and unloading compressor cylinders and control for cycling
compressors.
The control panel shall comprise all necessary safety and control devices for automatic
operation. Unit controls shall include positively acting timers to prevent short cycling of
compressors and delay to restart of compressors after shut-down.
All unit control boxes shall also include high and low pressure starts, multiple step air
temperature controller, field power and control circuit terminal blocks, circuit breakers, motor
contactors, control relays and disconnecting switches. On all units the source of control circuit
power shall be completely independent of unit power source.
4.8
GENERAL REQUIREMENTS FOR AIR COOLED CONDENSERS
The condenser coils shall be seamless copper tubes arranged in staggered rows, mechanically
expanded into copper fins. All copper coils in contact with outside air shall be electro-tinned.
Page: 20
Integral sub-cooling shall be included. All copper coils in contact with outside air shall be
electro-tinned. The design pressure shall be in compliance with the adverse cooling condition
plus spare capacity. Fins shall be factory coated using the manufacturers standard protective
system which shall be suitable for the prevailing adverse ambient condition.
To reduce the effect of sand clogging etc., condensers shall have a recommended fin spacing
of 8 fins per inch.
The condensers shall have sufficient capacity to allow that one cooling air fan can be out of
service without impairing the required cooling capacity of the A/C system.
The condenser fans shall be glass reinforced polypropylene, high efficiency, airfoil-type fan
blades directly driven by independent motors, and positioned for vertical air discharge. The fan
guards shall be constructed of heavy-gauge wire hot dipped galvanised steel. All blades shall
be dynamically and statically balanced for vibration-free operation.
The fan motors shall be totally enclosed air cooled squirrel-cage type. They shall feature ball
bearings that are double sealed and permanently lubricated.
The condensers shall have sufficient capacity to allow that one cooling air fan can be out of
service without impairing the required cooling capacity of the A/C system.
The condenser frame, supports and enclosure shall be of galvanised steel and be painted.
Extra protective finish shall be provided against saline and sand-laden atmospheres.
Where condensers are mounted outside the buildings, weatherproof motors shall be provided
and the condenser enclosure shall be designed to protect the fan, motor drive and finned coils
from the weather.
Externally mounted condensers shall discharge air vertically upwards. A means of maintaining
condenser pressures shall be incorporated. This shall be achieved by sequence control of three
or more condenser propeller fans.
4.9
REFRIGERATION PLANT - WATER COOLED CONDENSER (ALTERNATIVE)
General
Cooling water connection from e.g. the closed cooling water system of the Power Plant.
The condenser shall be fabricated similar to the evaporator and as for the water chiller it shall
be of shell and tube exchanger type for cold water connection.
Chilled Water Pumps
Electrically driven 2 x 100 % pump sets shall be installed on the chilled water systems.
Duplicate pump sets shall be installed throughout and they shall be suitable for the pressure
and temperature of the system in which they are installed.
Generally, pumps shall have cast iron casings with gunmetal impellers and stainless steel
shafts.
Generally, pumps shall be of the directly driven centrifugal type, or arranged for V-belt drive.
Where pump glands are required to be drained, the Contractor shall provide drain connections
discharging visibly over tundishes from which pipework shall be run to discharge over the
nearest sump or floor drain. Pumps with mechanical seals shall be used.
Each pump must be installed with isolating valves on suction and double regulating valves on
the discharge connections in such a manner that the pump and where necessary the associated
non-return valve on the discharge connection can be removed for maintenance without draining
Page: 21
down the whole pipework system. Pipeline strainers shall be installed on the pump suction
pipework.
Each pump and motor set must be installed in such a manner that the motor can be removed
without disturbing pipework connections. Altitude gauges are to be provided on the suction and
discharge of each duplicate pump set to indicate the head produced.
Each pump must be firmly supported and accurately aligned so that its weight is not taken by
adjacent pipework. Electric motors shall be of the commercially silent type. Both motors and
starter shall comply with the electrical section of this specification and motors shall be rated for
continuous duty.
All pumps and motors shall be provided with lubrication points which shall require attention at
intervals of not less than 3 months.
All pumps shall have an efficiency of not less than 60% and the motor speeds shall not exceed
1500 rpm.
Bearings shall be either sleeve type with oiling ring and reservoir or ball/roller type oil lubricated.
These bearings shall all be outside the stuffing box or shaft seals.
Drain points shall be provided in the pump casings.
4.10
AIR-HANDLING UNITS
General
The central station air-handling units shall be generally horizontal, arranged for vertical or
horizontal air discharge and comprise all or some of the following sections assembled in
sequence to meet the required applications:
Damper for Manual adjustment on 100% units and motorised damper for 3 x 50%
arrangements or 2 x 100 % applications (one as stand by)
Supply air fan
Return-air fan (if required)
Pre-filter
Bag filter
Cooling coil (DX)
Drip eliminator of corrosion resistant metal
Damper
Flexible duct connections
Mixing chamber (where required)
Humidity control, steam humidifier
All lubrication points shall be easily accessible
Lifting lugs shall be provided to enable lifting of equipment by crane and to assist in the
positioning of sections at Site.
All construction and components shall be designed in consideration of extreme high and low
total and shock pressure caused by different operating situations.
Page: 22
Equipment design shall be such that selected filter media, bearings, insulation etc. will be
suitable for the ambient temperature existing within the unit.
Each unit shall be constructed so as to prevent drumming, distortion and vibration and shall
be of modular construction for ease of handling and replacement of sections.
The units shall be designed to incorporate all those components specified separately.
Basic Construction
The sectional casing of air-handling units shall consist of rigid frames, manufactured from
galvanised steel sheets and covered with removable panels screwed on the top and bottom of
the air-handling unit and complete with removable side panels, which shall be fixed to the
frames by quick release fasteners including supplementary handles for easy handling and
accessibility for inspection and maintenance.
The unit casing shall be suitably stiffened to conform to the pressure characteristics of the
system under all operating conditions.
The unit casing shall be constructed of double skinned sheet metal combined with an
intermediate insulation layer made of mineral wool or glass fibre material. The internal and
external skins shall be made of solid galvanised steel sheet. The external skin shall be with
priming coat and heat-treated synthetic-resin finish. All guide and sliding tracks, access doors,
screws and bolts shall be made of stainless steel sheets. The intermediate insulation shall be
designed in consideration of a maximum permissible heat transmission coefficient of less than
0.70 W/m 2K (and for AHU in machine shall not exceed sound level of 65 dB(A) outside of AHU
in 1 m distance).
All bottom plates of the casing shall be designed walkable for easy access and serving and to
avoid damages.
The maximum permissible flow rate shall be less than 2.5 m/s within the air-handling unit. The
design of the casing shall be smooth to avoid separated air flow.
Joints of casing and frames shall be sealed airtight and waterproof by means of rubber sealing.
All side panels and access doors shall be sealed with profiled rubber joints.
All built-in components shall be easily withdrawable from the unit by means of special tracks.
All leading ducts, pipes and cables through as well as all connection with the panels of the units
shall be sealed air-tight and water-proof by means of permanent resilient plastic material and
plastic packing rings.
All rotating parts and components shall be mounted on spring or rubber vibration dampers.
All duct connections shall be jointed to the air-handling unit by mean of non-rotting, flexible
canvas connections with flange and counter-flange.
Flexible connections shall be of high density material and shall be securely fixed to the unit
sections by means of fixing straps and flanged connectors. All flexible connections shall be airtight and suitable for the maximum operating pressure associated with the system.
The air handling unit systems shall include but shall not be limited to following components
mentioned hereunder and described in these specifications.
In general, the air handling units, shall be indoor or outdoor, vertical or horizontal, floor
mounted, factory-assembled type.
Page: 23
Indoor units shall be installed in air conditioning plant rooms in which the air handling unit
control panel, fresh air intake, necessary water and drain piping, valves and insulation, etc. will
be installed.
Outdoor units shall include a technical duct in which the air handling unit control panel,
necessary water and drain piping, valves etc. shall be provided.
Components installed in air handling unit rooms shall conform to the following specification:
Factory assembled, vertical or horizontal, floor mounted type air handling unit complete with
return air filters, cooling coil, centrifugal fan(s), fan(s) drive, driving motor, casing and all
necessary accessories such as internal lighting, emergency stop push buttons and door
handles.
Supply air ductwork complete with flexible connection duct insulation and finish and all
necessary acoustic lining, etc.
Fresh air intake with motor operated damper, fresh air filter and casing if fresh air is not pretreated.
All necessary piping, condensate and drain piping with all required isolating and balancing
valves, pressure gauges, thermometers, vent valves, automatic control valves and thermal
insulation.
Casing
The air handling unit casing shall comprise a rigid frame with double skin sheet metal panels
with thermal/acoustic insulation sandwiched between the two skins. The sheet metal skins shall
be a minimum of 1.6 mm thick, suitably stiffened and braced to eliminate distortion and
drumming. The insulation shall be minimum 35 mm thick and have a thermal conductivity of not
less than 0.04 W/m K. Panels shall be arranged to give adequate and easy access to the
equipment whilst providing a good air sealed enclosure. The maximum face velocity shall not
exceed 2.75 m/sec.
The framework design inside the panel shall create smooth internal surfaces without bolts and
fixings. Factory fitted seals and gaskets ensure a high degree of air tightness.
Where surface condensation is a risk or high thermal losses may occur the construction must
be free from any cold bridges between inside and outside surfaces.
Sliding rails and facilities shall be provided to ensure easy cleaning, servicing and maintenance
of all components and built-in equipment.
All ducts, pipes and cables penetrating the panels of the unit shall be sealed airtight and
waterproof by means of permanent resilient plastic gasket material and plastic packing rings.
All rotating parts and components shall be mounted on spring or rubber vibration dampers and
joined to pipes, cables, ducts and frames by flexible connections.
All duct connections shall be joined to the air-handling unit by means of imputrescible flexible
canvas connection with flange and counter-flange.
All air-handling units shall be mounted on foundations made of reinforced 300 mm concrete
slabs or on concrete beams (and arranged at a right angle to the major axis of the unit) with
intermediate layers of vibrations and sound isolators made of cross-webbed rubber plates or
strips, or combined with spring dampen.
Pressure surges caused be tripped fire dampers may not damage any pads of the air handling
unit. Over pressure and pressure surges shall be accounted for in the design of the AC units.
Page: 24
Fan and Fan Drive

Centrifugal fan complete with fan motor drive, and controls. Fan impellers shall be forward
curved, multi-blade type, statically and dynamically balanced. Fans shall be selected for their
maximum efficiency.
Air-handling units contain two fans and two fan motors, they shall be equipped with non-return
dampers.
No noise shall be generated by high air velocities. Quiet running at all operating speeds shall be
guaranteed. Shaft bearings shall be of the permanent lubricated, self-aligning and maintenance
free type. All metal parts to be well protected against corrosion and finished factory coating.
Pulleys suitable for use with V-belt drive one V-belt more than necessary to be fitted to motor
and fan shaft. A removable galvanised steel belt guard to be furnished for each unit. Fan motor
sheaves shall be adjustable to permit the regulations of the fan speed when necessary.
Sufficient allowance in fan horse-power calculations should be made in order that design air
quantities are obtained towards the end of the useful filter life when the pressure drop across
the air filters is maximum.
Air Intake and Mixing Box
Air intake and mixing box dampers shall be of the counter rotating type. The galvanised steel
airfoiled blades shall be operated by means of rod linkages arranged outside of the damper
frame providing a smooth operation. Blade shaft bushes are made of nylon, requiring no
lubrication. A bracket for damper actuators shall be provided on each damper.
4.11
COOLER / EVAPORATOR FOR CHILLERS
The cooler shall be of the shell-and-tube, flooded type designed, when using R134a. The shell
shall be fabricated from rolled carbon steel plate with fusion welded seams; having carbon steel
tube sheets, drilled and reamed to accommodate the tubes; and intermediate tube support
spaced no more than 0.9 m apart. The refrigerant side shall be designed, tested and stamped in
accordance with the required codes. Tubes shall be of the high-efficiency, externally and
internally enhanced type. Each tube shall be roller expanded into the tube sheets providing a
leak-proof seal, and be individually replaceable. Liquid level sight glasses shall be located on
the side of the shell. A suction baffle or stainless mesh eliminators shall be located above the
tube bundle to prevent liquid refrigerant carryover to the compressor. The cooler shall have a
refrigerant relief device sized to meet the requirements of required codes.
Thermostatic expansion valve shall maintain the design degree of superheat at the evaporator
outlet; the remote sensing bulb shall be securely fixed to the evaporator outlet piping in a
position where the degree of superheat can be correctly sensed. Thermostatic expansion valves
shall incorporate an external equaliser line.
Water boxes shall be removable to permit tube cleaning and replacement. They shall be
designed for e.g. 10 bar design working pressure and be tested at 15 bar. Vent, and drain
connections with plugs, shall be provided on each water box. The cooler shall be covered with
flexible closed-cell foam insulation.
4.12
COOLING COILS FOR DX UNITS
The cooling coils offered shall be manufactured of seamless copper tubes and continuous
copper fins.
Accessories Standard Design:
Connection with flanges in case of installation in ducts.
Page: 25
Water connection sockets with flanges, counter flanges, screws and seals
Bend connections between single coils in a multiple-coil-arrangement,
Brass drain cock, nominal bore 15,
Brass vent valve,
Drop eliminator according to installation situation with separating profiles made of corrosion
resistant material but not plastics,
Condensation water collecting pan with discharge pipe made of corrosion resistant material
like e.g. stainless steel 304,
Odour seal, height of seal corresponding to static pressure above collecting pan.
Fin-and-tube type constructed of copper plate fins with belled collars mechanically bonded to
the seamless copper tubes. Coils shall be provided with pressure type brass distributors with
solder type connections. At least two distributors shall be provided with each coil. All copper
coils in contact with outside air shall be electro-tinned. Coils for full face active or face split
operation shall have intertwined circuits for equal loading on each circuit. Suction and discharge
connection shall be on the same end. After testing coils shall be dehydrated and charged with
Nitrogen or dry air. Coils shall be tested in accordance with American National Standards
Safety Code for Mech. Refrigeration (ANSI 89.1). Coil section shall have heavy duty coil tracks
extending, the full width of the unit to provide slip-in slip-out coils for ease of maintenance and
service. Coils shall be of the cartridge removable from the coil connection side of casing. Drop
separators and condensate collecting pans as described in water coils shall be provided with
each direct expansion cooling coil.
The frame construction shall be designed in consideration of the thermal expansion of the heat
exchanger using a sliding support within the mounting frame to compensate the expansion
effect. In case of outside air cooling, the air cooler shall be designed in consideration of full load
operation under most unfavourable ambient conditions.
Where direct expansion cooling coils are required within the air-handling unit, these shall be
provided with refrigerant distributors, and connections to the tubes shall be designed to ensure
an equal flow of refrigerant to each tube. Return or suction connections shall be arranged so as
to ensure complete drainage of any oil in the cooler. Coolers shall be dehydrated and sealed
after manufacture.
4.13
ELECTRIC AIR HEATING COILS
The electrical air heaters shall be designed for use as reheaters mounted in supply air ducts
and separate air chambers, or air-handling units.
Heater assembly shall be based on a separate housing made of welded and fully potgalvanised sheet steel with terminal box, inspection door and external fire-proof insulation made
of 120 mm mineral wool and including the built-in electric heating rods made of stainless steel.
The air intake side of the housing shall be equipped with a fine wire-mesh screen to secure the
heating rods against ruptured filter parts. The screen shall be accessible by an inspection door.
The electrical air heaters shall be equipped with two thermometers for the initial and final airconditions in each case.
The heating rods shall be pre-wired at the terminal box for 1, 3, or more heating stages. The
number and the capacity of the individual heating stages shall be designed according to the
required temperature difference at the air heater and in consideration of the allowance of the
room air temperature.
Page: 26
The housing shall be designed in consideration of 350 mm distance at minimum between the
heating rods and the other components.
The electric air heater shall be secured three-fold against super-heating by means of one
internal safety thermostat, one external safety thermostat and one flow controller in each case.
Electric air heater batteries shall comprise a series of black, heat-sheathed elements, each
comprising of a nickel chrome resistor of helical form embedded in a refectory material, the
whole encased in a sheath of heat resisting chrome steel, all contained in a flanged steel
casing. The batteries shall have a minimum of 4 single elements arranged across the air
stream. The power supply shall be 400/230 V, 3-phase, 50 cycle, to provide a minimum of 4
steps of control.
Each battery shall be provided with the following accessories.
High temperature cut-out switch (thermostat),
Manual reset facility for high temperature cut out,
The step controller and associated electric relays etc. shall be provided by the controls
suppliers
Heaters shall be interlocked with an air-flow switch to isolate the electrical supply when the
fan is not in operation.
The terminal box shall be suitable for conduit entry, Each heater element shall be separately
fused and the neutral point of all 3-phase-star-connected sections shall be brought out to a link
in the terminal box. Near any hot areas the writing insulation shall be of appropriate quality.
4.14
AIR FILTERS
4.14.1
General
Filters shall be fabricated and installed so as to prevent the passage of unfiltered air. Felt,
rubber or neoprene gaskets shall be provided between filter frames and unit casings, etc. All
steel filter parts shall be protected against corrosion by a baked enamel, epoxy resin, zinccoating, cadmium plating, two coats of oil paints, or two coats of lacquer.
The filter medium shall be M1 fire rating.
Differential manometers shall control the fire dirtiness and luminous indications shall be
provided on the air control panel.
A gasket around the outside of the main frame ensures good sealing, both between the outer
cells and the connection frame and between individual cells assembled into filter wall.
Provisions shall be made for easy removal for cleaning and reinstallation of filters.
Filter elements and media shall be adequately protected against dirt during construction and
shall not be operated until ductwork is thoroughly cleaned. Filters must be put in regular
operating condition before the fans to which they connect are operated for any purpose, such as
temporary ventilation or adjusting, After all adjustments etc., are completed and before the
filters are accepted for regular operation, they shall be cleaned and provided with additional new
media to put them in conditions as new.
Page: 27
A complete set of spare filters shall be provided, in addition to any spares required for
replacement, for use whilst the set in service is being cleaned. The filter assemblies shall be
housed within a purpose made box section. The filter shall comprise 50 mm thick washable filter
panels arranged in V-formation holding frames. The filters (e.g. B2) shall have a minimum
efficiency of 90% based on the tests specified in BS 2831 with test Dust No. 2.
4.14.2
Return Air filters
Remark: This description may only be used if no fresh air is brought into the air-handling unit.
The return air filter comprising 2 stages of filter section:
Prefiltration through 90% (ASHRAE Gravimetric) filters permanent cleanable metallic panel
filters.
Post filtration through bag filter. The efficiency of the post filters shall not be less than 95%
ASHRAE atmospheric dust spot opacimetric (ASHRAE Standard 52.76). The initial pressure
drop across the clean filter shall not be higher than 150 Pa and the final pressure drop shall
not be more than 350 Pa when operating at each rated capacity (1,500 or 3,000 m 3 /hr).
4.14.3
Fresh Air Filters
Remark : This type of filters is used for air handling units for once through systems or for units
with partial recirculation. In this case, the return air is injected in the air handling unit after the
general prefiltration over the inertial self cleaning sand filter.
The fresh air filter comprises of 3 stages of filter section:
The general prefiltration shall be accomplished by inertial self-cleaning sand filter (Dust
separator) in accordance with BS 2831 test No. 2 efficiency 82%.
Prefiltration through 90% (ASHRAE Gravimetric) filters of permanent cleanable metallic

panel filters.
Post Filtration through bag filters. The efficiency of the post filters shall not be less that 95%
ASHRAE atmospheric dust spot opacimetric (ASHRAE Standard 52.76). The initial pressure
drop across the clean filter shall not be higher than 150 Pa and the final pressure drop shall
not be more than 350 Pa when operating at each rated capacity (1,500 or 3,000 m 3 /hr).
4.14.4
Panel Filters
Panel filters shall be designed for use in air-handling units as well as in separate air chambers.
The filter assembly shall be based on one standard cell frame to be built-up to large areas of
filter sections within air chambers or to be built-in into air-handling units on sliding and guide
bars and rails made of stainless steel and designed for lateral filter removal.
For separate air chambers, the filter shall be installed within a separate housing and mounting
frame, both made of stainless steel sheets, for a flat or wedge type arrangement for Site
assembly.
All filter cells shall comprise a filter frame of galvanised steel sheet, correctly cut for air-tight
assembly, including bars, clamping devices with quick-release elements, frame and filter sealing
and completed with two new, unused and complete sets of filter media each.
The filter media shall be washable, cleanable, re-usable, chemical- and moisture-resistant, nonrottable and flame-resistant. The filter media shall be made of synthetic fibre material with
resilient spun fibre structure, variable density and strengthening against rupture and tearing.
All panel filters shall be equipped with one differential pressure controller and one inclined
pressure gauge in each case.
Page: 28
4.14.5
Bag Filters
Bag filters shall be designed for use in air-handling units, as well as in separate air chambers
and supply air ducts. The filter assembly shall be based on one standard cell frame to be builtup to large areas of filter sections within air chambers or to be built-in into air handling units on
sliding and guide bars and rails made of stainless steel and designed for lateral filter removal.
For separate air chambers, the filter shall be installed within a separate housing and mounting
frame, both made of stainless steel sheets, arranged as required for Site assembly.
All filter cells comprise a filter frame of galvanised steel with additional steel strip supports for
static rigidity, fixing and quick-release fasteners and clamping devices, sealing materials for airtight assembly and completed with two new, unused and complete sets of bag-filter insets.
The bag-filter insets comprise a cell frame of plastic with several filter made of high efficiency
glass fibre filament media and spun glass filament scrim in order to prevent migration of media
fibre even under rough handling and in arduous operation.
The bag-filter insets shall be designed for a high dust collection capacity and a low airflow
velocity in order to obtain a long service life.
The bag-filter insets shall be chemical and moisture-resistant, non-rotting and flame-resistant.
All pocket-filters shall be equipped with one differential pressure controller and one inclined
pressure gauge in each case.
4.15
SAND SEPARATION UNIT
The casing shall be constructed of sheet metal and shall be divided into sections to hold the
deflection type filter pockets, the deflection filter pockets shall be constructed AlMgMn with a
separating efficiency of 92% when using Arizona Road Dust Coarse (test dust), a screen shall
be mounted on the suction side to exclude small animals. The dust-collecting duct shall be
made of sheet steel up to the secondary fan. The radial type secondary fan for conveying the
dust-laden air (approximately 10% of the intake air) shall be mounted below the filter casing,
and shall b equipped with cleaning opening and a condensate drain pipe, suction and delivery
connections with flexible, reinforced PVC-collars and anti-vibration mounts. The frame for
holding the pocket filters shall be constructed of galvanised sheet metal with quick-action spring
clips and bonded-on permanently elastic sponge rubber seals.
4.16
DRIP ELIMINATORS
Drip eliminators with a minimum water separation efficiency of 99.9 % shall be provided on the
down stream face of all air coolers in air-handling units.
The drip eliminator shall be made completely of stainless steel sheet including separate drip
pan made of stainless steel and installation frame.
The drain pan shall be connected to the next floor drain by a separate siphon, a funnel and a
connecting pipe made of copper altogether, minimum size 40 mm (DN 40) connected to the
next floor drain. The siphon shall be designed for a water level according to the relevant air
pressure differential and in consideration of additional 50 mm W.G. for reserve.
4.17
FANS
4.17.1
Centrifugal Fans
Centrifugal fans shall be double inlet double width, statically and dynamically balanced and shall
be designed and constructed in consideration of all possible operating, start-up and shutdown
conditions under all foreseeable ambient conditions and as well as under a further increase of
the fan speed by 10 % at minimum.
Page: 29
Fan casings shall be constructed of mild steel plates with angle stiffeners and base angles to
ensure freedom from drumming and shall be suitable for operation at the maximum static
pressure of the system. Fan casings shall be constructed so that impellers can be easily
withdrawn after installation. Outlets shall be flanged and inlets shall be flanged or spigotted as
indicated, except that for suction pressures greater than 1000 N/m 2 (100 mm WG), inlets shall
be flanges. A drain and plug shall be fitted to the fan casing at its lowest point. For all kitchen
extract ventilation fans, an access door, for inspection and cleaning, shall be fitted to the volute
casing in an accessible position: it shall have the fill width of the impeller.
Impeller with backward curved blades for high efficiency shall be made of continuously welded
mild steel or aluminium where indicated sheet, statically and dynamically balanced on their
shafts after assembly.
Shaft shall be made of smooth polished stainless steel, sized so that the first critical speed is at
least 25 % greater than the operating fan speed.
Bearings shall be designed for a minimum average operating life of more than 20,000 operating
hours, to support the impeller shaft two-fold on one or both sides in maintenance-free and silent
roller bearings with insulating gaskets and permanent lubrication.
Shaft bearings of V-belt driven single inlet fans shall be truly aligned and rigidly mounted on a
pedestal common to both bearings. Double inlet, double width fans, shall have pedestalmounted bearings at each side of the fan.
The fan and motor assembly shall be mounted on a common frame, isolated from the fan
section by rubber-in-shear isolators and flexible fan connections.
Fan drive shall be V-belt type consisting of two endless anti-static type V-belts capable of
transmitting a power at least 75 % in excess of the rated b.h.p. of the motor and designed for
trouble-free start-up and operating conditions even if one of the belts is broken.
The fan motor shall be unit mounted, arranged on fan bases, designed for extreme ambient
conditions, maximum power consumption of the fan's characteristic curve, three immediate
starts one after another and 10 % power reserve at minimum, including slide rails with clamping
devices and adjustable belt tighteners.
A belt guard consisting of an easily accessible and removable casing made of reinforced and
stiffened perforated steel sheets, a short-vaned diffuser with several horizontal and vertical
arranged discharge vanes for high efficiency, made of continuously welded steel sheet and
combined with flexible connections, spring or rubber vibration mountings, a drain device and
wire-mesh guards at the intake-air cones of the fan casing shall be provided.
All metal parts made of welded steel sheet, sectional steel, perforated or folded steel sheet or
wire-mesh shall be factory fully pot-galvanised with 0.06 mm thickness of coat at minimum. The
total efficiency of the fan including the diffuser shall be 0.80 at minimum. The complete casing
shall be horizontally and vertically divided to be capable of being dismantled if so required for
transportation, installation or maintenance purposes.
All fan resistances indicated on the equipment schedules are quoted for estimating purposes
only and shall be checked by the Contractor before any equipment is ordered. Adjustable
pulleys shall be provided for V-belt for motors below 10 kW. Noise levels of fans shall comply
with the room noise levels specified.
Impellers shall be of steel or aluminium; the blades shall be secured to the hub or the blades
and the hub shall be formed in one piece. The hub shall be keyed to a substantial mild steel
shaft and the whole statically balanced. Blades shall have an aerofoil section. Shafts shall be
carried in two beatings which may be ball, roller or sleeve type. Lubrication nipples shall be
extended to the outside of the casing. An access door of adequate size shall be provided. The
Page: 30
fan shall be equipped with an inspection opening through which electrical connecting and
changing of blades position can be done without difficulties.
Guards
A guard shall be provided for all open unprotected intakes of axial-flow fans or centrifugal flow
fans, for V-belt drives, or in any position required by the Employer/Engineer.
Fan guards shall be manufactured by the fan manufacturer, of galvanised steel wire mesh, not
greater than 25 nun, attached to a rigid, galvanised steel rod framework.
Guards to V-belt drives shall be made of galvanised steel wire at least 12 gauge with a mesh,
not greater than 12 mm, attached to a rigid, galvanised framework of rods not less than 9 mm
diameter. The guard shall be readily removable to permit the belts to be changed. Adequate
access panels shall be provided in the side of the guard to allow tachometer readings of the two
shafts to be taken and belt tension tested. Allowances shall be made for the adjustment of the
motor on its slide rails.
Accessories
According to mounting situation: protecting screen, inlet venturi, elastic connection, mounting
frame and vibration absorbers.
4.17.2
Axial Fans
Axial flow fans shall be designed and constructed in consideration of all possible operating,
start-up and shut-down conditions under all foreseeable ambient conditions and as well as
under a further increase of the impellers blade angle by 20 degrees at minimum.
The cylindrical casing shall be made of continuously welded steel sheet, reinforced and
stiffened with connecting flanges.
The fan shall be consisting of a direct driven impeller with profiled aero-foils for high efficiency
and designed of the variable pitch type, continuously adjustable at stoppage and completely
made of aluminium alloy, statically and dynamically balanced, including a vaned diffuser with
radial arranged discharge vanes for high efficiency, made of continuously welded steel sheet
and combined with flexible and non-rottable canvass connections, spring or rubber vibration
mountings, an electrical motor designed for maximum power consumption of the fan's
characteristic curve, three immediate starts one after another and 10 % power reserve at
minimum, including a separate water-tight and dust proof terminal box fastened to the outside of
the fan casing and connected with the motor terminal box by a cable with outside protection
tube and completed with an intake-air cone, combined with a wire-mesh, if so required.
Axial flow fans shall be of either the single stage type or the multi-stage counter rotating type
with each impeller mounted on an independent motor. Casings shall be rigidly constructed and
braced to obviate drumming and vibrations. Cast iron or fabricated steel shall be provided
where necessary for bolting to the base or supports. Inlet and outlet ducts shall terminate in
flanged rings for easy removal. The length of the duct casing shall be greater than the length of
the fan(s) and motor(s), in such a manner that the complete section may be removed without
disturbing adjacent ductwork. Electrical connections to the motor(s) shall be through an external
box secured to the casing.
4.17.3
Propeller Fans
Propeller fans shall be either ring mounted or sleeve mounted type.

Where they are mounted in casings, the casing shall be longer than the length of the motor and
impeller. The casing shall be of steel, with flanged ends and incorporate an inspection door. A
Page: 31
terminal box shall be mounted externally on the casing. The maximum speed of fans shall not
exceed 20 m/s.
Impeller shall be of steel or aluminium, the blades shall be fastened to the hub of the blades and
the hub shall be formed in one piece. The bearings may be of ball, roller or sleeve type.
Back-draft dampers shall be provided on the discharge side of each propeller fan. The dampers
shall be as specified elsewhere in these Specifications.
4.17.4
Roof Mounted Exhaust Fans
The exhaust fans mounted on the roof shall be of centrifugal, vertical / horizontal discharge
type. The impeller shall be backward curved centrifugal type, statically and dynamically
balanced and made of aluminium.
The housing shall be manufactured from corrosion resistant stable spun or pressed aluminium
sheet metal. Bird screen, base plate and motor casing made of aluminium shall be provided.
A self-activating back draft damper and/or fire release dampers shall be provided. This damper
shall open automatically when the fan starts and close automatically when the fan shuts off.
The motor shall be installed outside of the airflow and wired to the terminal box.
Weather hood, rain proof, duct connecting piece with flexible section and automatic shutter
terminal isolating switch box mounted outside the casing. Cases shall be formed in such a
manner to ensure a weatherproof construction and fitting to the building structure. Adequate
access to motor terminals and lubricating points shall be provided by means of hinged cowls or
otherwise as appropriate.
4.17.5
Acid-Resistant Fans
Acid-Resistant fans shall generally comply with the requirements of centrifugal fans, roof
exhaust fans and axial flow fans depending on selected application. The motor needs to be
separated from the exhaust air stream and protected against direct radiation and weather.
The casing and base plate shall be made of corrosion-resistant plastic (PVC-Polypropylene
respectively) and shall be ribbed to accommodate stresses arising from mechanical and thermal
forces. The casing, inlet connection reinforcing ribs and discharge flanges shall be welded to
form a vapour proof, self-supporting structural unit.
The impeller shall be statically and dynamically balanced and shall be made of corrosionresistant plastic.
The self-closing shut-off damper shall be made of rigid PVC. The motor shall be explosion
proof type.
4.17.6
Domestic Extractors
Surface-mounted centrifugal extractors shall be installed within toilets, bathrooms, storerooms

etc. as indicated on the relevant drawings. The units shall extract small volumes of air through
100 mm pipe, and shall be switched with to the light switch by means of a straightening circuit.
They shall operate only when needed. The casings shall be made of decorative, mounted
plastic. Fans shall be of the single inlet centrifugal type manufactured in galvanised mild steel
or plastic. They shall be driven by 2-pole single-phrase motors held to the fan scroll thorough
resilient anti-vibration mountings. The motors have sealed self-lubricating bearings.
Page: 32
4.17.7
Domestic Kitchen Extractors
Surface-mounted centrifugal extractors with automatic opening shutters shall be provided where
indicated. The casing shall be fabricated from mild steel with a detachable front section to
provide access to the fan and terminal blocks.
Motor and fan shall be as previously described under Domestic Extractors. Operating selection
switch shall provide normal or boost and off position.
The grease filter shall be constructed from layers of washable, expanded aluminium sheets held
in an aluminium frame. The filter shall be easily withdrawable for washing.
Shutters shall be provided in the outlet spigot to prevent back draught.
4.17.8
Multifunction Natural Roof Ventilators
High-efficiency multifunction ventilator, constructed according to the wind deflection principle,

made of corrosion resisting aluminium alloy AlMg3.
All moving parts shall be equipped with maintenance free double nylon bearings.
All springs shall be made of stainless steel.
The installation shall be designed also as AUTOMATIC FIRE VENTILATOR with safety fuses,
which effects an automatic opening of roof ventilators to release heat, smoke and unburnt
explosive gases at the predetermined temperature.
The shut-off dampers, which admit a free and unhindered opening of the ventilator, shall be
operated by compressed air. The cylinders and pistons shall contain a special lubricant and
shall be maintenance free. The piston rods shall be protected against pollution by rubberbellows. The supply shall include all levers and links to transmit the force from the piston to the
dampers. Fuse melting point is to be set at 93C.
Also included shall be a sheet steel frame or plinth for installing the ventilator on flat or inclined
roofs.
Controllable in groups of 2 to 5 units.
Control Box
Lockable control box, to control approx. 5 multi-function high capacity roof ventilators, complete,
with manually operated control valve. Completely wired and piped, with pressure gauge. Suited
to be connected to an existing rain sensor to shut the roof ventilators fully automatically in case
of rain.
The housing shall be made of sheet steel 1.5 mm thick, and shall be primed and painted.
4.18
CHILLED WATER PIPEWORK
The chilled water pipework shall be ST35 (DIN Standard) or equivalent with flanges where
necessary.
The contractor shall offer his design for the pipe material, insulation material and finishing for
the chilled water pipe.[f2]
Inaccessible pipes in chases, ducts, partitions and, where no easy access is available, shall be
welded irrespective of size. No joints shall be made in walls or floors, etc.
All tubes shall be of even bore, clean and smooth throughout, commercially straight and free
from grooving, blistering and rust.
Page: 33
After installation and before any insulation is applied, the pipework shall be wire brushed and
cleaned of all dirt, dust and rust and coated with two coats of red oxide paint.
All ends shall be cut square and be well reamed or filed to ensure that the full bore of the pipe is
maintained.
Special care shall be taken to prevent the ingress of dirt or rubbish entering the open ends of all
pipework during erection. Approved caps shall be used for this purpose, the use of shavings,
rags or paper will not be allowed. Should any blockage in the circulation occur after the system
has been put into operation - owing to the non-compliance with this requirement the
Contractor shall attend and rectify the fault at his own expense.
All pipework shall be installed in a first class workmanlike manner throughout, with full provision
for venting, draining, expansion, contraction, maintenance and renewals.
Unless otherwise shown on the drawings or instructed on site, all pipework shall have a
minimum clearance of 25 mm between its finished face (including insulation) and the finished
face of any wall, pipe or other surface.
The Contractor shall include in his Tender for setting pipes around all work and apparatus
connected with other trades and building services.
Where pipework passes through walls, floors or partitions etc., mild steel sleeves with sufficient
diameter shall be provided to allow the pipework and its insulation to pass through
uninterrupted.
Screwed joints shall be made with best quality, fine-stranded hemp and approved jointing
compound or P.T.F.E. tape. All surplus jointing materials shall be cleaned off at the time of
making the joint. Joints on straight runs are not to be closer than three metres except where
fittings are necessary.
Joints on tubes 50 mm nominal and below shall be welded or screwed sockets. Joints on tubes
65 mm bore and above shall be welded.
All unions shall be malleable iron with two conical bronze seats and with hexagonal nuts on
both parts.
Mild steel mating flanges shall be provided on all connections to items of plant equipment, and
valves 65 mm and over. Connections below this size may be flanged or screwed.
Flanges on tubes shall be welded on both sides to the tube. All flanged joints shall be flushed
and truly aligned and compressed asbestos fibre joint rings shall be utilised. All bolts, nuts and
washers shall be galvanised. Bolts shall not protrude more than 6 mm outside the nuts.
Where branches are to be welded in, the ends of the branch pipes shall be correctly shaped to
the main pipe and the hole for the branch pipe cut in the main shall be the full diameter of the
branch pipe and shall be executed with the aid of a template. All loose scale and oxide shall be
removed from the inside of the main pipe before the branch boss is welded into position.
Generally swept branches shall be made except for T-pieces on headers. Where pipes are cut
by flame, all oxides shall be cleaned off with a file or hammer and chisel and all irregularities on
the outer edge shall be removed by filing.
Where butt-welded joints are used, they shall completely fuse the walls of the pipe without
leaving notches at the edges or undercutting at the sides of the welds on the external surface.
The finished surface shall be slightly convex and where one weld joins another there shall be
complete penetration and root fusion with a bead more than one half of the thickness of the end
tube.
Page: 34
Pipes out of alignment shall, where possible, be produced by fire mate sets and under no
circumstances shall pipes be joined by welding more than 10 out of alignment. Sleeve type
welding will not be permitted.
A reasonable number of specimen-welds may be cut from the installation as required by the
Consultant and subjected to visual examination and bending tests. Work which is defective shall
be re-welded at the Contractors expense. Defective work shall be considered to include work
which has not been satisfactorily prepared, not having achieved complete penetration, found
unsatisfactory under bending tests or unsatisfactory in any other way.
Should any leaks be detected during the specified testing, the defective portion of the weld shall
be cut out and re-welded, and further tested until found satisfactory.
All pipework shall be tested to at least one and a half times the working pressure of the
systems.
After the chilled water pipework system has been completed, but before the final connections to
the fan coil units are made, the systems shall be continually flushed through with clean water
until the discharge water is clean. To facilitate this the fan coil connections shall be isolated and
temporary loops made between the flow and return connections on the end of each run.
Pipework supports
The Contractor shall include all necessary drilling and plugging of walls etc. for fixing all
brackets and pipework supports.
Supports shall generally be provided adjacent to all valves, cocks and other pipeline equipment
to prevent undue strain on the adjoining pipework and so that the component can be removed
leaving the adjoining pipework adequately supported at the ends.
Supports shall be designed to allow free expansion and contraction of the pipework and guide
brackets shall be installed where necessary to ensure that movement takes place in the
required direction. In all cases care shall be taken to ensure that the centreline of the pipe is
parallel to that of the support.
Before fabricated brackets or hangers are placed in position, they shall be cleaned and painted
with two coats of an approved oxide paint.
Pipework shall be supported at intervals not exceeding the spacing given as follows:
Nominal Size of Pipe [mm]
Maximum Spacing of Supports [m]

Vertical
Horizontal
15
2.5
1.8
20 & 25
3.0
2.5
32
3.0
2.8
40 & 50
3.7
3.0
65 & 80
4.5
3.7
100
5.0
4.5
Underground Piping
Page: 35
Chilled water pipe work supplying chilled water from remote chiller plants to plant rooms shall
run below the ground within purpose-made service ducts.
In instances, as shown on drawings, where service ducts are not provided, the pipework shall
be buried at a depth not less than 90 cm below ground surface level.
All pipework so buried shall be fully insulated and adequately protected.
Sections of buried pipework shall be fully tested as described in the relevant section of this
specification prior to back-filling.
Expansion
All pipe fixings and supports shall be installed in such a manner to permit complete freedom of
movement of the pipework for expansion and contraction.
Potable Water System
The pipework systems shall be provided with soft water i.e. potable water.
The softening unit shall supply softened water to the 48 hour storage condenser water tank and
the feed and expansion tanks for the chilled water systems.
Chemical Treatment
Subsequent to the cleaning operation, the systems supplied with potable water shall be treated
with an initial dose of chemicals, which shall then be followed by routine testing and automatic
dosing in accordance with the make-up water supply.
The chilled water systems shall be dosed with chemicals which shall inhibit corrosion and
prevent biological fouling. The method of introducing these chemicals into the system shall be
by means of automatic dosing system. 2 x 100% dosing pumps shall be provided.
Valves
Isolating valves shall be provided on all pipework services to each item of plant and equipment
and on each main and sub-main.
Drain cocks and vent cocks shall be provided where necessary on the dead side of isolating
valves, on branch mains and on items of plant in order to facilitate emptying the pipes.
Double regulating valves, in place of isolating valves shall be installed on return pipework main
branches to facilitate balancing of the system.
All valves and cocks shall be fitted in such a manner that they are accessible for operation and
maintenance.
Screwed valves shall have heavy hexagon reinforcements at openings, threads of ample length,
and heavy shoulders to prevent over-entry of pipes or adaptors.
Flanged valves shall have flat-faced flanges of a thickness conforming to the appropriate
specification.
Each valve shall have the manufacturers name or trade mark cast or heavily stamped or rolled
on. Valves not bearing these distinguishing marks will be rejected.
All valves and valve components (e.g. seatings, packings etc.) shall be suitable for the working
pressures and also operating temperatures of the systems in which they will be installed. All
valves shall be hydraulically tested to at least 1 times the working pressures of the systems in
which they will be installed.
Page: 36
Body castings of valves and cocks shall be gunmetal, brass or bronze for valves up to 50 mm
nominal bore and of cast iron for valves 65 mm nominal bore and above. They shall be of even
thickness throughout, clean and smooth and free from scale and flaws. Holes in the valve
bodies for spindels etc., shall be machine-sealed to prevent water leakage. Plugs for gland
cocks shall be ground in and shall be operated by a loose key.
Expansion Vessel and Safety Valves
Expansion vessel for pressured plants: Vessel of welded construction, minimum sheet thickness
2 mm, otherwise depending on plant pressure and vessel dimensions, flange connection, with
anti-rust priming and final coating outside, inside equipped with plasticrubber diaphragm and
nitrogen charge. Vessels shall have the stamp of an independent Authority like e.g. TV or
equivalent.
Safety valve: Safety valve with covered spring cap, approved in accordance with the regulations
and standards, valve body of material suitable for the application, inner parts of stainless steel,
including spindle with locking device and connecting flanges.
4.19
SOUND-RESISTANT AIRTIGHT ACCESS DOORS FOR AIR CHAMBERS
The airtight doors shall be made of an angle steel frame with builder cleats a double skinned
and pre-insulated door panel with profiled rubber seals for airtight closing, including a bulls-eye
glass (minimum size: 200 mm diameter) and two double lever loading devices. As a safety
precaution, the cylinder lock must have the possibility to be opened from the inside without a
key. The door shall be installed in such a manner that the air pressure pushes and tightens it
against the frame. The inspection window shall be made of pressure-resistant material. The
mounting frame and the door panels shall be painted with protective primer and epoxy-resin
finish. Each door shall be designed, constructed and installed for a high sound reduction of at
least 35 dB.
Hinges for galvanised ducts shall be steel or iron, zinc-coated with brass pins. Access doors
fitted in insulated casings and ducts shall be insulated.
Where static pressure regulating dampers are installed in ducts and wherever else required, the
access door shall be provided with a clear-wired glass vision panel. The glass shall be secured
in a rigid sheet metal frame with sponge rubber gasket.
4.20
LOUVERS AND DAMPERS
4.20.1
Weather-Proof Louvers
The external weatherproof louvre shall be designed for installation in outside walls as air inlet
and outlet.
The weather-proof louvre for air-outlets (discharge openings) shall consist of a stainless steel
frame with vertically arranged, external and U-shaped front planks all made of stainless steel
sheet and mounted opposite to each other and an attached rear protective insect-screen made
of fine-mesh stainless steel wire-netting.
The weatherproof louvre for air-inlets (outside-air intakes) shall consist of a vertical louvre as
specified for air-outlets, however, completed with the following components:
An additional coalescer made of pyramidal formed stainless steel wire-netting to be supported
by stainless steel wire-grates and stitch-soldered at the jointing spots as well as an
supplementary drip eliminator with vertical blades made of double Z-shaped stainless steel
sheet and including a common drain-trough for all mentioned components together all made of
stainless steel sheet.
Page: 37
Each component shall be easily removable from indoor side. Therefore, adequate sub-frames
made of stainless steel and bolted to the mounting and supporting framework by means of
stainless steel bolts, nuts and washers shall be provided.
The effective air velocity shall be kept below 1.5 m/s in each case.
4.20.2
Multi-Leaf Dampers
The multi-leaf dampers shall be provided for outside air intakes, exhaust air outlets, mixing air
chambers, stand-by equipment and as face and by-pass damper, to be used in air chamber, air
handling units and air ducts.
The multi-leaf damper shall be opposed blade type comprising of a frame with built-in aerofoil
section blades, made of stainless steel sheet, which shall be coupled contra-rotating by an
external linkage, including an external lever for manual or motor action and combined with an
external blade position indicator.
Multi-leaf dampers shall be equipped with an electric motor (where required for remote-control),
including electric limit switches to indicate the damper position at the panel.
The individual blades shall be installed in dust-proof ball bearings, which are enclosed by
external plastic caps and charged with special grease for maintenance-free operation; whereas
the axles shall be made of stainless steel.
All blades shall be suitable to close airtight by packing washers made of profiled rubber strips.
4.20.3
Adjustable Dampers
Adjustable dampers shall be provided in all branch pipes and branch ducts of the air distribution
and extracting systems to balance the airflow rates individually.
Louver dampers shall be used for rectangular air ducts and circular flaps shall be used for air
pipes.
The construction of the louvre dampers shall be the same as specified for the multi-leaf
dampers.
The circular flaps shall comprise a cylindrical casing with a built-in flap made of reinforced and
stiffened steel sheet or cast steel including an external lever to regulate the flap position
indicator.
All parts shall be fully pot-galvanised.
All louvre dampers and circular flaps shall be equipped with an additional notched locking
quadrant with locking screw to adjust the individual dampers and flaps in final position.
4.20.4
Backdraught Dampers
Gravity operated backdraught dampers shall be provided for exhaust fans. The frame shall be
made of extruded aluminium sections. Dampers shall be of aluminium with parallel blade 50 mm
wide.
Blades shall be reinforced with bendings at seal edge and at centre. The damper shall be
provided with a brass stub shaft and PVC bearing strips.
Page: 38
4.20.5
Fire Dampers
Fire dampers shall be installed in:
All ducts leaving or entering the central air-conditioning and ventilation plant rooms and
installation shafts;
All ducts penetrating fire-rated walls and slabs.
The shut-off damper shall be designed and constructed in accordance with German Standard
DIN 4102, fire-resistance class of K 90 or equivalent. Fire dampers shall be closed by magnetic
trip initiated by smoke detectors via the fire alarm panel. It shall be possible to open the fire
dampers from the remote control station.
The fire damper shall comprise a housing with connecting frames made of welded steel
1.75 mm thick and fully hot dip galvanised, external inspection and access door, release
devices for solenoid (24 V), thermal manual action, unlocking device for manual action, an
electrical limit switch for position indication and an external blade position indicator.
The damper blade shall be made of fire-resistant, non-combustible, asbestos-free, abrasionresistant special insulating material, minimum thickness 40 mm, including an axle made of
stainless steel supported by sintered bronze bearing and locked by a locking bolt made of
stainless steel and equipped with a fusible link for thermal release at 72 C.
Each fire Damper shall have at least the same standard of fire resistance as the wall or duct
through which it passes, but in no case less than two (2) hours. Air ductwork shall be
strengthened enough at fire compartment barriers to resist buckling. The duct shall securely be
fixed to the barrier to prevent the spread of fire around the air duct.
Single bladed or multi-bladed fire dampers may be used, provided they conform to the
requirements of the authorities or the specification of the fire protection standards having
jurisdiction. Multi bladed fire dampers may not be mounted in vertical ducts.
As required fire dampers shall be provided with electrically operated actuators ion addition to
the melting fuse.
The complete locking and release devices shall be installed on a separate mounting plate at the
housing of the damper for easy removal and access from outside.
The fire damper shall be embedded in concrete or bricked up with fire-resistant cement mortar
according to the DIN 4102 standard.
All fire dampers shall be arranged, placed and installed for easy inspection, checking, service
and manual actuation.
Fire damper should be closed by spring return actuators. On interruption of the power supply
the actuator should close by spring action. Closing time should not be more than 10 seconds.
4.21
VIBRATION ISOLATION, FOUNDATIONS
All relevant safety regulations shall be observed carefully. All heavy equipment such as pumps,
condensers, fans, etc. shall be placed on concrete foundations with inserts of anti-vibration
material to avoid vibration transfer from the equipment to the building. The equipment shall be
set-up on additional vibration isolators or isolating material where required.
To keep the pipe systems and duct systems free of vibration, vibrating components shall be
connected to the system by flexible connections only.
All systems shall be designed, constructed and installed with special precautions and with
regard to compensation of some movements caused by temperature changes.
Page: 39
Anti-Vibration Mountings
Fans, compressors, motors, pumps pipe systems and many other vibration-inducing equipment
shall be isolated from the building structure by anti-vibration mountings which shall be of the
caged spring type selected to provide the static deflections as quoted in the schedules.
Compensator
The compensator shall avoid transmission of vibration of the machine installation and shall take
up pipe expansions. The compensators shall be suitable for the relevant working pressure and
operating temperatures of systems in which they will be installed. The compensator shall be
hydraulically tested according to the standards and regulations (at least 1 times the working
pressure of the system).
The compensator shall consist of an expansion body inside and/or outside arranged guide pipe
as well as suitable connections. The material has to be corrosion-resistant.
Vibration Absorbers
Vibration absorbers shall be installed in order to avoid transmission of noise from plant to the
building structure; number and arrangement depending on mass, speed and imbalance of the
unit. If not specially mentioned, spring or rubber elements will be used.
The absorber consists of mounting flanges and metal spring or special caoutchouc anti-vibration
body. All parts of metal have to be treated against corrosion.
4.22
REGISTERS GRILLES AN D DIFFUSERS
4.22.1
General
All air-diffusion equipment shall be sized and installed to match the suspended ceiling and shall
be selected according to the manufacturers catalogues, taking into consideration the geometry
of the spaces and partitions or columns, etc. which may disturb the air-distribution.
The velocity of air in conditioned room shall not exceed 0.25 m/s but not less than 0.125 m/s.
The induction-rate of the air diffusers shall be increased where the supply air temperature
difference is increased. The induction shall be made to ensure even temperature levels by
means of efficient mixing.
All air outlets shall be easily detachable. They shall be connected with flexible gaskets made to
ensure air tightness.
Air outlets shall be of robust construction and shall be made out of anodised aluminium except
where otherwise indicated. The deflection-blades shall be designed to permit directional
regulation of the airflow and minimum noise generation.
The automatic or manual regulating device of the airflow shall be accessible and easily
regulated without the necessity of dismounting. Apart from fan coil units, all the diffusers and
grilles shall be equipped with dampers.
4.22.2
Registers
Supply registers shall be adjustable 2 way directional type, constructed with horizontal and
vertical bars or vanes in aluminium frames and shall be provided with opposed blade dampers
for air volume control. The Employers/Engineers approval must be obtained before placing the
order of this item whether horizontal or vertical face bars are required. Register frames shall be
made of aluminium sections. Corner joints shall be finished to provide a neat trim appearance.
All supply registers shall have airtight felt, neoprene or plastic sealing strips at all edges,
designed to prevent leakage.
Page: 40
Each register shall be provided with a factory fabricated volume damper furnished by the
register manufacturer. Volume dampers shall be key adjustable. Operating mechanism shall
not project through any part of the register face. Dampers shall be of the gang operated
multiple opposed blade type.
Exhaust and return registers shall be constructed as specified for supply registers, except that
they shall have single set of non-directional face bars or vanes having the same appearance as
the supply registers. They shall be installed flush with finished wall, ceiling or door and, where
indicated, they shall be double surface type.
4.22.3
Ceiling Diffusers
Ceiling diffusers shall be provided for supply, return and overflow air distribution.
Quadratic, rectangular and circular types shall be provided as required and specified.
All ceiling diffusers shall comprise a frame with built-in front blades made of anodised aluminium
and rear contra-rotating flow regulating device made of phosphatised and stove-enamelled
sheet steel to balance and to adjust the airflow rate individually.
The ceiling diffuser shall be designed in consideration of a high induction and a low noise level.
Ceiling diffusers shall be of the circular, square, rectangular, or linear type subject to
Employers/Engineers approval. The type of ceiling construction where the diffuser is to be
installed shall determine the type of compatible diffuser ring or frame to be provided. The
diffuser shall be sized in accordance with the quantity of air passing and the air velocity as
recommended by ASHRAE specifications.
Intermediate pieces, etc., required to connect ducts to the diffusers selected shall be furnished
without additional cost. Factory fabricated tuning vanes, furnished by the diffuser manufacturer,
shall be provided at each diffuser branch or take-off. Vanes except for linear diffusers shall be
installed so that they can be removed through the diffuser for access through the duct.
Each diffuser shall be provided with a factory fabricated single key, opposed blade volume
damper constructed so that the required air flow can be obtained at any duct pressure not
exceeding 120 Pa and without affecting the air distribution pattern. The volume damper shall be
provided by the diffuser manufacturer and shall be installed so that it can be removed through
the diffuser neck for access to the duct.
All internal parts of each diffuser shall be removable as a unit to permit cleaning and provide
access to the ducts. Removable parts shall be constructed so that they cannot be reassembled
in any manner that will produce an incorrect air distribution pattern. The internal assembly shall
be fastened so that it can be removed and reassembled without special tools.
Diffusers used for exhaust or return shall be similar to diffusers used for supply, except those
elements used solely for air pattern control may be omitted.
Sheet metal air duct or plenum connections to diffusers shall be secured in accordance with
manufacturer recommendations.
4.22.4
Sectional Diffusers
Sectional diffusers shall be provided for supply air discharge by installation within suspended
ceilings of offices, rooms, halls etc.
Sectional diffusers shall be of the linear type including all required blind, intermediate and end
sections, as well as all required plenum boxes with incorporated airflow regulating devices and
pipe connections.
Page: 41
The sectional diffuser shall be designed in consideration of a high induction effect and a low
noise level.
Any air discharge port shall be adjustable at all air distribution angles from 0 to 180 degrees.
Sectional diffusers shall comprise a casing with one, two, three or four slots made of anodised
aluminium, including built-in and adjustable air discharge guide vanes made of plastic, complete
by a rear plenum box made of galvanised steel sheet including perforated orifice plates and
pipe connections made of galvanised steel sheet.
4.22.5
Linear Diffusers
Linear diffusers shall be provided for supply and return air by installation within suspended
ceiling. The fixed blades shall be arranged for horizontal, one- or two-way air discharge.
The linear diffuser shall comprise face sections and end caps made of aluminium to balance
and adjust the airflow rate individually.
The diffusers shall be designed in consideration of a high induction and a low noise level.
Diffusers shall be provided with alignment slots for insertion of key strips or with other
concealed means to align all exposed diffuser butt edges. Corner joints of steel frames, and
flanges exposed diffuser below ceiling or side wall, shall be metal filled and ground smooth,
Corner joints of aluminium frames and flanges exposed below ceiling or side wall shall appear
as hair line crack with unexposed sides of corner joints welded or secured with alignment keys.
Diffusers shall be furnished with separate pivoted hinged adjustable air volume damper and
separate air deflection blades. Air volume dampers shall be made adjustable without disturbing
the air blade setting. Volume and deflection blade sections shall have structural rigidity to
operate uniformly over the entire length of the diffuser without bending, warping, buckling or
creeping during normal operation.
Diffusers and all component parts shall be constructed of extruded aluminium or of steel and
shall be finished with baked enamel or other approved equivalent finish.
Diffusers installed in plaster ceilings shall be the snap-in type which is provided with pre-lined
frames flush with finished ceiling. Screws, bolts, etc., shall not be used in an exposed face of
diffusers frame of flange.
4.22.6
Supply and Return Grilles
Supply and return grilles shall be provided for air distribution systems installed visibly in plant
rooms, etc., as air intake or air extraction ports.
All supply and return grilles shall be designed with regard to high induction and low noise level.
All supply and return air grilles shall comprise a front section consisting of a frame with
individual adjustable aerofoil blades and made of pre-phosphatised or galvanised steel sheet
with stove-enamelled finish, including rear built-in flow regulating device, made of common
adjustable and contra-rotating coupled blades or adjustable baffle plate.
Supply air grilles shall be equipped with vertical front blades, additional rear built-in horizontal
blades, individual adjustable and contra-rotating flow regulating device.
Return air grilles shall be equipped with horizontal front blades and baffle flow-regulating device.
Supply and return air grilles made of rigid PVC shall be designed likewise.
All grilles and diffusers shall have a free area of at least 70% and shall be selected to suit the
layouts of ceiling tiles, room, sizes etc.
Page: 42
Ceiling diffusers shall be of the adjustable eyelash deflection blade type and shall have an
opposed blade damper located at the rear. The diffuser shall be fixed to the ductwork by a
purpose-made sub-frame assembly.
Special Air Grilles:
Air Transfer Grilles: These shall be of the non-vision, door-mounted type having a fixed core
of invert V blades.
Extract Grilles: These grilles shall be of the fixed blade of egg-crate type with an opposed
blade damper located at the rear.
4.22.7
Disc Valves
Disc valves shall be provided for exhaust and air-intake by installation within suspended ceilings
of toilets, showers, tea-kitchen and small kitchens, cleaning and ante-rooms, etc.
The disc valves shall be designed in consideration of the required pressure drop and low noise
level.
All disc valves shall be adjustable by twisting the valve disc.
The disc valve shall comprise a valve housing and a valve disc made of white finished, stoveenamelled steel sheet, including built-in rear mounting frame with an adjustable spindle and
lock-nut made of galvanised steel sheet and additional gasket ring.
4.22.8
Overflow Grilles
Overflow grilles shall be provided for door and wall installations to transfer air from one room or
area to another.
The maximum permissible velocity of airflow shall be less than 1.0 m/s.
The overflow grille shall comprise two equal front sections consisting of a frame with horizontally
fixed non-vision blades, made of angular profiled extruded aluminium and additional opposite
blind frame.
The overflow grille shall be designed with regard to a smooth and heavy construction.
4.22.9
Plenum Boxes
Plenum boxes shall be provided for ceiling diffusers to straighten the airflow and to reduce the
velocity of flow as well as the sound pressure level.
The plenum box shall be designed to fit the associated ceiling diffuser.
All plenum boxes shall be made of 1 mm galvanised steel sheet including built-in diagonal baffle
plates made of perforated steel sheet and fully pot-galvanised and additional sound-absorbing
lagging on the inside consisting of 50 mm glass fibre panels with external glass fibre quilt
pasted up holohedral.
4.22.10 Spin Type Ceiling Diffuser
Spin Type Diffuser shall be constructed as described for ceiling diffuser but consist of built in
vanes to provide high induction of room air.
4.22.11 Grease Intercepting Grille
Grease intercepting grilles shall be provided for kitchen exhaust systems. Grilles consisting of
frame with removable grease filter and grease pan. Frame and pan to be made of galvanised
steel sheet, filter media to be woven aluminium with expanded metal cover on both sides.

4.23
DUCTWORK AND ACCESSORIES
4.23.1
Ductwork
Page: 43
The following is covered under this item:

Ducts made of galvanised steel sheet
Ducts made of stainless steel sheet
Ducts made of rigid PVC
Duct Hangers
Generally, all air-ducts shall be made of galvanised steel sheets, including duct joints made of
galvanised connecting frames with galvanised bolts, washers and nuts.
All air ducts shall be designed with regard to a low-pressure drop, a low sound pressure level
generated by the airflow and a smooth, streamlined and airtight construction.
All ducts shall be reinforced, stiffened and braced as required or necessary to prevent any
damages, rattling, expansions or contractions and in consideration of the greatest foreseeable
stress by air on shock-wave pressure.
Straight ducts and shaped parts with rectangular cross-section made of PVC-hard or
polypropylene, shall be fire-resistant. Wall thickness min. 3 mm, duct connections by glued
sleeves, hanging and supporting as described under galvanised air ducts before.
All ducts made of rigid PVC shall be stiffened by external ribs made of welded PVC as required.
All ducts and pipes shall be joined together by connecting frames or flanges made of welded
angle or steel sheet, fully pot-galvanised, bolted and sealed airtight by sealing strips made of
foam-rubber and permanent elastic sealing material made of silicon compound, whereas all
ducts made of stainless steel or rigid PVC shall be welded airtight.
All connections to equipment shall be made with angle-flanged joints. In plant rooms and for
long runs, angle-flanged joints shall be included at 10 meter intervals.
All duct systems shall be fixed to the ceilings and to the walls or any backgrounds by means of
threaded rods and dowels made of galvanised steel including supporting traverses made of
angle steel of perforated steel beams and fully pot-galvanised, or wall brackets or supports
made of welded angle steel and fully pot-galvanised for the mounting of ducts and pipes within
installation shafts and trenches.
All ductwork support ties to the structure shall be made resilient with the use of 12 mm thick
non-intercellular neoprene strip, gaskets or washers.
Ducts shall be fixed to other steel girders and supporting pillars of the building structure or to
other mechanical or electrical equipment only by means of special clamping devices to avoid
drilling and welding, which is not permitted.
Transverse joints of all ducts shall be constructed with angle joints, the application of drive slips
and other types of undetachable joints are not permitted.
All duct-work shall be manufactured from best quality galvanised steel sheet and shall be
erected in a neat and workmanlike manner, true to size. The ductwork when erected must be
free from movement or drumming and be air-tight.
The ductwork inside the building shall be manufactured from hot-dipped galvanised sheet metal,
complying with BS 2989, Group 2, Class 2A and shall comply with the U.K. Heating and
Ventilating Contractors Association (HVAC), Specification DW/121.
Page: 44
Internal roughness and internal obstructions to air-flow (other than dampers, splitters, vanes,
etc.) will not be accepted. Sharp edges or corners on the outside of the ductwork, flanges or
supports, etc., will also not be accepted.
Any part of the galvanised ductwork, where the galvanising has been cut or damaged during
manufacture or erection, shall be cleaned down to bright metal and painted two coats of
aluminium, zinc or other corrosion-resisting paint.
All ducts shall be thoroughly cleaned before erection. All open ends shall be sealed with
polythene covers at all times during construction. All joints shall be sealed with an approved
mastic and taped externally to make an air-tight joint. All flanges shall be fitted with gaskets.
Before fitting any filter media into the plant the ductwork system shall be cleaned out and blown
through for at least 2 hours,
Round duct joints for spiral-pipes shall be constructed with special coupling sleeve joints, locked
and sealed airtight by metal bonding agents and additional external adhesive canvas tapes (80
mm).
Connections are sealed with permanent elastic material (shrunk sleeves), sizes larger than
1,000 mm diameter will be connected by flanges. Fixing shall be done with iron band,
acoustically insulated.
All longitudinal duct seams shall be constructed with a Pittsburgh lock seam or equal.
All air pipes of the spiral-type shall be constructed with grooved longitudinal seams.
In all cases, the duct end must be finished with a mating flange and where this is fixed to timber
frame, the flange should be wide enough to overlap the joint between timber and masonry by at
least 15 mm.
The material of the duct shall be extended in the form of spigots, beyond the flanged connection
and into the builders void.
Ends of sections where connecting to grilles and diffusers shall be flanged or shaped according
to the connection required. Sharp edges or corners on ducts, associated equipment, supports,
angle stiffeners etc., shall not be permitted and these must be removed.
Vertical ducts shall be supported by the stiffening angles or angle flanges.
All ducts installed in the battery rooms as well as all suction duct of the battery room shall be
made completely of rigid PVC.
Test holes for instruments shall be provided at regular intervals along the duct-work and to
enable fan duties to be tested and the performance of regulating dampers to be accessed. All
holes shall be 25 mm diameter and provided with an effective seal. Test holes shall be provided
accordingly.
Flexible joints shall be of full cross-sectional area of the mating plant connections and duct
section and the end of the duct and plant connection shall be in line.
On spirally wound circular and flat oval ducts, a coupling shall be attached to duct ends to
provide a smooth surface and ends carefully cleaned with a suitable solvent over a length of
100 mm. On all circular spigots, the flexible material is to be secured by a clip band with
adjustable screw or toggle fittings unless a proprietary metal edged material is used when
screws and sealant may be used.
The material thickness for the rectangular and spiral-type ducts shall be determined by the
greatest width of the duct or pipe section as mentioned below:

Duct/Pipe Dimensions
up to
500 mm
Page: 45
Material Thickness
0.75 mm
501 to
1,000 mm
0.88 mm
1,001 to
1,500 mm
1.00 mm
above
1,500 mm
1.25 mm
The material thickness for the rectangular and round ducts made of rigid PVC shall be
determined by the greatest width of the duct or pipe section as mentioned below:
Duct/Pipe Dimensions
Material Thickness
Up to
300 mm
3.0 mm
301 to
350 mm
3.5 mm
351 to
400 mm
4.0 mm
401 to
500 mm
5.0 mm
501 to
650 mm
6.0 mm (with ribs)
651 to
800 mm
8.0 mm (with ribs)
All ducts and pipe take-offs shall be equipped with adjustable splitter dampers or dampers for
ducts and adjustable flaps for pipes.
All duct elbows shall be equipped with built-in turning vanes to reduce the pressure drop.
Bends and offsets shall have a minimum throat radius equal to the width of the duct. Where
shorter radius bends are indicated or agreed by the Employer/Engineer as necessary due to
site limitations, internal splitters or turning vanes shall be used.
All transformations, expansion and contraction pieces of the ducts and pipes shall be designed
in consideration of limitation for the duct slope, which shall be less than 15 degrees for duct
increments and less than 30 degrees for duct decrements.
All air pipes shall be mounted only with pipe clamps combined with threaded rods and dowels.
All air ducts and pipes shall be equipped with all required fittings, as in particular, elbows,
bends, transformations, stages, branch take-offs, tee- and crosspieces, expansion- and
contraction-pieces, sliding connection branches, end plates, access covers and panels,
discharge and suction end-pieces for installation of diffusers, grilles, valves, etc. including all
required or necessary mounting and connecting frames and flanges, supports, brackets,
traverses, pillars, beams, etc. made of welded angle steel and fully pot-galvanised.
All ductwork connections to air handling equipment shall be made by means of 10 cm long
Reverters, JPT020 FR flexible connections or similar equal and approved material.
All air ducts and pipes shall be installed and fastened by means of vibration isolators to
minimise the intensity of vibrations transmitted to the pipes and ducts and to the surrounding
structure, as e.g. by means of isolation hangers with rubber suspensions of vibration supports
with plastic-foam strips or rubber sponge plates of soft-rubber buffer or equal.
All through-roof, through-wall and through-floor fittings of air ducts and pipes shall be sealed airtight and water-tight.
Page: 46
Where ducts penetrate any structural wall or slab, they shall be sleeved and 25 mm thick rock
wool inserted between the sleeve and the duct. Any gaps between the sleeve and the structure
shall be sealed with heavy grout and finished with a dense mastic.
All air ducts and pipes shall be insulated against thermal heat gain, condensation effects, sound
transmission by air or conducted through solids and against spreading fire.
Drill holes for measuring purposes shall be filled with plastic plug or closed by means of sheet
metal cover plates fixed with self-tapping screws.
Ductwork exposed to outside weather conditions shall be of at least 16 gauge and hot-dipped,
galvanised after manufacture.
Painting and corrosion protection of the ductwork shall be made in accordance with Part G5.5.
4.23.2
Supports for Ductwork
All necessary ductwork supports shall be provided and fixed to the building structure and all
necessary bolts, nuts, washers, screws, plugs shall be provided. Supports shall generally
comprise hot-dipped galvanised mild-steel sections and drop rods assembled in a suitable
manner to permit adjustment for height and alignment of the ducts, and to prevent the
transmission of vibration and/or noise.
Supports for horizontal rectangular ducts shall comply with the following table:
Length
Longer
(cm)
of
side
Drop rod MS
Rod Dia. (mm)
Or Hanger MS
Flat (maximum)
Minimum
Bearing Member
Maximum
Spacing (m)
Up to 50
12
25 x 3
25 x 3 flat or
25 x2 5 x 3 angle
3.0
50 to 80
12
25 x 3
40 x 40 x 4 angle
3.0
80 to 100
12
25 x 3
40 x 40 x 4 angle
2.5
100 to 150
12
25 x 3
50 x 50 x 5 angle
2.5
150 and larger
12
40 x 3
100 x 50 channel
2.0
Where additional loads are to be applied, further supports shall be designed to suit the loading.
All ductwork shall be supported at branch connections and where heavy items of equipment
occur within ductwork distributions, additional support shall be provided as necessary.
Design of supports for vehicles ducts will be dictated by site conditions and spacing may be
greater than for horizontal ducts. Ducts shall be supported by the stiffening angles or angle
flanges but where this is impractical, supporting angles shall be fixed to the ducts.
All ductwork shall be supported in such a manner that no weight is imposed upon the plant to
which it is connected
All mild steel sections used for the construction of ductwork supports shall be hot-dipped,
galvanised. Welded work shall be galvanised after manufacture, zinc-sprayed or otherwise
rust-proofed in a suitable manner. An approved insulation is to be provided between the
ductwork and all supports to isolate the duct from the building structure. Supports for insulated
ducts with a vapour barrier shall be constructed in order to provide a continuous vapour barrier.
Page: 47
Inspection Openings
Maintenance and inspection openings shall be arranged in all cases where components are
installed in ducts (fire dampers, air heaters, etc.). Ducts must be accessible for cleaning or if
the inside of the duct must be examined for fouling.
Accessories - standard design:
Profiled frame and counter frame with corrosion-protection,
Foam neoprene gaskets.
Single-walled galvanised door panel,
Fasteners.
Air tight steel panel shall consist of a steel angle frame with builders cleats, a robust door panel
complete with a profiled rubber seal, and lever type fastener.
Profile Steel Construction.
Bolted or welded constructions of profile steel, angle or flat iron, surfaces galvanised,
galvanised screws and bolts, for special and heavy fastenings and constructions of different airconditioning and ventilation equipment.
Duct Thermometers
Vapour pressure in steel type 10 cm diameter dial thermometers shall be installed in the
following locations:
Fresh air inlet duct to each air-handling unit,
Main re-circulation air ducts to each air-handling unit,
Main supply-air duct from each air-handling unit, before and alter each air-cooler,
Before and after each air-heater
Thermometer as bimetal indicator to indicate the air temperature consisting of:
Diving shaft, steel housing with nickel-plated over-slide ring.
4.23.3
Flexible Ducts
Flexible air ducts shall be provided to connect all slot diffusers, linear diffusers, ceiling diffusers
and disc valves installed within suspended ceilings to connect them with the air ducts and pipes.
Flexible air ducts shall be made of two layers of aluminium strips which shall be spirally wound
round a cylindrical mandrel with overlap of each layer and additional beading of both together to
ensure crushing strength and inherent stability.
All flexible air ducts shall be full-flexible and the bending radius shall be equal to the pipe
diameter.
All flexible air ducts for supply air distribution shall be thermal-insulated against external heat
gains and condensation effects by means of a double-walled construction with intermediate
insulation layer.
The insulated and flexible air ducts shall be fabricated of two full-flexible air ducts made of
spirally and lap wounded metal strips of aluminium including an intermediate layer of thermal
insulation material made of 25 mm flame-resisting, non rottable glass fibre wool.
Page: 48
4.24
INSULATION OF DUCTWORK
4.24.1
General
Unless otherwise required all components of the insulation shall be fire-resistant, non-rottable
and free of corrosive ingredients. See also Part G5.1 General Requirements for Mechanical
Equipment and Piping.
4.24.2
Thermal Insulation
Ductwork Insulation Standard

The following thermal insulation standards (and/or vapour-tight) shall be applied to all supply
and return ductwork used on air-conditioning systems.
Ducts located above ceilings, in voids, shafts and trenches, where not in view, the insulation
shall be 50 mm thick glass fibre flexible mattress, density 32 kg per cubic meter, having a
facing of reinforced aluminium foil paper laminate rated as class I, when tested in
accordance with BS 476. Longitudinal and circumferential joints shall be sealed with 75 mm
minimum width aluminium foil tape.
To be finally secured with a layer of galvanised wire netting:
Duct work located externally shall have an insulation standard of 100 mm thick glass fibre
rigid slab, minimum density 48 kg per cubic metre, having a facing of reinforced aluminium
foil paper laminate rated as class I when tested in accordance with BS 476. Longitudinal
and circumferential joints shall be sealed with 75 mm minimum width aluminium tape.
Material to be adequately secured to prevent by adhesive and/or mechanical fittings where
necessary to prevent sagging under its own weight. The insulation shall be further protected
with a layer of heavy quality roofing felt, well-lapped at joints to prevent the ingress of
moisture secured by means of galvanised wire netting and finally painted with two coats of
black bitumastic paint.
Ductwork that is visible within important areas such as plant rooms and occupied areas, the
insulation shall be as above, except that the finish glass fibre slab shall be over clad with 22
gauge hammered or stucco embossed aluminium sheet cut to fit and secured by galvanised
self tapping screws or by lock forming.
Ductwork located in above ceiling, in voids, shafts, and trenches, where not in view, and
extremely in visual areas the insulation shall be on synthetic caoutchouc basis (e.g.
Armaflex or similar) and heavy flammable, tested in accordance with DIN 4012, Class B2.
The sheets shall be bonded to the cleaned metal surfaces with contact adhesive applied
over the whole surface area to the manufacturer's application instructions. Joints and cut
edges shall also be bonded.
Ductwork located in outside areas, where aggressive air and UV-protection is expected, the
insulation, shall be coated with final finish according to the manufacturers application
instructions
Thermal Insulation for Refrigerant

Discharge and liquid shall be shielded or insulated with 12 mm thick insulation material having a
thermal conductivity of less than 0.04 W/m K and weatherproofed with a material having a
reflective or a light coloured finish.
The suction line from the evaporator to the compressor shall be insulated with a material having
a thermal conductivity of less than 0.04 W/m K and at least 12 mm thick for pipes of up to 80
mm diameter and 19 mm thick for pipes of 100 mm diameter and above.
Page: 49
This insulation shall be protected by a vapour barrier which shall not be interrupted between
joints of sectional material or at discontinuities at valves or brackets.
4.24.3
Insulation for Air-Conditioning Ductwork
Thermal insulation shall be non-combustible and is to be provided for supply, return and outside
air ducts.
The heat conduction coefficient shall be less than 0.04 W/mK.
Impassable Areas
Concealed installed ductwork in impassable areas shall be insulated with 30 mm minimum thick
rigid board glass fibre panel with resin binder and factory applied vapour barrier made of
aluminium foil, to be glass fibre reinforced. Insulation shall be applied with adhesive and metal
clips spaced not less than one per 0.2 m2 of insulation. Joints and seams shall be sealed with
vapour barrier sealer and tape of same type as facing.
Round ductwork shall be insulated with 30 mm minimum thick blanket type glass fibre with
external vapour barrier facing and sealing as specified before. Insulation shall be adhered to
ductwork with 100 mm wide bands of duct insulation adhesive applied on 300 mm centres and
fastened with metal clips on 450 mm centres.
Accessible Areas
All duct insulation provided for application in accessible areas shall be protected against
damages by means of an additional external protective sheet metal cover made of 1.0 m
aluminium sheets.
4.24.4
Insulation for Ductwork of Ventilation Systems
Ductwork of ventilation systems within accessible, air-conditioned areas shall be insulated as

specified in Chapter above.
4.24.5
Acoustical Insulation
Acoustic insulation shall be provided, if required to meet the specified sound pressure level for
ductwork to prevent sound transmission from the plant room into the duct system.
Acoustic insulation shall be made of an additional external sound reducing cover as a
supplementary insulation to the thermal insulation of the ducts and pipes, made of 20 mm
plaster cast lagging.
In general, acoustic insulation shall be provided for all sound attenuators and the associated
duct section between sound attenuators and through-wall fitting within the plant room (where
required).
4.24.6
Fire-Proof Insulation
Fire-proof insulation shall be provided whenever required to substitute the use of fire dampers
within short fire sections, as e.g., exit air pipes of toilets passing through several fire walls of
corridors, etc.
All fire-proof insulation shall be made of non-combustible mineral wool, minimum thickness 120
mm, comprising three layers of mineral wool mats (40 mm each) including reinforcing wire-mesh
screens and an external sheet metal cover against damages, made of 1.0 mm aluminium sheet.
All supply and return air ducts installed within outdoor trenches, shall be equipped with an
additional sub-layer made of 10 mm polyethylene plastic foam to prevent condensation effects
on the duct surface, in case of fire-proof insulation is required.
Page: 50
4.25
ACCESS DOORS AND SOUND ATTENUATORS
4.25.1
Inspection Covers and Access Doors
Inspection holes, covers, doors and flaps as well as access covers, doors and plates shall be
provided wherever necessary for inspection, revision, operation, checking, controlling, access,
service, repair, cleaning, maintenance, etc., at all air ducts and installation shafts or trenches as
well as at all suspended ceilings and false floors.
All covers, doors, flaps and plates shall be made of double walled galvanised steel sheet of
1.25 mm thickness including thermal and acoustic insulation made of an intermediate layer of
mineral wool, if required.
Covers, flaps and plates shall be equipped with quick-release fasteners to ensure an easy
handling. Duct inspection doors shall have a minimum size of 400 x 250 mm whereas covers,
plates and flaps shall have 600 x 600 mm at least. Doors with hinges and double lever locking
devices, covers, flaps and doors with airtight sealing strips
4.25.2
Sound Attenuators
Sound attenuators shall be designed as splitter type to be used in air ducts, air pipes and air
chambers, comprising sound-absorbing elements and an external casing with flanges and
mounting frames, including external heat and sound insulation, if required.
The casing and flanges or frames as well as the frames of the sound-absorbing elements shall
be made of galvanised sheet steel. The sound-absorbing elements shall be made of nonrottable moisture-resistant and non-combustible mineral wool, covered with acoustic transparent
lagging against abrasion made of perforated stainless sheet steel.
The sound-pressure level of the air-generated noise shall be lower than the required sound
pressure level for the connected room by 10 dB at minimum.
All supports, hangers, etc., shall be installed sound insulated to avoid sound transmission
conducted through solids.
4.25.3
Cross Talk Silencer
Cross talk silencers shall be designed as sound-absorbing shell type to be used in air pipes,
comprising the sound-absorbing shell and pipe joints.
The sound-absorbing shell shall be made of double-walled semi-flexible air pipes fabricated
from spirally and lap wounded metal strips made of galvanised steel sheet including an
intermediate layer of 50 mm sound-absorbing material made of non-rottable and moistureresistant glass-wool and finished up with plastic end caps.
The internal air pipe shall be performed acoustically transparent and abrasion-resistant.
The sound transmission reducers shall be designed to obtain the required sound pressure level
within the connected room as well as to reduce the sound transmission from one room to
another room by 35 dB at minimum in order to avoid telephone effects.
In general, all sound transmission reducers shall have an effective absorbing length of 1.5 m at
minimum.
5
5.1
GENERAL
All the I&C Equipment shall be in accordance with both the General Requirements for and with
both the Technical Specification I&C Equipment.
Page: 51
The air coolers of the direct expansion type (evaporators) shall be protected from freezing by
means of a back pressure valve in the suction pipe of the refrigerant system and an antifreezing thermostat.
The electrical air re-heaters shall be provided with 3 or 7 load ranges according to the heater
power size and with indication on control board.
Duct sections shall be provided with test measuring apertures to adjust the airflow.
The air conditioning plants shall be able to operate pre-select manually from the respective local
control boards or from the Building Management workstations and also automatically by means
of switch-clocks for selection of hours and days. The clock shall be equipped with running
reserve in case of power failure.
Stand-by equipment shall be equipped with service hour meter.
Tacho-generators for speed monitoring, alarm and automatic change-over of parallel operating
fans shall be mounted on the driven shaft end and shall be equipped with adjustable switching
speed and in case of necessity with attached speed increaser drive.
Differential pressure indication and monitoring shall be provided for air filters with local
indication of static pressure differential and supplementary alarm in pertaining control board.
Measuring and switching range depends on mounting position. A relay shall protect from
switching at short intervals.
Equipment Specifications:
Safety Thermostat
Safety thermostat for installation within air-handling units, air chambers, supply air ducts, return
air ducts, exhaust ducts and down-stream of electric air heaters, including 8.4 m resistancesensing element and electronic monitor for alarm by excess temperature as well as for turning
off electric air heaters and related electric consumers.
Superheating Protective Circuit Breaker
Superheating protective circuit breaker (detonator safety type) for electric air heaters, consisting
of glass-cartridge, filled with expansion fluid and fitted on a spring bolt of switching relay for
fastening on side panel of air heater casing for alarm as well as for turning off electric air
heaters including pertaining electric consumers.
Back Pressure Valves (Self Acting Valve)
Back pressure valves for installation in suction pipe of refrigerant system in case of variable
airflow regulation by means of by-pass damper to avoid freezing of evaporator and stop of
compressor by low-pressure drop.
Control System for Mixed Air Temperature
Control system for mixed air temperature, consisting of a resistance-sensing element, including
electronic measuring transformer, central controller for control board installation and
supplementary reversible operating characteristics as a function of outside air temperature
acting upon mixing air damper.
Control Systems for Dew-Point Temperature
Control system for dew-point temperature of supply air consisting of a long resistance-sensing
element, including electronic measuring transmitter and central controller for control board
installation acting upon air cooler valve or load control system of compressor.
Page: 52
Control Systems for Ai r Humidity

Control system for air humidity consisting of a humidity sensing element with immersion well for
installation in return air duct, including electronic measuring transmitter and central controller for
control board installation, acting upon by-pass and face damper for air cooler. Humidity shall be
kept at 50-60% in the air-conditioned areas.
Control System for Room Air, Supply Air or Return Air Temperature
Control system for room air, supply air or return air temperature consisting of a resisting-sensing
element, including electronic measuring transmitter and central controller for control board
installation acting upon electric air heater, air cooler and/or face/by-pass damper.
Control System for Room Air or Return Air Temperature with Compensation
corresponding to Outside Air Temperature
Same as before, with supplementary compensation of room air or return air temperature as a
function of outside air temperature.
Outside Air Temperature Sensors
Outside air temperature sensor consisting of 8.4 m long resistance-sensing element, including
electronic measuring transmitter, acting upon controller of mixed air temperature or controller of
room air or return air temperature.
Low Limit Controllers for Supply Air Temperature
Low limit controller for supply air temperature consisting of 8.4 m long resistance-sensing
element, including electronic measuring transmitter and controller for control board installation
acting upon air heater.
Dial-type Thermometers
Dial-type thermometers consisting of a temperature sensing element with immersion well for
installation of air-handling units and air ducts to indicate inner air temperature. Length of
immersion well: 250 mm.
Alarm on Local Control Boards
In general the following alarms shall be provided:
Fire damper tripped
Air filter dirty
Failure of electrical humidifier
Overheating of air heater
Airflow failure of air heater
Temperature limit exceeded
Freezing danger (DX-coil)
Refrigeration unit disturbed
Important single alarms and group alarms shall be provided on single terminals and are to
be cabled to the central, remote control and alarm system.
Page: 53
Remote Alarm
For remote alarm systems all individual alarm devices shall be equipped with potential-free
contacts.
Local Alarm
For local alarm systems an acoustic alarm horn shall be provided for each control panel or A/C
plant room.
Remote Release System for Fire Dampers
Fire dampers shall be equipped with a magnetic actuator to close them automatically in case of
remote fire alarms initiated by smog detectors or fire alarm signal boxes or other fire dampers.
It shall be possible to open the fire dampers from the remote control station.
Fire Dampers and Fan Interlocking System
Fire dampers shall be equipped with limit switches in order to shutdown the appertaining A/C
ventilating systems as well as to close the appertaining fire dampers of the above A/C
ventilating systems automatically in order to prevent spreading of fire or smoke through the
building (appertaining system means all systems within the same fire zone).
Smoke Detector and Fan Interlocking System
The A/C- and ventilation systems serving one or more fire zones shall be shut-down by
appertaining room or zone smoke detectors via the fire-alarm panel.
5.2
BUILDING MANAGEMENT SYSTEM
Building Management System with two main loops shall be provided.

One loop shall handle all HVAC remote indications, signalisation and controls in the
Administration Building with one central PC based workstation on the computer floor (third
level).
A second loop shall handle all HVAC remote indications, signalisation and controls from all
indoor electrical, instrumentation & control and process areas of the Packages P (Power Plant),
D (Desalination) and S (400 kV Sub-Station). The central workstations of this loop shall be
located in the Central Control Room (CCR) in the Central Control and Switchgear Building.
The BMS shall be interfaced with the DOS LAN in CCR to forward to the DCS operator stations
temperature alarms of the rooms, faults alarm and status indication of the equipment.
The BMS shall be a digital microprocessor based system of the latest proven technology. It
shall incorporate microprocessor based general purpose Direct Digital Controllers (DDC) at the
field level which shall interface directly with sensors, actuators, pneumatic and electric controls,
etc. The DDCs shall be provided on stand alone basis and individually for each area. Each DDC
shall have real time clock, EEPROM, RAM, PEER to PEER communication and shall be
provided with a Portable Operator Terminal. The BMS shall incorporate at the automation level
System Controllers which shall have, but not limited to, the following functions:
To manage communication with the DDC controllers.
Communication with other system controllers.
Communication to the BMS operator work stations.
Alarm and message management.
Trend log.
Page: 54
At the management level, the BMS shall incorporate 2 identical redundant operator workstations
for the loop of the power and desalination plant and one operator workstation for the loop of the
Administration Building. Each operator workstation shall be complete with monitor, keyboard
and mouse. The operator workstations shall have, but not limited to, the following functions:
32 bit applications
Graphic based operation of the HVAC system
Trend viewer
Scheduling
Alarm management
Log viewer
Fast navigation facility through the BMS
Hierarchical views with instant access to detailed point information
Control functions, set points and parameters control, outputs (manual override) commands.
ELECTRIC INSTALLATIONS
All the electric installations shall conform to the requirements as specified under the relevant
Clauses of Part P2.26 and Part G5.2.
Generally, each mechanical and electrical device must be provided with an earthing screw of
sufficient diameter suitable for connection to the protective earthing system.
The Contractor is responsible that all metallic housings, ducts, pipes and other parts of
complete installations such as fans, pumps, compressors, filters, heat exchangers, etc. are
effectively connected by earth conductors so that only one or two main connections to the
above mentioned protective earthing system are required.
7
SPARE PARTS AND TOOLS
Refer to Spare Parts, Special Tools, Tackles and Consumables (Part G4.6) and Price
Schedules Part G3.2.
CNE/015/2002
P2.25
WORKING DOCUMENT
Part P2.25 Emission Monitoring System Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
PAGE
GENERAL ..................................................................................................................................... 1
LAYOUT ........................................................................................................................................ 1
SCOPE OF WORKS..................................................................................................................... 1
SCOPE OF EQUIPMENT ............................................................................................................. 2

4.1
EXHAUST GAS MONITORING STATIONS.................................................................... 2
4.2
EFFLUENT MONITORING............................................................................................... 6
4.3
CUBICLES AND MEASURING CONTAINERS .............................................................. 7
4.4
DATA ACQUISITION/STORAGE/EVALUATION/VISUALISATION .............................. 8
4.5
PORTABLE NOISE MONITORING EQUIPMENT......................................................... 10
WORKSHOP AND SITE TESTS................................................................................................ 11
INTERFACES ............................................................................................................................. 11
CORROSION PROTECTION..................................................................................................... 11
P2_25_EMS_Working_Doc.doc
Page: 1
GENERAL
This Part specifies all equipment required for emission monitoring of exhaust gases and effluents
released to the environment during operation of the Jebel Ali L, Phase I power and water
production facility.
The general technical performance requirements of the following systems are covered:
Exhaust gas emission monitoring station(s)
Effluent monitoring station
Portable noise monitoring equipment
Data Evaluation System
with all necessary equipment for satisfactory operation of the emission monitoring facilities.
Contractor's supply shall include but not be limited to the engineering design, manufacturing,
performance testing, delivery, installation and commissioning of the equipment.
All monitoring equipment for gaseous substances as well as the corresponding calibration, data
conversion and evaluation procedures shall be in accordance with the relevant ISO Standards. For
the GTs/HRSGs the ISO Standards No. 11042-1 Measurement and Evaluation and No. 11042-2
Automated Emission Monitoring shall be applicable.
The systems and their components supplied shall meet this specification and shall also conform to
the applicable requirements of this and other general clauses in Part 5 General Technical
Requirements.
LAYOUT
The layout arrangement of the monitoring stations shall provide adequate access for safe, simple
and easy operation.
SCOPE OF WORKS
Continuous monitoring equipment for the following exhaust gas emission and reference
parameters shall be provided for each GT bypass stack, each HRSG and for each auxiliary
boiler stack:
NOx
SO2
Dust
O2
CO
CO2
Exhaust gas temperature
Exhaust gas pressure
Page: 2
Continuous monitoring equipment for the following effluent parameters shall be installed at the
discharge pipe of waste water and boiler blowdown:
pH-value
Waste water discharge flow
Waste water discharge temperature
Data acquisition module (pre-processing unit)
Two personal computer workplaces for separate evaluation of the emission monitoring and
sample analyses results with connection to the main DCS system, allowing extraction of the
emission monitoring data and relevant reference parameters from the DCS for environmental
analysis. The two PC workplaces shall be located in the computer room of the central control
building.
One (1) portable noise monitoring system for regular check of the noise impact at different
facilities of the CCPP shall be provided.
4
4.1
SCOPE OF EQUIPMENT
EXHAUST GAS MONITORING STATIONS
The Jebel Ali L, Phase I Power Generation and Water Production Station consists of three (3)
gas turbines, three (3) HRSGs, two (2) auxiliary boilers and five (5) MSF units.
Exhaust gas emission monitoring stations shall be installed as follows:
- one at each GT bypass stack
- one at each HRSG and
- one at each auxiliary boiler stack
Provision shall be made that all measuring sensors and instruments are working properly under the
prevailing measuring conditions.
The system main components shall be the
Sample probes
Temperature controlled heated sample lines
Condensate pots
Sample gas pumps
Sample coolers
Solenoid valves system
Multi-component analyser system
Calibration gas bottles filled with gas for automatic calibration
Data acquisition modules
Emission calculator
Emission Monitoring computer system for data evaluation
The sample coolers, analysers and pre-processing equipment shall be installed in an air
conditioned container near to the stacks at 0,00 M level. The Emission Monitoring computers shall
be installed in the computer room close to the CCR.
Equipment handling the samples shall be of corrosion and temperature resistant material.
Page: 3
Appropriate protection against lightning has to be provided.

Measuring Instruments
Measuring modules for NO x , SO2, CO, CO 2 Humidity, O2, as well as sample temperature and
pressure shall be provided for each monitoring station, capable of future system extension
(addition of sensor modules). For the gaseous substances a multi-component Analyser system
shall be used.
Analyser with self testing and auto calibration shall be provided.
Each exhaust gas emission monitoring station shall include the following measuring instruments:
NOx -Monitor
Method: non-dispersive infrared absorption or UV
Analyser including cubicle and sampling probe capable of self testing and auto calibration
Measuring ranges: 0 - 1000 ppm in appropriate ranges
Resolution: better than 0.5 % of full scale of range used or 1 ppm, whichever is greater
Repeatability: better than 1 % of full scale of range used or 1 ppm, whichever is greater
Stability: better than 2 % of full scale of range used or 1 ppm, whichever is greater, over a
period of 2 h
Zero drift: better than 1 % of full scale of range used or 1 ppm, whichever is greater over a
period of 2 h
Noise: 0.5 Hz and greater, less than 1 % of full scale of range used or 1 ppm, whichever is
greater over a period of 2 h
Response time: < 10 s from entry of the sample into the analyser to attaining 90 % of the final
reading
Signal output: 4 - 20 mA
Status signal outputs
Power supply: 230 VAC, 50 Hz
ambient operation conditions: 5 - 50 C
calibration gas to be included
SO2-Monitor
Method: non-dispersive infrared absorption or UV
Measuring ranges: 0 - 50 ppm and, in appropriate ranges up to 1000 ppm
Resolution: better than 2 % of full scale or 2 ppm, whichever is greater
period of 2 h
period of 2 h
Page: 4
Noise: 0.5 Hz and greater, less than 2 % of full scale of range used or 0.05 %, whichever is
Response time: < 50 s from entry of the sample into the Analyser to attaining 90 % of the final
reading
calibration gas to be included
O2 Monitor
Method: Continuous Paramagnetic Oxygen Analyser
Measuring ranges: 0 - 25 vol % in appropriate ranges
Resolution: better than 0.2 % of full scale of range used or 0.05 %, whichever is greater
Repeatability: better than 0.2 % of full scale of range used or 0.05 %, whichever is greater
Stability: better than 2 % of full scale of range used or 0.05 %, whichever is greater, over a
period of 2 h
Zero drift: better than 0.2 % of full scale of range used or 0.05 %, whichever is greater over
a period of 2 h
Noise: 0.5 Hz and greater, less than 0.2 % of full scale of range used or 0.05 %, whichever
is greater over a period of 2 h
reading
status signal outputs
CO Monitor
Method: Non-dispersive infrared
Measuring ranges: 0 - 2 500 ppm in appropriate ranges
Resolution: better than 0.5 % of full scale of range used or 1 ppm, whichever is greater
period of 2 h
Page: 5
period of 2 h
Noise: 0.5 Hz and greater, less than 1 % of full scale of range used or 1 ppm whichever is
reading
CO2 Monitor
Method: Non-dispersive infrared analyser
Measuring ranges: 0 - 20 % in appropriate ranges
Resolution: better than + 0.5 % of full scale of range used or 100 ppm, whichever is greater
Stability: better than 2 % of full scale of range used or 100 ppm, whichever is greater, over
a period of 2 h
period of 2 h
Noise: 0.5 Hz and greater, less than 1 % of full scale of range used or 100 ppm, whichever
is greater over a period of 2 h
reading
Dust Monitor
Method: Continuous measuring of optical transmission or triboelectric method
Analyser including cubicle and optical installation or sampling probe, capable of self testing
Measuring range: 0 - 200 mg/m3
Resolution: 2 % of full scale of range used
Detection Limit : 2 % of full scale
Page: 6
Temperature Sensor
Method: NiCr-Ni-thermocouple
Measuring range and resolution: 0 - 550 C + 0.5 C
Pressure Sensor
Method: semiconductor or capacitor sensor
Measuring range: -200 - + 200 mbar
Resolution: 0.01 mbar
Measuring Locations
Sample extraction facilities for measurement of NO x , SO2, CO, CO 2, O2, H2O concentration as well
as dust, temperature and pressure sensors shall be installed at each GT bypass stack, each
HRSG and at each auxiliary boiler stack, approximately 3 m below the stack outlet on the highest
boiler platform.
The extracted exhaust gas shall be transferred through heated sample lines to the measuring
instruments mounted in the emission monitoring container.
4.2
EFFLUENT MONITORING
All effluent monitoring shall take place at the outlet pipe of the waste water monitoring basin.
The average effluent conditions will be as follows:
- Average effluent temperature:

approx. 30 C
- Average effluent pH:
6-9
Continuous Measuring Instruments

One effluent monitoring station shall be provided, including the following continuous measuring
instruments:
Combined pH and Temperature Monitor
Method (pH): Redox electrode (Ag+/AgCl/Cl- or polymer electrolyt system)
Method (temperature): Thermistor sensor (resistance measurement)
Analyser including cubicle and pH-electrode capable of auto calibration and self testing
Measuring range and resolution (pH): 0 - 14 + 0.05 pH
Measuring range and resolution (temperature): 0 - 60 C + 0.2 K
Automatic temperature compensation of pH measurement
On-line display for actual measurement values
Two spare pH-electrodes to be provided
Page: 7
Discharge Flow Monitor

Method: Electromagnetic flow sensor
Analyser including cubicle and measuring sensor capable of self testing
Measuring range and resolution (pH): 0 - 14 + 0.05 pH
Measuring range and resolution (temperature): 0 - 100 C + 0.2 K
On-line display for actual measurement values
Measuring Locations
Sample Extraction for Laboratory Analyses:
A tapping shaft for extraction of samples for laboratory analyses shall be provided and installed at
the discharge line of the waste water monitoring basin, before the waste waters are mixed with the
circulating cooling water and discharged to the sea.
Continuous Effluent Monitoring:
The sensors for continuous monitoring of effluent pH and temperature shall be located within the
sample tapping shaft. The flow sensor shall be mounted within the discharge line.
The corresponding electronic equipment shall be mounted in a weatherproof container to be
located nearby the point of measurement at the discharge pipe of waste water and boiler
blowdown.
The corresponding analogue measuring signals (4-20 mA) and the status signals (24V DC) shall
be transmitted by multicore cables to the DCS.
4.3
CUBICLES AND MEASURING CONTAINERS
All cubicles for air pollutant and for effluent parameter measurement shall be mounted within
weatherproof measuring container(s) with redundant air conditioning.
Page: 8
All measuring containers shall be equipped with sun protection roofs. The cubicles and containers
shall be of solid and rigid design. They shall be painted at least with two coatings.
Cubicles shall be constructed of braced rolled steel sheet of at minimum of 1 mm thickness with a
rigid structure that will not distort during transportation and after installation. The front door shall be
equipped with glass windows in order to allow the supervision of the instruments without opening
the front door. The cubicles shall have a pocket for the documentation necessary for service and
maintenance.
The doors of containers and cubicles shall have a lock.
4.4
DATA ACQUISITION/STORAGE/EVALUATION/VISUALISATION
The results of the measurements performed automatically by the emission monitoring equipment
(continuous stacks and effluent emission monitoring) as well as the required analogue and status
signals shall be pre-processed in a data acquisition module and transmitted to the main DCS.
Separate evaluation, storage and visualisation for environmental analysis shall be carried out on
two personal computer (PC) workplaces, which shall be connected to the DCS for extraction of the
relevant emission monitoring data and reference parameters of plant operation.
Provision shall be made that all signal exchange between measuring containers, power plant
control panels and data evaluation system is made using interfaces for galvanic signal isolation.
Data Acquisition Module
The data from the continuous emission monitoring instruments shall be converted to appropriate
physical units in a pre-processing computer (data acquisition module) which shall be connected to the
main DCS system for data evaluation, storage and visualisation.
The data acquisition module shall sample the analogue and status signals, perform corrections
related to standard conditions, automatic comparison with applicable limits and output of
corresponding alarm messages, calculate time averages of analogue signals taking into account
the corresponding status information and provide a circular data buffer of at least five days of
estimated emission characteristics. Data acquisition and data evaluation shall be performed in
accordance with approved regulations of emission monitoring (e.g. ISO standards, TA Luft or
equivalent). All monitoring equipment provided shall also comply with local environmental
regulations, if applicable. The Contractor shall inform himself about all applicable local standards
and legislation.
The data acquisition module shall be adapted to facility requirements by means of a configuration
tool, no software programming shall be allowed to follow changes of facility requirements.
Signal Output to DCS System
The actual emission concentrations of NO x , SO2, CO, CO2, Dust, and O2 measured at the installed
exhaust gas monitoring stations, the effluent parameters pH, temperature and flow, as well as the
corresponding alarm messages (instrument failure, limit exceeded) shall be made available for the
DCS system of the Plant.
All conventional signals interfaced with the DCS shall be made available as potential free contact
for binary and as galvanic isolated 4-20 mA for analogue signals.
Data Extraction from DCS to the PC Workplaces
The two PC workplaces for separate evaluation of environmental data shall be connected to the
main DCS system, allowing extraction of the pre-processed emission monitoring data, as well as
the relevant operational reference parameters such as fuel consumption, generated power, etc. for
any given time period from the DCS for the analysis, correlation and assessment of environmental
impacts.
Design of PC Workplaces
The two computer workplaces shall be located in the computer room of the central control building.
Page: 9
Both PC workplaces shall be equipped with the required standard office computer hard- and
software including spread sheet calculation, graphic tool, word processing, data base
management, and modem connection to the telephone system for on-line data transmission and
sufficient data storage capacity.
The application software of the PC Workplaces shall allow the following functions:
Extraction of Data from DCS on request for environmental evaluation for any selected time
interval, collection of Channels ad lib, including gas turbine operation data (GT fuel
consumption, power output, etc.)
Password protected access to the computer system, user rights be definable by a system
administrator
Display of on-line values
Output of emission concentration values alternatively in mg/MJ, mg/m at standard conditions,

or ppmvd.
Automatic comparison with applicable limits, colour indication and alarm messages in case of
exceeded limits. The Contractor shall inform himself about applicable local/international
standards and legislation.
Comparison shall be made using the unit mg/MJ and referring to the actual calorific value of
the fuel used. A corresponding input routine for the calorific value shall be provided
Graphical presentation of results (bar charts, tables, trends) on monitor and printer
Indication of margin left until limit is reached
Frequency distribution of data (classification)
Preparation, storage and handling and keyword access of free definable record sheets
Automatic preparation of emission monitoring reports for monitor, printer and modem from the
system data base. These reports shall be saved and printed out in regular intervals or on
request. The contents of these reports shall be free definable by the user (e.g. report
containing mean and peak values within a defined time period)
Output for standard software (word processing, spread-sheet calculation, data base, graphic
programs, etc.)
Diagnosis function for check of all connected subsystems
Alarm Messages
Alarm Messages shall be displayed at data acquisition module and automatically transmitted to the
DCS system of the Plant in case of instrument failures and in case applicable emission limits are
exceeded.
In case of exceeded limits alarm messages shall be indicated at the DCS showing the measured
value and the corresponding limit value for comparison. The alarm messages shall be repeated in
intervals of some minutes as long as limits are exceeded. The alarm messages shall not disturb
the normal software operation and working procedures.
PC Workplaces
Two PC workplaces shall be provided including the following hardware:
2 personal computers, each with the following specification:

*
CPU Type:
Pentium
Page: 10
*
*
*
*
*
*
*
*
*
*
*
*
CPU clock rate:

RAM:
Hard disks:
Graphic adapter:
CD writable:
CD ROM, 40x:
Keyboard:
3.5 Zip Drive:
3.5 Floppy Drive:
Mouse:
Monitor:
Network adapter:

1000 MHz or higher
256 Mbyte
2 x 40 Gbyte IDE
SVGA, 32 MB RAM
1
1
1
1
1
1
18, LCD TFT
1 for data extraction from DCS
2 colour printers
Office furniture (2 workplaces)
Interruption free power supply
All computer inputs/outputs software programs and documentation shall be in English.

Access to the computer system shall be password protected, user rights be definable by a system
administrator.
Automatic data safety backup shall be performed automatically on a second hard disk drive in
regular intervals. System booting routine shall be possible with both hard disk drives.
Data Output by DCS system
For evaluations of the emission monitoring data the software of the DCS shall be designed for the
following tasks:
Automatic data acquisition from connected sub-systems (data acquisition module)
Display of on-line values
Output of emission concentration values alternatively in mg/MJ, mg/m at standard conditions,

or ppmv
Automatic comparison with applicable limits, colour indication and alarm messages in case of
exceeded limits
Calculation of actual pollutant emission rates, based on calculated flue gas volume flow rates
Data output and transmission to the two PC workplaces
Diagnosis module for check of all connected subsystems
Alarm functions on monitor and triggering of external alarm indicators
4.5
PORTABLE NOISE MONITORING EQUIPMENT
The noise impact from plant operation shall be measured at different locations in regular intervals
to ensure compliance with applicable standards.
For this purpose a portable noise monitoring system shall be provided including the following
items:
Sound level meter with standard features in agreement with the regulations
Microphone and all accessories
Page: 11
Frequency analysis module
Interface module for connection to personal computers
Noise level recorder
Printer
Calibration facilities
Maintenance materials
Meteorological instruments for hand use with sensors for wind velocity, ambient temperature,
humidity
Battery based power supply
WORKSHOP AND SITE TESTS
See Part G5.6 Inspection and Testing.
INTERFACES
The interfaces specified as follows are valid only for the system demarcation and do not represent
supply limitations.
Measuring instrument sensors at the boilers and GT bypass stacks
Sensors of effluent monitoring instruments at the discharge pipe of waste water and boiler
blowdown
Connection to public telephone system
See Part G5.5, Corrosion Protection and Painting.
Annex I:
Technical Specification for Insulating Oils
1.5.1.9.0.05 Rev.01
TECHNICAL SPECIFICATION FOR
INSULATING OILS
SCOPE
This specification details the requirements on Insulating Oils for Transformers,
Shunt Reactors and switchgear.
APPLICABLE STANDARDS
Except where modified by this specification, the following standards shall be
applicable to Insulating Oils.
IEC 296
Specification for unused mineral insulating oils for Transformers and

Switchgear.
IEC 422
Supervision and maintenance guide for mineral insulating Oils in

electrical equipment.
DESIGN CRITERIA
Insulating Oil shall be suitable to ensure satisfactory operation under site and
system conditions as per General Design Criteria described in Part G4.
QUALITY ASSURANCE
Supplier shall conform to General Quality Assurance Standard for Electrical
Equipments described in Part G4
Insulating Oil is being considered as Special Equipment. Hence the supplier is
required to be certified on conformity to ISO 9000 by an organization authorized
for certification.
DETAILED SPECIFICATION
1.
The Insulating Oil shall be inhibited type and fulfil the Requirements on
Insulating Oil as per Appendix-1, which meets the specification as per IEC
296, Class 1A, with some additional requirements. Where supply of
uninhibited type oil is specifically asked for, the oil shall meet the requirements
as per specification IEC 296, Table-I, Class I
2.
The supplier shall give a detailed specification of the Insulating Oil to be

delivered.
3.
The Insulating Oils must not contain PCB. If oil samples taken on delivery
contain 2 ppm or more of PCB, DEWA has the right not to accept the delivery.
The supplier is then also liable to pay back payments already received and
expenses incurred by DEWA.
4.
Mutual compatibility with DEWAs Reference Oil as per Appendix-2 is

required for all Insulating Oils to be supplied. Test of mutual compatibility is to
be done in DEWAs presence as per IEC 422. However, this requirement may
be relaxed by DEWA, if the oil being supplied is intended for filling exclusively
in new equipment purchased, prior approval of DEWA shall be obtained.
5.
After treatment, test shall be done in DEWAs presence to prove that the
breakdown voltage shall be at least 70kV.
6.
The supplier shall arrange to carry out all tests on the oil as per IEC 296 in
presence of DEWA engineers at the manufacturers laboratory. In case the
witness test is waived by DEWA, the supplier shall furnish reports on test
carried out as per relevant standards, on the particular batches of oil being
supplied to DEWA, for DEWA verification before acceptance.
7.
Where the insulating oil is supplied as part of a new equipment, the supplier
shall arrange to take oil sample from the equipment before energization and
test it at an independent laboratory approved by DEWA, for the following
characteristics. The results shall satisfy the requirements as per table-I of IEC
422, if not otherwise specified elsewhere in this specification.
Breakdown voltage
Water content
Dissipation Factor at 90 oC
Resistivity at 90 oC
Neutralization value
Interfacial Tension
Oxidation Stability
Flash Point
APPENDIX -1
REQUIREMENTS ON INSULATING OIL
As per IEC 296, Table II

With additional requirements by DEWA (within brackets)
Test method
Permissible limiting
Property
subclause of
values for
Section One of this measured
publication
characteristics
Class 1A
Kinematic Viscosity
16.5
mm/s
7.3
at 40 C -15 C
808
140
Flash Point
7.4
Pour Point
Appearance
7.5
7.1
kg /dm
N/m
mg KOH/g
7.2
7.6
7.7
7.8
mg/kg
mg/kg
mg/kg
Wt %
7.9
7.9
7.10
0.3
7.11.2
>120
kV
kV
7.12
7.12
30
( 70)
7.13
0.005
Density at 20 C
Interfacial tension at 25 C
Corrosive Sulphur
Water Content
Bulk delivery
Drum delivery
After treatment
Antioxidant additives
DBPC
Oxidation stability\
Induction period
Breakdown voltage
As delivered
After treatment
Dissipation factor at 90 C
and 40 Hz to 60 Hz
Additional Requirements:
- PCB content < 2 ppm

- Compatibility with DEWAs Reference Oil (see following table)
-30
Clear, free from
sediment and
suspended matter
0.895
40.10-2
0.03
Non-corrosive
< 30
< 40
table I of IEC 422
DEWAs Reference Oil

(Conforms to IEC 296, Class IA)
PROPERTY
UNIT
TEST
METHOD
GUARANTED DATA
Min
Max
TYPICAL
DATA
IEC 296
ISO 12185
ISO 3104
ISO 3104
ISO 2719
ISO 3016
Clear, free from sediment

0.895
0.8
800
140
-45
0.876
7.60
730
144
-60
.
P1.Physical
Appearance
Density, 20 C
Viscosity, 40 C
Viscosity, -30 C
Flash Point, PM
Pour Point
kg/dm
mm/s
mm/s
C
C
2. Chemical
Corrosive Sulphur
Aromatic content
Antioxidant, phenols
Water content
3. Electrical
Dielectric dissipation
Factor at 90 C
Interface tension
Breakdown Voltage
- Before treatment
- After treatment
mg KOH/g
%
Wt %
mg/kg
IEC 296
ISO 5669
IEC 590
IEC 666
IEC 814
0.03 <0.01
mN/m
IEC 247
ISO 6295
40
kV
kV
IEC 156
IEC 296
30
70
Non-corrosive
7
0.3
30 <20
0.005 < 0.001
45
40-60
> 70
4. Oxidation Stability
At 100C 164 h
Neutralization Value
Sludge
At 120C
Induction period
IEC 1125A
mg KOH/g
Wt %
< 0.01
< 0.005
IEC 1125B
150
> 236
CNE/015/2002
P2.26
WORKING DOCUMENT
Part P2.26 Electrical Equipment Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
1
PAGE
GENERAL ..................................................................................................................................... 1
1.1
VOLTAGE LEVELS.......................................................................................................... 2
1.2
ARRANGEMENT OF ELECT RICAL COMPONENTS .................................................... 3
GAS TURBINE GENERATOR..................................................................................................... 4

2.1
SCOPE OF WORKS......................................................................................................... 4
2.2
GENERAL ......................................................................................................................... 4
2.3
TYPE OF GENERATOR AN D RATING........................................................................... 6

2.3.1
Stator.............................................................................................................. 8
2.3.2
Rotor .............................................................................................................. 8
2.3.3
Bearings ........................................................................................................ 9
2.3.4
Sliprings and commutators......................................................................... 9
2.3.5
Generator cooling equipment................................................................... 10
2.3.6
Generator temperature measurement equipment.................................. 11
2.3.7
Excitation system....................................................................................... 11
2.3.8
Voltage regulation...................................................................................... 13
2.4
GENERATOR MAIN CONNECTION AND CIRCUIT BREAKER ................................. 15

2.4.1
General ........................................................................................................ 15
2.4.2
Phase isolated bus ducts.......................................................................... 15
2.4.3
Generator circuit breaker .......................................................................... 16
2.5
GT AUXILIARY SYSTEMS............................................................................................ 17
2.5.1
Generator protection, synchronising and metering .............................. 17
2.5.2
Current and voltage transformers............................................................ 19
2.5.3
Auxiliary transformers............................................................................... 19
2.5.4
380 V LV unit boards (MCC)...................................................................... 20
2.5.5
DC and UPS systems ................................................................................. 20
2.6
INSTRUMENTATION AND CONTROL ......................................................................... 21
STEAM TURBINE GENERATOR .............................................................................................. 21

3.1
SCOPE OF WORKS....................................................................................................... 21
3.2
GENERAL ....................................................................................................................... 21
POWER TRANSFORMERS ....................................................................................................... 21

4.1
SCOPE OF WORKS....................................................................................................... 21
4.2
TRANSFORMER CAPACITIES..................................................................................... 22
4.2.1
Unit Step up Transformer.......................................................................... 22
4.2.2
Unit Auxiliary Transformer........................................................................ 23
4.2.3
Auxiliary Transformers.............................................................................. 23
4.3
GENERAL DESIGN CONDITIONS AND DATA............................................................ 23
4.4
CONSTRUCTION FEATURES....................................................................................... 24
P2_26electrical_equipment_Working_Doc.doc
Page: ii

4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
4.4.6
4.4.7
4.4.8
4.4.9
4.4.10
4.4.11
4.4.12
4.4.13
4.4.14
4.4.15
4.4.16
4.4.17
Windings ......................................................................................................24
Bushings......................................................................................................25
Magnetic Core .............................................................................................26
Transformer Tank .......................................................................................26
Cooling.........................................................................................................27
Voltage Adjustment ....................................................................................27
Oil..................................................................................................................28
Filter and drain valves, sampling devices and air release plugs..........28
Piping and Valves.......................................................................................29
Joints and gaskets......................................................................................29
Oil Conservator...........................................................................................29
Dehydrating breathers ...............................................................................30
Pressure relief device.................................................................................30
Transformer Terminals...............................................................................31
Earthing Terminals .....................................................................................32
Painting ........................................................................................................32
Rating, diagram and property plates........................................................33
4.5
INSTRUMENTATION AND CONTROL..........................................................................34

4.5.1
Electrical Controls ......................................................................................34
4.5.2
Measuring and Monitoring.........................................................................35
4.5.3
Marshalling Kiosk, Wiring and Conduits .................................................36
4.6
NEUTRAL EARTHING OF TRANSFORMERS..............................................................37
4.7
SPECIAL REQUIREMENTS FOR DRY TYPE TRANSFORMERS...............................37
4.8
TESTS..............................................................................................................................37
4.8.1
Workshop Tests..........................................................................................37
4.8.2
Tests on Site ................................................................................................37
MEDIUM VOLTAGE SWITCHGEAR..........................................................................................38

5.1
SCOPE OF WORKS .......................................................................................................38

5.1.1
11 kV Plant Switchgear ..............................................................................42
5.1.2
Busbar Interconnector and spare Feeders..............................................42
5.2
GENERAL DESIGN CONDITIONS AND DATA............................................................42

5.2.1
General.........................................................................................................42
5.2.2
MV Switchboards ........................................................................................43
5.2.3
Circuit Breakers..........................................................................................44
5.2.4
High Speed Transfer Equipment...............................................................44
5.2.5
Instrument Transformer.............................................................................45
5.2.6
MV Metal Oxide Surge -Arresters...............................................................46
5.2.7
Interlocks .....................................................................................................46
5.2.8
Feeder and Busbar Protection..................................................................46
5.2.9
Earthing Switches or Devices...................................................................47
5.3
LIST OF SWITCHBOARD COMPONENTS...................................................................47

5.3.1
Incoming Feeders.......................................................................................47
5.3.2
Bus Bar Sectionalisers and Coupling Feeders.......................................47

5.3.3
5.3.4
5.3.5
5.3.6
5.3.7
5.4
Page: iii
Outgoing Cable and Transformer Feeders.............................................. 47

Motor Feeders............................................................................................. 48
Measuring Cubicle...................................................................................... 48
Control Voltage supply, remote control and Bus bar undervoltage
monitoring ................................................................................................... 48
Remote indications .................................................................................... 49
TESTS............................................................................................................................. 49
5.4.1
Workshop Tests.......................................................................................... 49
5.4.2
Tests at site................................................................................................. 50
LV POWER DISTRIBUTION SYSTEM ...................................................................................... 50

6.1
SCOPE OF WORKS....................................................................................................... 50
6.1.1
380 V AC System........................................................................................ 50
6.1.2
Direct Current (DC) and Uninterruptible Power Supply (UPS).............. 51
6.2
GENERAL DESIGN CONDITIONS AND DATA............................................................ 52

6.2.1
General ........................................................................................................ 52
6.2.2
Switchgear Assembly................................................................................ 52
6.2.3
Instrument Transformers........................................................................... 53
6.2.4
Remote Indication and Control................................................................. 53
6.2.5
Voltage Monitoring..................................................................................... 53
6.2.6
Space Compartments ................................................................................ 53
6.2.7
Spare Feeders............................................................................................. 53
6.2.8
Terminal Boxes and Subsidiary Distributions........................................ 53
6.2.9
Interlocks..................................................................................................... 54
6.3
LIST OF SWITCHBOARD COMPONENTS................................................................... 54

6.3.1
AC Incoming Feeder, Bus Sectionaliser and Bus-coupling Feeder..... 54
6.3.2
AC Outgoing Feeder to Individual Auxiliaries ........................................ 55
6.3.3
AC Outgoing Feeder to Boards/Sub-distribution Boards ..................... 55
6.3.4
AC Motor Feeders....................................................................................... 55
6.3.5
AC Valve Feeder......................................................................................... 55
6.3.6
AC Measuring Section............................................................................... 56
6.3.7
DC Incoming/Coupling Feeder.................................................................. 56
6.3.8
DC Motor Feeder......................................................................................... 56
6.3.9
DC Outgoing Feeder to Boards ................................................................ 56
6.3.10
DC Outgoing Feeder to Individual Auxiliaries ........................................ 57
6.3.11
Safe AC Outgoing Feeder.......................................................................... 57
6.3.12
DC Measuring Section............................................................................... 57
6.3.13
Selective Earth Fault Detection System.................................................. 57
6.4
TESTS............................................................................................................................. 57
6.4.1
Workshop Test............................................................................................ 57
6.4.2
Tests at Site................................................................................................. 57
CHARGERS, BATTERIES AND INVERTERS.......................................................................... 58

7.1
SCOPE OF WORKS....................................................................................................... 58
Page: iv
7.2
GENERAL DESIGN CONDITIONS AND DATA............................................................59

7.2.1
Chargers.......................................................................................................60
7.2.2
Batteries.......................................................................................................62
7.2.3
Battery Fuse Box ........................................................................................62
7.2.4
Inverters with electronic change -over equipment..................................63
7.3
TESTS..............................................................................................................................64
7.3.1
Chargers.......................................................................................................64
7.3.2
Batteries.......................................................................................................64
7.3.3
Fuse Box......................................................................................................65
7.3.4
Inverters.......................................................................................................65
LIGHTING AND SMALL POWER ..............................................................................................65

8.1
GENERAL .......................................................................................................................65
8.1.1
Main technical data.....................................................................................66
8.2
LAYOUT ..........................................................................................................................67
8.3
SCOPE OF WORKS AND SERVICES...........................................................................67
8.4
EQUIPMENT REQUIREMENTS.....................................................................................68
8.4.1
General.........................................................................................................68
8.4.2
Distribution boards.....................................................................................68
8.4.3
Cables...........................................................................................................71
8.4.4
Conduit.........................................................................................................72
8.4.5
General.........................................................................................................72
8.4.6
Cable trunking.............................................................................................74
8.4.7
Socket outlets and plugs ...........................................................................76
8.4.8
Lighting ........................................................................................................77
8.4.9
Earthing and bonding.................................................................................83
8.4.10
Table 1 service illumination levels, glare index...................................83
8.4.11
Table 2 Schedule of Luminaries.............................................................84
8.5
SPECIAL EQUIPMENT AN D TOOLS ............................................................................85
8.6
SPARE PARTS...............................................................................................................85
8.7
INSPECTION AND TESTS.............................................................................................85

8.7.1
Insulation tests............................................................................................85
8.7.2
Continuity tests...........................................................................................85
8.7.3
Earth loop impedance tests.......................................................................85
8.7.4
Earth electrode tests ..................................................................................85
8.7.5
Phase rotation tests....................................................................................86
CABLE SYSTEM.........................................................................................................................86
9.1
SCOPE OF WORKS .......................................................................................................86

9.1.1
Power Cables...............................................................................................87
9.1.2
Control Cables.............................................................................................87
9.2
DESIGN REQUIREMENTS AND DATA.........................................................................87

9.2.1
General.........................................................................................................87
9.2.2
Main Data .....................................................................................................87

9.2.3
Page: v
Cable Sealing and Drums .......................................................................... 88
9.3
CABLE CONSTRUCTION.............................................................................................. 89
9.3.1
MV Power Cables........................................................................................ 89
9.3.2
LV Power Cables........................................................................................ 90
9.3.3
Control Cables............................................................................................ 90
9.3.4
Pilot Wire/Telephone Cables..................................................................... 90
9.4
CABLE TERMINATIONS AND ACCESSORIES........................................................... 92

9.4.1
General Requirements............................................................................... 92
9.4.2
MV Cable Terminations and Joints .......................................................... 92
9.4.3
Grounding of Cable Screens..................................................................... 94
9.5
TESTS............................................................................................................................. 94
9.5.1
HV and Pilot Cables ................................................................................... 94
9.5.2
MV Cables.................................................................................................... 94
9.5.3
LV/ Control Cables..................................................................................... 95
10 EARTHING SYSTEM AND LIGHTNING PROTECTION .......................................................... 95

10.1
SCOPE OF WORKS....................................................................................................... 95
10.2
TECHNICAL REQUIREMENT........................................................................................ 95
10.2.1
General ........................................................................................................ 95
10.2.2
Potential Gradient Control (PGC)............................................................. 96
10.2.3
Earthing ....................................................................................................... 96
10.2.4
Lightning Protection .................................................................................. 97
10.3
TESTS............................................................................................................................. 98
11 ELECTRICAL CONTROL SYSTEM .......................................................................................... 98

11.1
GENERAL ....................................................................................................................... 98
11.2
SCOPE OF WORKS....................................................................................................... 98
11.3
LAYOUT .......................................................................................................................... 99
11.4
DESIGN AND CONSTRUCT ION REQUIREMENTS..................................................... 99

11.4.1
Remote Control and Supervision............................................................. 99
11.4.2
Alarm Indication ....................................................................................... 100
11.4.3
Data Logging/Event Recording............................................................... 100
11.4.4
MV Quick Transfer Device ....................................................................... 101
11.4.5
LV Transfer/Change -over ........................................................................ 101
11.4.6
Transformer Supervision and Control................................................... 102
11.4.7
Synchronisation Systems ....................................................................... 102
12 ELECTRICAL PROTECTION SYSTEM .................................................................................. 103

12.1
GENERAL ..................................................................................................................... 103
12.2
SCOPE OF WORKS..................................................................................................... 103
12.3
LAYOUT ........................................................................................................................ 104
12.4
DESIGN/CONSTRUCTION REQUIREMENTS............................................................ 104
Page: vi

12.4.1
12.4.2
12.4.3
12.4.4
12.4.5
12.5
Additional Requirements for Numerical or Mixed (Numerical,

Electronic and Mechanical) Protection Equipment..............................108
Requirements for Generator Protection Relays ....................................110
Requirements for Step-up Unit Main Transformer Protection ............114
Requirements for Unit / Main - Auxiliary Transformer Protection......117
MV Switchgear Protection .......................................................................118
TESTS............................................................................................................................120
12.5.1
General.......................................................................................................120
12.5.2
Workshop Tests........................................................................................120
12.5.3
Site Testing Procedures and Commissioning.......................................121
13 CATHODIC CORROSION PROTECTION ...............................................................................122

13.1
SCOPE OF WORKS .....................................................................................................122
13.2
DESIGN REQUIREMENTS AND DATA.......................................................................122

13.2.1
General.......................................................................................................122
13.2.2
Sacrificial Cathodic Protection ...............................................................123
13.2.3
Impressed Current Cathodic Protection................................................123
13.2.4
Design Particulars....................................................................................123
13.3
TESTS............................................................................................................................124
Page: 1
GENERAL
This section covers the design, supply, erection, commissioning and handing over of the electrical
plant and equipment for the Jebel Ali L Station Phase I and co-ordination of the interfaces with
package D - Desalination and package S - 400 kV Substation.
It should be read in conjunction with Part G4 General Project Requirements, Part G5 General
Technical Requirements, Part P4 Technical Schedules and Data Sheets and Part G6
Attachments and other Parts of this specification as relevant.
The general structure of the L station electrical system is shown in the attached overall single line
diagram (see Drawing-No.: CNE/015/2002-S-00-E-S-00001).
However, the n
i dicated number of auxiliary transformers and related LV boards are only for
information.
The Contractor shall provide all required auxiliary transformers and LV boards to cover the loads
and 20% spare capacity.
Each GT Unit shall be provided with a 11 kV Unit Board each divided in two sections. High-speed
changeover systems shall be provided between the infeeds and the section coupling breakers.
Two 11 kV Station Service Switchboards (0BBA and 0BBB) shall be provided. Each Switchboard
shall have two incoming feeders connected to the 11 kV Unit Auxiliary Switchboards. High speed
changeover systems shall be provided between the infeeds and related bus-coupler.
The principle connection diagrams and the single line diagram have been worked out for five (5)
desalination units in Phase I.
If less or more desalination units will be provided, the Contractor shall adapt his scope of Works
and the single line diagram during the tender period.
Two infeeds from the GT unit boards will supply the 11 kV switchgear of each desalination unit.
Independent from the 11 kV boards of the desalination units the seawater pump house and the
potable water pump station will be provided with 11 kV switchgears supplied by the 11 kV Unit
boards of the power plant.
The modified single line diagram shall be included in the Tender Documents.
The L Phase I essential consumers of the power plant shall be supplied from the 380 V
Emergency Boards provided under this scope of Works.
The capacity of the transformers, the estimated loads and the designations indicated are to be
considered as preliminary information and shall be verified by the Contractor.
The entire electrical system will be remote controlled and monitored by the DCS system described
in Part P2.27.
Fire fighting / fire detection systems will be provided for all electrical rooms and equipment in
accordance with part P 2.23 Station fire fighting and fire protection system of this specification.
As mentioned elsewhere in this specification, all major electrical equipment provided under this
Contract shall be type tested. Type test report shall be provided by the respective manufacturer.
Field test equipment (for the tests recommended by the respective equipment manufacturer) are
also to be provided. However, generators and motors of each type shall be tested in presence of
the Engineer / Employer,
The Contractor shall perform the following electrical system studies to prove the viability of the
electrical design under both steady state and transient conditions.
Page: 2
The study shall take the existing and new facilities into consideration
The study shall include, but not be limited to:
Load flow studies
Short circuit calculations
Transient stability studies including simulation of operation under-voltage protection and

automatic change-over
Motor start studies
Relay protection setting studies
The Contractor shall submit a detailed list of all studies to be carried out together with the computer
program description which will be used for each study for approval by the Engineer.
All parts and components shall be complete in every respect and suitable for safe, reliable and
continuous operation at Jebel Ali power station.
The gas and steam turbine generators shall be connected via the Unit Main Transformers (BAT) to
the new 400 kV GIS switchgear units.
All gas turbines shall be equipped with a generator circuit breaker and Unit Auxiliary Transformers
(BBT).
The steam turbines shall not be provided with Unit Auxiliary Transformers and generator circuit
breakers, because of no operation requirements.
Each GT shall have its dedicated 11 kV Unit Board normally supplied from the GT-Unit Auxiliary
Transformer, the 0.4 kV LV unit board and DC and UPS systems.
Feeding from the 11 kV common board shall also be possible for black-start purposes.
For emergency run down of the GTs, HRSG, Steam Turbines and other equipment there shall be
infeeds to the related 0,4 kV boards from the 0,4 kV Emergency Board. Two emergency diesel
generator units shall be provided.
In case of one Unit Auxiliary Transformer (BBT) outage, the other Unit Auxiliary Transformers shall
have the capacity to cover the loads of all connected consumers effected by the system loss.
All equipment in the Power Station shall be numbered by the KKS system. Generally the gas
turbines will be designated as e.g. GT 11, GT 12, GT 13, etc. and the steam turbines will be
designated as ST 14, ST 15, etc.
11kV switchboards shall be designated as 10BBA, 10BBB for common services and 11BBA,
11BBB for GT11 unit boards, etc.
1.1
VOLTAGE LEVELS
The electrical system design philosophy shall be in line with the existing systems to minimise the
spares inventory and to achieve a high contingency of the new installations.
15 kV and above - rated generator voltage (depending on generator design)
11 kV - distribution voltage to the main loads (MV motors and auxiliary transformers)
380/220 V LV supply for consumers at the boilers, turbines desalination units and general
consumers like air conditioning lighting, building services, etc.
220 V DC safe DC voltage for essential drives and supply of inverters
110 V DC DC control voltage for the switchgear
24 V DC DC voltage for control and instrumentation
220 V AC safe AC voltage level for control, instrumentation and emergency lighting.
1.2
Page: 3
ARRANGEMENT OF ELECTRICAL COMPONENTS
The new installations shall be installed at the following locations:
Control and Switchgear Building (multi-storey building) MV and LV switchgear installations for
the plant common services, etc., for DC and UPS systems, for the BPST, for auxiliary boilers
and control and monitoring installations.
Standardised container housing including the GTs / HRSGs LV unit boards, DC and UPS
systems, excitation, voltage control equipment, SFC and others. HVAC system design and
installation should ensure, there will be no surface condensation and water dripping inside the
container under any weather condition and under HVAC malfunctioning.
It shall be possible to remove the generator rotor without major dismantling of the generator.
Provision shall be made to remove the rotor with special tool and low bed trailer. Clear access
shall be available in the generator building. The Contractor shall demonstrate the rotor
removal exercise to the satisfaction of the Employer / Engineer. All tools and equipment shall
be included in the scope of works.
Emergency diesel generator and black start diesel generator building diesel generators, day
tanks, coolers, starting facilities, control and monitoring equipment
GTs, HRSG area Unit Main (BAT) and Unit Auxiliary Transformers (BBT), generator circuit
breaker
ST area Unit Main Transformer (BAT)
Switchgear building for each desalination unit 11 kV Boards (MV and LV), DC and UPS
systems (No part of Package P)
Switchgear buildings seawater pump house MV and LV switch boards, aux. transformers,
DC and UPS systems (No part of Package P)
Seawater screening and pumping station MV switchboard, LV switch boards, aux.

Transformers, DC and UPS systems (No part of Package P)
All oil filled transformers shall be located outside and shall be provided with the necessary oil pits
with oil water separators and fire protection walls. All oil filled transformers shall be provided with
fire protection system (sprinkler systems). Suitable fire detection/protection and alarm system to be
made available for dry type transformers and cables. Alternatively generator transformer and unit
transformer KEMA "Coolcloud" type fire fighting system may be proposed.
The 11 kV switchgear, AC and DC distribution boards, rectifiers, inverters and control cubicles
shall be installed in closed and air-conditioned rooms.
Page: 4
2
2.1
GAS TURBINE GENERATOR

SCOPE OF WORKS
The Gas Turbine generator forms an integral part of the works with the GT Units described in Part
P2.1. The specific scope for this Part is as follows as well as specially requested supplies and
services but without excluding other necessary components and services mentioned:
Synchronous AC generator with complete closed cooling system
Air or hydrogen / water coolers having at least 10% spare capacity
Static excitation system
Static frequency converter
Generator control panel
Generator star point and terminal cubicles and bus duct system up to the unit auxiliary
transformer and the unit main transformer, including generator circuit breaker
11/0.4 kV auxiliary transformers
MCC for GTG auxiliaries including essential board sections
DC system (220 V, 110 V and 24 V complete with battery charger Battery, distribution panel,
etc.) for GT package Works
UPS system complete with battery charger, battery, inverter, distribution Panel etc., for GT
package Works
Lighting and emergency lighting system for package
Power and control cabling etc. Complete within GT-package Works
Connection/terminal boxes for interfacing between GT-package and the outside
Separate protection panel for generator, unit main transformer and unit
Auxiliary transformer
Synchronising equipment
Enclosure with internal walkways for the gas turbine/generator unit in Order to obtain reduced
sound power level and environmental protection
Including ventilation, lighting etc.
Housing for the electrical and control and instrumentation equipment
2.2
GENERAL
At rated speed the gas turbine generator shall have sufficient capacity such that it does not limit
the capability of the gas turbine over the range of ambient conditions specified in Part G4. The
rated terminal conditions shall be 3 phase, 50 Hz, 0.8 power factor lagging (over excited) to 0.9
power factor leading (under excited). The voltage level shall be in accordance to supplier
standard.
The sum of generator and main generator step-up transformer impedance shall be limited to a
minimum 28 % (without negative tolerance) to limit the short circuit contribution to the 400 kV
system.
Page: 5
The generator shall comply with IEC 60034, as amended and supplemented by this specification.
The generators shall be capable of supplying their rated output at rated power factor and during
continuous operating over a frequency range of 5% of nominal frequency (50 Hz) with a voltage
variation of 5% accruing concurrently from the rated generator voltage.
The limits of temperature rise shall be according to Clause 16.3.3/16.3.4 figure 12 of IEC 60034-1.
The generator shall have a guaranteed capability to operate at 0.9 lead power factor at full load.
This capability refers specifically to the condition where the automatic AVR channel is not in
operation and the machine is under manual control.
The generator shall operate satisfactorily as a single unit and in parallel with all or any of the other
units and the grid system under all normal working conditions.
The Contractor shall quote the gross generator output as measured at the generator terminals and
also the gross power absorbed by all the normally running electric power auxiliaries including a
terminal-fed excitation system, if applicable.
Synchronous reactance where specified in the schedules shall be based on the short circuit
excitation at rated generator current and the no-load excitation at the rated generator voltage.
The Contractor shall provide all necessary parameters and time constants for the gas turbine,
governing system, generator and excitation systems and carrying out the transient stability and
dynamic response studies (included in scope of Works) by using appropriate models/ computer
programs. The results shall be demonstrated during commissioning.
The generator shall be connected though a generator circuit breaker to a star/delta connected
step-up unit main transformer via a phase isolated bus ducting system. The step-down gas turbine
Unit Auxiliary Transformer shall be fed from the generator via a tee-off from the phase isolated bus
ducting system and bolted disconnecting links. Short circuit facility in the phase isolated bus ducts
shall be provided for test purposes.
For start up of the GT a SFC shall be used. To get operational flexibility all provisions shall be
provided to start any GT from any SFC. Each SFC shall be housed separately. Isolator boards
including all interlocks and cable connections between the GT related boards shall be arranged
separated in such a way, that in case of fire in one board, others are in operation condition.
(Reference is made to Part P 2.1 of this specification)
For supply of the unit and related HRSG consumers, station service consumers, two desalination
units and - if necessary other 11 kV sub-distribution boards as the sea water pumping station
each GT generator unit shall be provided with an 11 kV and an 0.4 kV unit board as indicated in
the Single Line Diagram drawing No. CNE/015/2002-S-00-E-S-00001.
The 11 kV unit board shall be normally fed from its own MV (Generator voltage) /11 kV Unit
Auxiliary Transformer. However feeding from the 11 kV unit boards of the both other GTs 11 kV
unit boards shall be also possible.
Feeding from the 11 kV common board shall also be possible for black-start purposes.
In case of one auxiliary transformer outage, the other unit auxiliary transformers shall have the
capacity to cover the loads of all connected consumers effected by the system loss.
The interconnection between the unit and the common board shall be sized and designed
accordingly.
The 0.4 kV unit board will be fed from the 11 kV unit auxiliary board via 2 x 100%, 11 /0.4 kV unit
auxiliary transformers. The essential section shall have an additional supply from the 0.4 kV
emergency distribution board.
Page: 6
The unit main transformers and the unit auxiliary transformers as well as the 11 kV unit auxiliary
boards are specified in Part P2.26, Clause 3 and 4
The Generator and the auxiliary equipment shall be remotely controlled through the DCS system
specified in Part P2.27.
2.3
TYPE OF GENERATOR AND RATING
The Generator shall be of the 2 pole cylindrical rotor type and shall comply to the relevant IEC
standards and other standards as mentioned below.
The Generator shall use a closed circuit air or a hydrogen cooling system. Heat shall be
transferred by suitable heat exchangers from the air or hydrogen system to the closed cooling
water system.
In case a hydrogen cooling system is provided it shall be complete in every respect including all
auxiliary systems including sealing oil system with all ancillaries, sealing oil cooling using closed
cooling water, hydrogen leakage detectors, hydrogen purity measurement equipment, hydrogen
filling system with hydrogen cylinder racks having a minimum capacity of three generator fillings,
CO2 purging system with CO2 cylinder racks having a minimum capacity of three generator
purgings, air supply system (to purge CO2), etc.
The Bidders offering hydrogen cooling of the generators shall also investigate whether the required
amount of hydrogen is available on the local market and shall submit evidences of their
investigation together with price quotations.
In case the required amount of hydrogen is not available on the market the Contractor shall include
in the offer a hydrogen generation plant. In this case the Bidder can offer to regain the Hydrogen
generated by the Seawater Chlorination Plant.
H2/CO2 Gas Supply System
As part of the hydrogen cooling system of each generator, the gas supply system shall comprise all
components for gas filling, scavenging and total emptying, as listed below, not being limited to:
Hydrogen gas filling station consisting of 2 sets of H2 gas cylinder racks per generator i.e. one in
service the other one in stand by. The filling station shall include all accessories, such as
pressure reducing valves for large and small flow rates, pressure gauges and flow meters, all
kinds of check, relief, purge and distribution valves, etc.
Carbon dioxide gas station for purging the hydrogen out of the generators consisting of one set
of CO2 gas cylinder racks or buffer tanks per generator with all accessories, such as
evaporators, pressure gauges and flow meters, all kinds of check, throttle, relief, vent and
distribution valves, etc.
Complete measuring and monitoring system for local and remote supervision of gas
temperatures, pressures, flows, purity and leakage.
All interconnecting pipework for gas filling, purging and blow-out with instrument air.
Seal Oil System
A seal oil system to safely seal-off the generator against hydrogen leakage during all normal
operation, start up, shutting down and stand-still conditions shall be provided.
The processing and distribution of the oil shall be redundant for all required ancillary equipment to
prevent the formation of explosive hydrogen gas/air mixtures at any part of the system, and to keep
down the hydrogen gas leakage or the penetration of oil dissolved oxygen into the hydrogen gas
atmosphere.
Page: 7
The system shall basically comprise the following components but it shall not being limited to:
All intermediate storage and oil degasifying tanks with level switches, full range sight glasses
and pipe connections.
Two (2) water/oil heat exchangers for 100% capacity each with shut-off valves for both cooling
circuits. The heat exchangers shall have a spare capacity of min. 10%.
Three (3) motor-driven auxiliary seal oil pumps for 100% capacity each, two (2) for AC as main
units and one (1) for DC as emergency stand-by unit with all necessary check and shut-off
valves.
Two (2) 100% AC motor-driven vacuum pump(s), working in conjunction with the oil degasifying
process.
All necessary piping, strainers, oil traps, check valves, control valves, pressure reducing valves,
relief valves and shut-off valves.
All required measuring and monitoring equipment, such as thermometers, pressure gauges,
flow meters and switches, level switches, sight and inspection glasses, etc.
The seal oil shall be circulated by the AC seal oil pump as specified above. Upon failure of the
pump or of the AC network, the DC oil pump shall automatically start. Stopping of the DC pump
shall be effected automatically upon recovery of the AC mains and starting of the AC pump. The
seal oil system is to be pressure regulated so as to achieve and maintain automatically a slight
over-pressure as referred to the hydrogen gas pressure. Penetration of hydrogen through the seal
oil system into the surrounding atmosphere shall be avoided by all means.
The Contractor shall guarantee the max. hydrogen leakage rate per day and shall indicate the
amount of hydrogen needed for filling under the assumption that the generation unit is in turning
gear operation. Furthermore the quantity of CO2 needed for purging the hydrogen and the air shall
also be provided.
The Generator shall be suitable in every respect for continuous operation.
The generators, in conjunction with their excitation systems, shall operate stable at all loads up to
the peak reserved capability when connected to the high voltage transmission system.
Class "F" insulation materials complying with the requirements of IEC 60034 and IEC 60085 to be
used throughout the whole generators and exciters.
The continuous maximum rating shall be achieved at the maximum ambient air and cooling water
temperatures stated in the schedules and the maximum rating shall not be less than that available
from the associated gas turbines at all temperatures. Under these conditions the maximum
temperature rise according to insulation class "B" is to be maintained.
At peak load conditions of the gas turbine, the generator temperature rise may increase maximum
15 K over class "B" limits. This is to be understood within the whole range of ambient conditions.
Consideration shall be given to frequent starting and stopping of the sets and variable load
operation.
The Contractor shall quote the percentage harmonic content at rated voltage at no load.
Capability curves, V%, f% curves, capability diagram and also permissible single phase and
unbalanced 3-phase loading plotted against time shall be submitted with the Tender Documents.
The capability curves shall be marked with various limit lines. (Such as minimum generation limit,
rotor winding heating (field current) limit, auxiliary bus high voltage limit, voltage regular maximum
Page: 8
output & volts / Hz limit, turbine limit, voltage regulator at minimum output limit, minimum excitation
limit, etc.
2.3.1 Stator
The casing of the stator shall be of fabricated steel construction.
The casing, including end shields, all joints, seals and pipe connections shall, as far as possible,
be air/gas tight under normal operating conditions.
The stator core shall be made up of high permeability low loss stampings, tightly clamped together
to reduce noise and vibration to a minimum. Attention shall be given to prevent excessive vibration
at twice rated frequency being transmitted to the generator foundations, pipes or associated
equipment.
The stator winding shall be star connected, all six (6) winding ends shall be brought out on top to
terminals and shall be designed such that the replacement of a damaged portion is a relatively
simple matter. The winding insulation materials shall withstand voltage rises and mechanical stress
which may occur during both normal operating and fault conditions.
The winding shall be effectively braced and blocked to withstand without being permanently
disturbed, the forces set up by single phase or three-phase short circuits at the terminals. The
general construction of the stator and the bracing of the winding overhang shall be, such as to
provide adequate cooling surfaces and the avoidance of hot spots.
The insulation of the windings shall be adequately proportioned to withstand system voltage
transients.
The insulation shall be class "F" standard.
The generator star point shall be earthed through the primary winding of a distribution type
transformer with an unbreakable grid type resistor connected across the secondary winding.
Means of disconnecting and isolating the generator star point shall be provided.
Suitable anti-condensation heaters shall be provided which shall be energised automatically when
the generator is shut-down.
2.3.2 Rotor
The cylindrical rotor body shall be of forged steel, comprising one solid forging. After rough
machining the forging shall be subjected to 100% ultrasonic examination to BS 4124. Damper
windings or damper wedges shall be fitted as necessary to prevent cyclic irregularities and as a
precaution against local overheating of the rotor surface.
Rotor retaining ring material shall not be prone to stress corrosion under site conditions. With the
proposed material, failure of retaining ring (due to stress corrosion induced cracks), if any
reported, the report shall be made available.
The rotor winding shall be of suitable silver bearing copper. All joints shall be silver soldered as a
minimum standard.
All components of rotor insulation shall be class "'F" standard or better.
Deformation of the rotor winding due to "copper-shortening" or phase or earth faults developed
either in the machine or on the connected system shall be avoided by suitable choice of material
and rotor design. The rotor cooling system shall be provided with radial passages where necessary
to ensure that no hot spots develop. The packing blocks used in the rotor winding shall be of
approved materials and suitable for the high temperatures and mechanical forces which exist in the
rotor.
Page: 9
Particular attention shall be given to the insulating and securing of the rotor winding and its
connections to avoid vibration and the possible failure of either conductors or its insulation. Rotor
retaining rings should be thoroughly tested before application to the generator rotor. Selected
forging should be cyclically loaded to stress levels greater than expected in service to confirm that
the retaining ring is uniformly stressed and ultrasonic and dye penetrant inspection shall be carried
out to verify that the retaining ring is free from defects.
The maximum negative sequence current (I2) for continuous operation and maximum value of
negative sequence thermal capacity (I2 2x t) for transient operation of which the generator shall be
capable, shall not be less than the figures stipulated in IEC 60034-1.
An earthing brush shall be fitted at a suitable position on the shaft, which is free from
contamination by oil, etc.
Rotor earth fault protection shall be provided as stipulated in the protection schedule.
2.3.3 Bearings
Wherever possible, the type of bearing fitted to generators should be standardised throughout,
and, if practicable, of the same design as for the prime mover.
The bearings shall be of the metal sleeve and self-alignment type and designed so as to be readily
accessible and replaceable without the removal of the rotor.
All bearing oil wells shall be provided with visual oil level indicators and ready means of checking
oil flow, filling and draining.
Approved means shall be provided to prevent the possibility of damage due to vibration from
adjacent machinery, whilst the machine is stationary for long periods.
All pedestal bearings shall be fully insulated from earth to avoid circulating currents and one of the
bearings shall be earthed by means of a strap which shall be easily removable for the purpose of
insulation checks. Where the bearing insulation is not easily accessible, test terminals shall be
brought out to a convenient point outside the bearing.
Separate resistance temperature detectors for remote monitoring and control shall be fitted in the
bearing metal at the hottest running position.
Thermometer pockets shall be provided on each sleeve bearing with a dial type Thermometer with
adjustable alarm contacts to provide warning of excessive oil temperature. However remote
monitoring is preferred.
All bearings shall be fitted with suitable vibration monitoring probes compatible with those used on
the turbine bearings.
Lubrication
Bearings dependent on lubricating oil shall be provided with a complete and approved lubricating
oil system capable of maintaining the continuous operation of all parts of the machine, without
undue heating, at all loads, together with the necessary equipment to provide suitable lubrication
during normal start-up and shut-down, emergency shut-down, barring and all other conditions. The
system for the generator shall be part of that for the prime mover and automatically maintained.
2.3.4 Sliprings and commutators

Sliprings, commutators, and associated brushgear shall be designed to operate without injurious
sparking or excessive wear and it shall be possible to run for at least six months without
replacements of the brushes.
Page: 10
Arc light monitoring system shall be provided to detect sparking in a early stage. Necessary
auxiliaries to avoid false alarm, e.g. effected by light, shall be provided. Detailed technical
description of such a monitoring system shall be included in the offer.
The brushgear housing shall be designed to provide maximum visibility via inspection windows.
Maximum ease of adjustment and replacement of individual brushes shall be guaranteed with the
generator on load. Guards of insulating material shall be mounted between the sliprings and
between brushholders of opposite polarity to prevent an accidental short circuit when maintaining
the brushes.
Approved arrangements shall be made for locating and operating a grinder for grinding surfaces.
The grinder shall be supplied under this contract.
Sliprings and commutators shall be in a cooling medium circuit so that the dust from the brushgear
shall not enter into the main generator windings The generator cooling system shall include all
necessary coolers, fans and control apparatus as appropriate and shall comply with the
requirements of IEC 60034-3. The cooling classification shall be IC7 A1W7 to IFC 60034-6.
The system shall be complete with all necessary equipment for safe and efficient operation of the
plant. The Contractor shall give full details of the capacity and method and operation of the system.
2.3.5 Generator cooling equipment

General
The generator cooling system shall include all necessary coolers, fans and control apparatus as
appropriate and shall comply with the requirements of IEC 60034-3. The cooling classification shall
be IC7 A1W7 to IEC 60034-6.
The gas turbine generator shall have the IC8H1W7 generator cooling classification. The gas
turbine Generator shall be provided in accordance with IEC 341, IEC 342, IEC 343 and IEC 344
standards.
The closed cooling water system is specified in Part P2.9.
The system shall be complete with all necessary equipment for safe and efficient operation of the
plant. The Contractor shall give full details of the capacity and method of the system.
Closed Cooling system
The cooling medium shall be circulated by fans mounted on the generator shaft in a closed circuit
system incorporating cooling medium to water coolers.
The coolers shall be located at the side of each generator.
The generator coolers etc. shall be sized, that maximum rated generator output according to above
mentioned definitions of Clause 2.3 "Type of Generator and rating" can be maintained with one
section of the coolers out of service for cleaning and with 15% of the tubes blocked. The cooler
and isolating valves shall be arranged to permit isolation and cleaning of individual sections whilst
the generator is on load. The cooling air make-up system shall include an approved type air filter.
Provision shall be made for visual inspection of the individual cooler sections from outside whilst
the machine is operating and a drain to discharge water shall be piped to an open funnel
connected wit the plants drain system.
The cooler tubes shall be mounted and supported to allow for the effects of expansion and
vibration. Any necessary apparatus required to withdraw the coolers or permit on load repair shall
be provided.
Page: 11
All necessary ductwork between the generator and the coolers shall be provided.
Water leak detectors shall be provided in each section of the cooler, which shall initiate an alarm in
the event of a leak occurring.
To avoid moisture formation on internal parts of the generator during plant shutdowns, facilities
shall be included in the ductwork for the connection of portable warm air blowers. Warm air
blowers for each generator shall be provided of suitable size.
Provision shall be incorporated for visual inspection of the air chamber floor from outside while the
generator is operating.
Secondary cooling water system
The heat of the Generator coolers shall be dissipated from the plant closed circuit cooling water
system.
2.3.6 Generator temperature measurement equipment

Pt 100 temperature detectors (four wire type) or thermocouples, as appropriate, shall be provided
for monitoring the internal temperature of the generator and the cooling medium temperatures. The
positions shall be subject to agreement and provision should be made for the following
requirements:
stator windings, between coils in slot
9 positions
stator core
3 positions
cooled air from coolers (per cooler section)
1 position
hot air from generator (per cooler section)
1 position
exciter cooling air inlet
1 position
exciter cooling air outlet
1 position
bearings
in accordance with Clause 7.3 of P2.1 and

Clause 4.5 of P2.6
spare on terminal board (for test purposes)
2 positions
Each indicator shall have adjustable settings for initiating a high temperature alarm which shall be
independent of the temperature indication selected.
The leads from the temperature detectors shall be brought out to a terminal box on the generator in
a position which is accessible during normal operation of the set. All temperature detectors shall
have the same characteristics. Adjustable settings for initiating high temperature alarms shall be
provided. All temperatures shall be indicated locally and remotely in the Central Control Room.
Each of the above positions for each measurement shall have duplex RTDs/Thermocouples, one
in use and one as spare which shall be connected up to the final cubicle termination.
Temperature measurement signals to be used for protection shall be provided as triplex sensors at
each measurement location with 2v3 voting logic.
2.3.7 Excitation system

2.3.7.1 General
The generator excitation shall comply with the requirements of IEC 60034-3 unless otherwise
specified.
Page: 12
Provision shall be made for testing the excitation equipment without

generator.
operation of the main
Static excitation system shall be supplied. The Contractor shall prove that this is his standard
system and that there is extensive experience or installations in similar site conditions. The
excitation system shall comply with the voltage regulation grades as defined in BS 4999 and shall
be not less than VR3 for steady state regulation and VR2.12 for transient regulation.
The equipment shall be complete in every respect and designed for the highest degree of reliability
and minimum maintenance requirements.
Brushless excitation shall be applied for steam turbine generator.
A block diagram of the complete excitation system shall be supplied together with the constants of
the transfer functions for the control and stabilising circuits. The time constant of the exciter shall
also be included. The block diagram and the system description shall include all details of the
combined operation of the SFC and the static excitation during the start up of the GT unit.
The excitation system shall be capable of producing a steady state short circuit current of not less
than 1.6 p.u. (stator nominal current) for at least 15 s (during test conditions and terminal faults)
with a 3 phase terminal short circuit applied.
The nominal exciter response, as defined in Appendix A, of BS 5000 Part 2, shall not be less than
0.5.
The continuous rated current and voltage of the main exciter shall not be less than 110% of the
generator excitation current and voltage required to maintain rated output at the terminals of the
generator.
The ceiling voltage shall not be less than 200% of maximum continuous rating (at rated power).
Rotary exciters shall be of the enclosed, ventilated type. The generator shall directly drive them.
Anti condensation heaters shall be provided in the air circuits of the generator and its exciters. The
leads from the heaters shall be brought out to an isolator located close to the bedplate with
suitable interlocks provided to energise the heaters with the generator at standstill.
Sufficient space shall be provided at the cubicles to allow testing and maintenance of the
equipment to be readily carried out.
All terminals shall be arranged for easy termination of the necessary cabling.
2.3.7.2 Exciter
The thyristor converter shall incorporate a number of three phase full wave bridges, and shall be
arranged so that a minimum of 20% reserve capacity is incorporated. The converter should be of
modular construction so that a minimum of one bridge may be removed for maintenance whilst
maintaining full -load excitation without any restrictions. On multiple output bridge converters, the
Contractor shall state the minimum generator output rating with further reduction in the number of
operating bridges.
In the event that the converter derives its AC power requirements from the main generator
terminals, the excitation supply transformer shall be capable supplying full field forcing voltage at
80% of rated Generator output voltage. For the 200% ceiling voltage required at 80% generator
voltage, a stator current up to nominal values shall be considered. In addition a permanent DC
control supply for electronic circuits shall be provided with such a method of converter supply, this
may be obtained from either the station battery via a DC/DC converter or from a shaft-driven
permanent magnet machine using an AC/DC converter.
The thyristors shall be protected by line or arm H.R.C. fuses as appropriate and may operate in
connection with suitable crow-bar circuits. Indication of thyristor failure shall be provided.
Page: 13
Provisions shall be made in the design of the converter for the protection of the thyristors against
gross overvoltages, which may arise for example from asynchronous Generator operation. This
may take the form of protection capacitors and resistors. Voltage-controlled crow-bar circuits,
overvoltage limiters, or other systems of a suitable type as approved by the Engineer.
The repetitive peak reverse voltage rating of the thyristors in each arm of the three phase bridges
of the converter shall be greater than the maximum reverse voltage appearing across an individual
thyristor by a factor of at least 2.0. The maximum reverse voltage appearing across the thyristor
converter shall be determined from a calculation of the induced voltage following a faulty
synchronisation.
Suitable surge suppression equipment shall be provided across the input of the converter unit to
ensure overall protection of the converter.
If field flashing is required in order to obtain initial field voltage build-up, the Contractor shall state
in the schedules the peak current and ampere-hours required from the station battery.
Provision shall be included for the detection and annunciation of excess heat sink temperatures.
The thyristors shall be continuously rated such that Generator full load, field forcing and fault
conditions can be carried with one failed device per bridge section.
2.3.8 Voltage regulation

The excitation control equipment shall include two automatic voltage regulator of the static type.
(One unit running and one hot standby). The standby AVR shall be continuously monitored, and
system operation and protection shall be unaffected by transfer of control from one AVR to the
other. The system shall be capable of either automatic and manual operation and shall incorporate
appropriate auto/manual changeover facilities. The system shall be so designed as to ensure
bumpless changeover from auto to manual mode and vice-versa. Local and remote set point
control shall be provided for both automatic and manual control. Additionally a selectable manual
control feature to be provided with the AVR which will be used during testing of the unit.
The generator unit step-up transformer shall also be provided with an AVR. As soon as the
generator CB is closed, this AVR shall be disabled automatically. If the generator CB is closed but
the 400kV CB is open the AVR of the unit step up transformer should automatically bring the OLTC
to nominal tap. (reference is made to chapter 4 Power Transformers, pos. 4.5.1 Electrical control
(3) automatic voltage regulation
The system shall include suitable limit control features, fault detection and protection features and
where appropriate generator transformer overfluxing protection.
The thyristor output stage of the excitation control equipment shall be continuously rated for the
excitation demand of the generator at full load, field forcing under fault conditions and a
contingency of 75%.
2.3.8.1 Automatic Voltage Regulator

The automatic voltage regulator shall be of the continuously acting type with no dead bands
enabling control of the excitation over the whole generator operating characteristics.
The AVR shall be capable of maintaining the generator terminal voltage within 0.5% of the set
value for any voltage deviation over the whole load range of the generator.
The voltage response characteristic shall be given by the Contractor for AVR damping control at
normal, maximum and minimum settings.
The AVR shall be equipped with an active power dependent voltage stabilisation circuit (Power
System Stabiliser) for damping rotor oscillations.
Page: 14
An automatic VAr controller with VAr shedding facility shall be incorporated in the control system.
The voltage regulating equipment shall be mounted in a free standing cubicle which forms part of,
or is adjacent to, the excitation equipment.
2.3.8.2 Excitation Limiter

A minimum excitation limit device shall be incorporated to prevent the AVR reducing the generator
excitation below a value which might endanger power system stability limits. The limit unit shall be
arranged to provide an alarm and interlock in the event of extreme low excitation when operating
under either automatic or manual excitation control.
The characteristic of the VAr-limiter shall be adjustable and facilities shall be provided so that the
VAr-limiter operating characteristic can be adjusted to any setting within the specified range.
Over-excitation protection shall be incorporated to ensure that if excessive excitation is sustained
beyond an adjustable present current/time limit, the AVR is either tripped or the excitation is
automatically ramped down. The current/time setting shall be such that no damage will be caused
to any part of the AVR or any component of the excitation system.
The AVR shall in addition include the following protective devices which shall trip the AVR to
manual control and initiate appropriate alarms and still trip the set after a predetermined delay in
the range 0-30 minutes.
a.
Overvoltage protection
b.
Overcurrrent protection
c.
VT fuse failure protection
d.
AVR failure protection
e.
Overfluxing protection (volts/Hz protection)
f.
AVR power supply failure protection.
Overfluxing protection shall be provided and shall be part of the excitation control system and shall
be operative during both automatic and manual modes of excitation control. The protection shall
prevent the transformer magnetic flux from rising to a value at which the voltage/frequency ratio,
pre-set within the range 1.00 to 1.25, would be exceeded.
2.3.8.3 Control
An approved device of manually controlling the excitation shall be provided primarily for generator
commissioning and maintenance purposes. Control shall be possible from approximately 0 to
110% UN.
Means for both local and remote operation of the manual control shall be provided. An
auto/manual balance indicator and changeover contact shall be provided at the cubicle and in the
central control room; however, remote changeover shall be inhibited when the local control is in
use.
A follow-up device shall be provided to automatically adjust the standby manual excitation control
so that in the event of a changeover from automatic to manual control there will be a minimum
change in the level of excitation.
An automatic limiter shall stop the automatic follow-up device or the manual voltage controller from
reducing the manual voltage regulator setting below the prescribed safe limits of excitation for the
generator when under manual control. The characteristics of the limiter shall have the same range
of adjustment as the VAr-limiter of the AVR channel, but when commissioned shall be set for less
leading conditions than the VAr-limiter.
Page: 15
Droop Compensation:
Quadrature droop compensation shall be provided to ensure correct sharing reactive power in
accordance with generator rating.
The compensation shall have an adjustable compensation range 10% and shall be so connected
that the compensation can readily be taken out of Service.
Generator and exciter field suppression equipment:
Generator field suppression equipment shall be provided for minimising as much as possible the
damage caused by certain internal generator and excitation system faults, i.e. those faults which
cannot be switched off by tripping the circuit breaker.
The exciter field suppression equipment shall be provided and may be accommodated within the
AVR cubicle.
The field switches shall be capable of making and breaking the circuits under the most onerous
fault conditions. The switches shall be suitable for local and remote as well as automatic operation.
The generator field switch shall also be suitable for manual operation.
Means shall be provided on the cubicles for indicating locally and remotely whether the switches
are in the open or closed position.
The field suppression resistor shall be non-inductive and rated to suppress maximum field current
as quickly as possible.
2.4
GENERATOR MAIN CONNECTION AND CIRCUIT BREAKER
2.4.1 General
The generator main connections are to be designed as isolated - phase bus duct system.
Terminal copper work shall generally comply with BS159 and shall be of electrolytic copper.
The line terminals, shall be located on the generator in an approved position and order to enable
the outgoing connections to be made to phase isolated bus ducts. These terminals and the leads
from the winding to the terminals shall be suitably insulated and rigidly supported, porcelain
bushing insulators shall not be used.
The Contractor shall provide all necessary current transformers and voltage transformers required
for generator protection, excitation system, control and instrumentation as described within the
applicable Part of this specification.
The terminals shall be indelibly marked in accordance with their time-phase sequence in an
approved manner and co-ordinated with the phase-sequence of the unit main transformer and the
400 kV GIS.
The generator star point shall be earthed through the primary winding of a distribution type
transformer with an unbreakable grid type resistor connected across its secondary winding.
Metalclad terminal boxes shall be provided in an accessible position for the termination of all
protection, control and supervision cables.
Two suitable earth terminals shall be provided on the stator frame.
2.4.2 Phase isolated bus ducts

The insulation of busbars and their connections shall be capable of withstanding without damage,
the thermal and magnetic effects of a short-duration solid phase-to-earth or phase-to-phase fault at
the stator terminals.
Page: 16
Bus ducting where it passes through walls shall have provision for weather sealing. Where bus
ducting is located outdoor it shall be weather and dust protected to IP 65.
The bus duct enclosure shall be made of suitably fabricated tubular shaped sheet metal. All
external surfaces must be protected in an approved manner suitable for corrosive environmental
and salt laden atmosphere.
Each bus ducting shall be equipped with a silica gel breather and a positive air pressure
maintaining system. All seals must be fire resistant.
Compressed air for pressurising the generator bus duct system shall be taken from the station
instrument air or a separate compressor system shall be provided.
The bus duct shall be totally enclosed, dust, moisture and vermin proof and completely sealed,
Drain plugs shall be provided at the lowest parts of the housing or enclosures.
Pressure relief devices shall be provided to prevent over-pressurising of the bus ducts.
The Contractor is required to provide sun-shades due to the ambient conditions and must
demonstrate that such sun-shades, where provided, are adequately supported.
Where the bus ducting connects the transformers at one end and to the generator at the other end,
the connections shall be made with flexible copper.
Short circuit facilities in the bus duct shall be provided for test purposes.
Where necessary, expansion joints shall be provided in the run of the bus ducting. The materials
used in flexible connections shall be electrolytic similar to the busbar materials and made
compatible by approved anticorrosive protection.
Drawings must be submitted with the tender showing the run of the bus ducting, the details of the
connections to the transformers, the generator and expansion joints.
2.4.3 Generator circuit breaker

The Generator circuit breaker has to fulfil the requirements according to IEEE (ANSI) 37.013, IEC
60694, IEC 60298 and IEC 60129. The near short circuit faults have to be switched off without any
delay of the generator circuit breaker (i.e. by delay of the tripping command).
Exclusively circuit breakers of the vacuum or SF6 type with 110 V DC motor-driven stored energy
mechanism are to be provided. All CBs shall be fitted with operational counters.
Mimic diagram with symbols and actuating components for the following to be provided in front of
the Generator circuit breaker cabinet:
Generator symbol
Earthing switches with position indicator and actuating components
Generator circuit breaker with position indicator
Generator main connections
Transformer symbols
All signals indicated locally are to be transmitted to the central control room.
All current and voltage transformers are to be provided in accordance with IEC 60044 and IEC
60186.
Motor-driven earthing switches of short-circuit-proof design are to be provided. The necessary
interlocks with the 400 kV line isolator, generator circuit breaker etc. are to be provided.
Page: 17
To reduce the overvoltage stress, protective capacitors at generator and at transformer side shall
be part of the generator breaker unit. Surge arrestors must be installed and connected to the
phase ducts near the Unit Main Transformer (BAT).
To avoid accidental energising of the generator, while at standstill or on turning gear, due to
operational error, breaker head flash-over or control circuit malfunction, a dedicated protection
scheme shall be proposed to detect inadvertent energising. This scheme shall provide protection
when the generator is off-line. Protective capacitors shall be installed in the generator CB cubicle
at the generator busbar-side. The surge arrestors shall be gapless metal oxide type with pressure
relief device. Breaker failure protection shall also be provided.
The CB enclosure shall be capable of withstanding internal pressure generated during switching
operations and overpressure relief device shall be fitted to discharge any excess pressure.
Regular staircase to be provided to reach the circuit breaker location.
2.5
GT AUXILIARY SYSTEMS
2.5.1 Generator protection, synchronising and metering

Each turbine generator shall be provided with the protection, synchronising and metering
equipment. The equipment shall be installed in suitable cabinets.
The description of the generator and transformer protection is included in Clause 12 Electrical
Protection System of this specification.
2.5.1.1 Synchronising
Synchronising schemes shall be provided for all generator circuit breakers, the related 400 kV
circuit breakers and the related 11 kV Incoming feeder of the 11 kV Unit Board, which will include
the use of synchronising point and auto/off/check synchronising selection commands at the
generator control facilities located in the Central Control Room and at the local turbine control
panels for gas turbines.
For generator synchronising dual channel synchronising relays shall be provided. Independent
measuring and confirmation of both channels shall permit synchronisation. Dead bus closing
facility shall also be provided for all generators
Interlocking shall be provided to guarantee, that in case of synchronisation in the 400 kV only one
CB at a time will be possible to select for synchronisation. Any attempt to select a second circuit
breaker (from same location or different location) to be prevented by the interlocking schema.
For generator circuits, incoming and running voltages shall be obtained either from voltage
transformers associated with the generator circuit breakers or with the 400 kV circuit breakers and
synchronising shall be carried out from the local generator control panels and the central control
room.
For each generator, the Contractor shall provide a fully automatic synchronising system and also a
separate independent selectable semi automatic synchronisation system. For the semi automatic
system the adjustment of frequency and voltage shall be accomplished automatically. Operators
intervention will be required to close the selected circuit breaker only.
An auto-off-check synchronising selection scheme shall be provided.
Each automatic synchronising and semi automatic equipment for the generator units shall
comprise an electronic unit and shall be designed to perform the following functions:
bring the incoming generator into acceptable conditions of voltage and speed for
synchronising to be carried out
Page: 18
Additionally the automatic synchroniser will
initiate the closure of the 400 kV circuit breaker or generator circuit breaker or 11 kV incoming
breaker of the related 11 kV Unit Board at an instant in time such that the breaker shall close
within given limits of phase-coincidence of the running and incoming voltages
For voltage matching this equipment shall be adjustable in 3 fixed steps of approximately 2%, 4%
and 6% difference between incoming voltage and running voltage.
The synchronising equipment shall include features to ensure that the frequency of the incoming
generator shall be raised above the running frequency at the time of synchronising. On
synchronising, automatic loading to a set percentage of the Generator rating shall occur. The
frequency and load setting shall both be adjustable.
The equipment shall be fully interlocked and shall be designed to ensure that incorrect
synchronising cannot result from any component failure.
If it is necessary for the generators to be switched onto dead bars the check synchronising system
shall be used.
Check synchronising facilities shall be provided across the following circuit breakers:
all 400 kV circuit breakers
generator circuit breakers
11 kV incoming and bus section circuit breakers;
380 V incoming circuit breakers of Auxiliary Boards and Essential Services Board.
It shall not be possible to close these circuit breakers without following the check synchronising
procedure.
Each off/synchronise selection command shall be interlocked with the relevant control command
and check synchronising relay.
In order to close a circuit breaker the operator shall first select a synchronising screen and the
circuit on the electrical control panel. Visual indication of running and incoming voltage and
frequency shall be given. When all necessary conditions are correct, the operator shall have visual
indication from the synchronising screen and a permissive signal from the check synchronising
relay and he shall then be able to close the breaker by the use of a control command.
Check synchronising relays shall only permit closing of a circuit breaker if the voltages of the
running and incoming circuits are within the required time, voltage and phase limits and shall also
permit closures onto "dead" busbars by use of a no-volt relay and timer. The use of an override
switch is prohibited.
2.5.1.2 Tariff metering system and internal metering system

For each 400 kV unit feeder circuit import and export tariff meters MWh and lagging and leading
MVARh plus maximum demand meters will be provided in the 400 kV Substation. (Not part of
package P)
Additionally for internal metering Wh and VARh meters (accuracy class 0,2) shall be provided for
measuring of
Generator output (Export Wh and VARh)
Incoming feeders of 11 kV Unit Auxiliary Boards connected to 11 kV side of Unit Auxiliary

Transformers 1BBT01, 2BBT01, 3BBT01 (Import Wh and VARh)
Page: 19
Above mentioned meters shall be installed in the relay room of the Central Control Room and
Switchgear Building.
All these meters shall be of 3- phase / 4 wire (3 element) type provided with test sockets / plugs.
Meters to be provided with pulse output connected to the DCS. Irrespective of plant operating
condition reading of meters to be always available. As well individual unit wise Wh & VARh energy
as plant wise total Wh & VARh generated and consumed to be available in the control room for
indication, recording, calculation and other applications. (Plant wise schema, if not incorporated in
the DCS should be open to incorporate future units in L phase II.)
Further meters (kWh / kVArh) shall be installed in all incoming feeders of 11 kV Sub-distribution
boards and 380 V incoming feeders of all LV boards. (Reference is made to Clause 5 Medium
Voltage Switchgear and Clause 6 LV Power Distribution System
2.5.2 Current and voltage transformers

All necessary CT's and VTs shall be provided and the "General Technical Requirements", Part G5
shall be considered accordingly.
The CT's shall comply with IEC 60044 and shall have the following classes:
differential protection
class X
other protections
class 5P10 or 5P20 *
metering
class 0,2
instrumentation
class 1
AVR
class 0.5
* As per IEC 60044 protection CTs are classified as P, TPS, TPX, TPY and TPZ. The bidder
should select particular type of CT which is best suited for each application, justification for the
choice to elaborated.
Separate CTs, no multicore CTs shall be provided.
Actual burden shall have to match with rated burden. CT's shall be capable of withstanding an
open circuit at secondary terminal for 1 second without adversely affecting the CT.
Saturation factor of measuring / metering CT to be less than 5.
The 'VT's shall comply with IEC 60044 or IEC 60186 and shall have the following classes:
protection and synchronising
1P
automatic voltage regulation
0.5
metering
0.2
VT's shall be capable of withstanding a short circuit at secondary terminal for 1 second without
being adversely affected.
All CTs and VT's are subject to the approval of the Employer/Engineer. The supplier shall prove
the suitability of the CTs and VT's by providing calculations for approval.
2.5.3 Auxiliary transformers

Each gas turbine generator shall be provided with an MV/11 kV Unit Auxiliary Transformer (BBT)
and the required 11/0.4 kV auxiliary transformers (BFT). The transformers shall comply with the
General Technical Requirements, Part G5 and Part P2.26.4.
Page: 20
The Unit Auxiliary Transformer BBT shall be installed outdoors and connected to the generator bus
duct by means of bus duct connection (Tee-off).
The Unit Auxiliary Transformers of two GTs shall have the capacity to cover the entire plant load in
case of the 3rd GT aux. transformer is out of operation.
The indicated 11/0.4 kV auxiliary transformers in the overall single line diagram are for information
only. The Contractor shall provide all required transformers (each 2 x 100%) to cover the unit LV
load (GT + HRSG) and 10% spare capacity.
2.5.4 380 V LV unit boards (MCC)

The 380 V switchgear cubicles shall be free-standing, self-supporting construction made of steel
and shall comply with the General Technical Requirements Part G5 and Part P2.26, Clause 6.
Beside the normal turbine-switchgear an additional section is to be provided which shall be linked
to the 380 V emergency supply board.
The cubicles are to be installed in the electrical control compartment close to the relevant
generator turbine unit.
The design of the switchgear shall cater for continuos operation of the equipment supplied.
Final arrangement shall be subject to approval.
2.5.5 DC and UPS systems

The arrangement shall be rated for the total DC and UPS requirements of the gas turbine
generator/ HRSG unit, including a spare capacity of 10%. Each DC system must be capable of
keeping the consumers in operation in case of loss of AC power supply for at least 1 hour with one
battery and for 3 hours with two batteries.
The equipment shall comply with the requirements of Part G5 and P2.26, Clause 6.
Following Systems shall be provided for each gas turbine generator unit as applicable:
(one) 2 x 100% 220 V DC system comprising chargers, batteries and DC distribution
(one) 2 x 100% 110 V DC system comprising chargers, batteries and DC distribution
(one) 2 x 100% 24 V DC system comprising DC/DC converter and DC distribution
(one) 2 x 100% 220 V AC UPS system comprising chargers, batteries, inverters and AC
distribution
The exciter for the DC and UPS systems can use nominal 110 VDC batteries.
The equipment shall be installed in the control/switchgear compartment close to the relevant
generator turbine unit.
The DC supply unit is to be provided as indoor, sheet-steel cabinet(s) with suitable partitions
between the individual items to allow maintenance or repair to be carried out in safe way.
Starting of big DC consumers (e.g. emergency lube oil pump etc.) shall not hamper any other DC
consumer (e.g. control).
All alarms shall be made available for connection to the remote supervisory system as a group
alarm.
For detailed Protection requirements refer also to Clause 12 Electrical Protection System.
2.6
Page: 21
For the I&C requirements refer to Clause 11 Electrical Protection System and Part P2.27 I&C
systems
3
3.1
STEAM TURBINE GENERATOR

SCOPE OF WORKS
This Part contains the specification of the Steam Turbine Generator that has to be read in
conjunction with Part P2.6 Steam Turbine and Auxiliaries as well as specially requested supplies
and services but without excluding other necessary components and services not mentioned.
One (1) generator, complete, with all auxiliaries containing at least:
Closed air cooling system and air/water coolers (including 1 stand-by cooler)
Terminal fed static excitation system and AVR
Generator star point and terminal cubicle including the bus duct system up to the terminals of
the unit main transformer with all necessary CTs and VTs
Generator control panel
Synchronising facilities
Generator and unit main transformer protection in separate cubicles
3.2
GENERAL
The steam turbine generator shall have sufficient capacity such that it does not limit the capability
of the steam turbine over the range of ambient conditions specified in Part G4. The rated terminal
conditions shall be 3 phase, 50 Hz, 0.8 power factor lagging (over excited) to 0.9 power factor
leading (under excited). The voltage level shall be in accordance to supplier standard. The
generator shall comply with IEC 60034, as amended and supplemented by this specification. The
complete turbine generator capability diagram shall be provided with the Tender.
The sum of the generator and generator step up transformer impedance shall be limited to a
minimum 30 % (without negative tolerance) to limit the short circuit contribution to the 400 kV
system.
The generator shall be connected directly to the star/delta connected step-up unit main transformer
via phase isolated bus ducting system. The unit auxiliaries shall be connected to the LV, DC and
UPS switchboards located in the switchgear control building.
The unit main transformers are specified in Part P2.26, Clause 4
The relevant design concept described under GT generator Part P2.26, Clause 2 shall apply
however the BPSTs shall not be provided with unit auxiliary transformers.
4
4.1
POWER TRANSFORMERS
SCOPE OF WORKS
Based on the overall single line diagram the following power transformers shall be supplied,
installed and commissioned:
Page: 22
One (1) unit main transformer (BAT) for each GT-Unit, ratio: 400/ UGen kV, three-phase, oil
immersed, outdoor type step-up transformer Cooling: ONAN/ ONAF; Tap changer: on-load *,
with AVR
One (1) unit main transformer (BAT) for each ST-Unit, ratio: 400/ UGen kV, three-phase, oil
immersed, outdoor type step-up transformer Cooling: ONAN/ ONAF; Tap changer: on-load *,
with MVR
One (1) Unit auxiliary transformer (BBT) for each GT-unit, ratio: UGen / 11 kV three phase, oil
immersed, outdoor type transformer, connected to the GT generator busbars according to SLD
Cooling: ONAN/ ONAF Tap changer: on-load *; with MVR
One (1) lot auxiliary transformers 11 / 0.4 kV, three phase, oil immersed, outdoor type
distribution transformers Cooling: ONAN Tap changer: no-load. Dry type transformers up to
1500kVA ratings will also be acceptable .
Excitation transformers as specified in the generator specifications
SFC (start up) transformer for Gas Turbines
Neutral earthing transformers as specified in the generator neutral earthing specifications
* Note: The unit main transformers and unit auxiliary transformers shall be equipped with on-load
motor driven tap changer (OLTC). During transportation from the factory to site manufacturer
impact recorder has to be installed. Maximum allowable limit of impact shall be stated by the
OLTCs manufacturer. Inspection of all OLTCs before expire of the warranty period shall be
included in the scope of Works. A tap changer diverter lifting device suitable for lifting each type of
diverter shall be included in the scope of Works.
On line DG (Dissolved Gas) monitoring system shall be provided for the unit main transformers.
Alternatively provision of a DGA (Dissolved Gas Analyser) in the workshop and testing equipment
will be accepted. A capacitance and tan delta test set with range extension unit and oil test shall be
also included in the scope of workshop and testing equipment.
The numbers and ratings of transformers as defined in the SLD are provisionally only and have to
be defined/ verified finally by the Tenderer/ Contractor for the power requirements of the offered
plant under consideration of the criteria as defined in item 4.2, Transformer Capacities, below.
4.2
4.2.1
TRANSFORMER CAPACITIES
Unit Step up Transformer
The unit step up transformers connected directly to the generators shall, under exceptional
circumstances due to sudden disconnection of the load, be capable of operation at a voltage 40%
above normal voltage for a period of not less than 10 seconds.
Short time over-excitation capability of the transformers, should be provided according to IEC/IEEE
requirements, whichever is more stringent. A curve depicting this capability is to be provided.
The unit step up transformers shall fully match the outputs of the turbines over their temperature
operating range for base load and peak load and full transformer tapping range.
The capacities of the GT and the ST unit step up transformers shall at least be 5% higher than the
maximum output of the generators at all operating conditions.
The ONAN rating shall be at least 60 % of the turbine base load MVA output rating over the whole
range of site temperatures up to the maximum site ambient temperatures.
Between the unit step up transformers of the gas turbines and the unit auxiliary transformer a fire
protection wall must be provided.
Page: 23
4.2.2 Unit Auxiliary Transformer

Rated capacity at ONAF cooling and the specified temperature rises shall be defined by the
Contractor under consideration of the power demand of all auxiliaries to be fed from the unit
distribution boards. In case of one auxiliary transformer outage, the remaining unit auxiliary
transformers shall have the capacity to cover all plant loads.
The capacity with ONAN cooling shall be approx. 55 - 70% of the ONAF capacity.
4.2.3 Auxiliary Transformers

Rated capacity at ONAN cooling and the specified temperature rises shall be defined by the
Contractor under consideration of the power demand of all auxiliaries to be fed from the connected
main distribution board. Each of the two transformers connected to the same main LV distribution
shall be designed for 100% auxiliary demand of both bus sections of such a board, i.e. the bus
sectionaliser shall be considered as closed whilst one transformer is shut down.
4.3
GENERAL DESIGN CONDITIONS AND DATA
The mechanical and electrical design of the transformers and their accessories shall strictly follow
the IEC Recommendations and shall be based on the following conditions and requirements:
The ambient climatic conditions are specified in the Particular Technical Specifications,
Prevailing Weather Conditions and in the General Requirements for Electrical Equipment. All
transformers shall be designed for site ambient temperature of 50oC. Hot spot temperature
shall not exceed 98 oC.
For dry type indoor transformers the respective maximum room temperature and enclosure
protection class have to be considered.
The maximum permissible temperature rise at ambient temperature of 50 C shall be:

Oil immersed transformers
Oil:
winding:
winding:
43 K (Top oil)
48 K (average)
48 K (hot spot, k1 = 1.3 according to IEC 354)
Dry type transformer (insulation class F)

windings:
48 to 50 K
other parts:
48 to 50 K
The temperature of the tank wall and other exposed parts (e.g. bushing turrets) shall not exceed
100 C under all operating conditions at an ambient temperature of 50 C. This includes hot
spots due to eddy and stray current on the tank walls. The location of the hot spot (if the hot spot
will not lie in the winding) shall be clearly mentioned in the offer.
All oil immersed transformers shall be designed as three phase power transformers for outdoor
installation.
Unit Step up Transformers and Unit Auxiliary Transformers shall be able to withstand 1.4 times
rated voltage for at least 5 sec. at the transformer terminals.
Unit auxiliary and 11/0,4 kV auxiliary transformers shall be able to operate safely for 30 seconds
with a voltage of 1.3 times rated voltage imposed to the feeder winding. All transformers shall be
able to operate continuously at their nominal ratings within the limits of temperature rises, at
voltage variations of +10% at their feeder windings, at any frequency variation between -5% and
+5% and at any combination of voltage and frequency variation of total +10% together with any
voltage ratio to be adjusted by the tap changer.
Page: 24
The short circuit capability of the transformers shall be such that they can withstand for 3
seconds without damage or deterioration secondary short circuits when fed from the primary
side with the maximum possible fault current.
Characteristic data:
The OLTC tapping steps shall be 1.25%
Based on the final transformer data the Contractor shall prove that the finally selected voltage
ratios and tap changer ranges are suitable for operation of the plant under all operation
conditions and within the specified operation voltage ranges.
The impedance voltage shall refer to 75 C winding temperature, tap-changer centre position
and nominal output.
The Contractor shall provide a 3-phase, phase sequence diagram to ensure identical phase
relationship of all systems, which might be interconnected and correct cable/ busbar
connections.
The transformer neutral (star) points on the high voltage winding of the unit step up
transformers are to be solidly earthed with the possibility of isolating them when necessary.
Therefor the star points are to be fitted with single- pole earthing switches and lightning
arresters in parallel with the earth connections.
The neutrals of the star connected windings of transformers BBT shall be designed as
required for resistance earthing in accordance with the existing plant as defined in the
Protection Specifications
The neutrals of the star connected windings of 11/0,4 kV transformers shall be designed for
solid earthing via bolted links.
The transformers are to be provided with flange connected radiators for ONAN/ONAF
operation.
Earthing resistance of BBT transformers shall have rating of 10 minutes construction features
Each transformer shall, as far as applicable, comply with the stipulations of the following articles.
4.4
CONSTRUCTION FEATURES
4.4.1 Windings
All transformers shall be provided with high conductive electrolytic copper windings. Insulation
material of dry type transformers shall be of Class F (IEC 600 60726 / IEC 600 60085).
The insulation of windings and connections shall be free from insulation compositions likely to
soften, shrink or to collapse during service. None of the materials used shall shrink, disintegrate,
carbonise or become brittle under the action of hot oil at any load condition.
The neutral of unit step up transformers may be graded to AC:275 kV. All remaining transformer
windings including neutral ends shall be fully and uniformly insulated. The windings shall have the
following insulation strength (all values in kV):
Nominal voltage
400
15-17
11
0.4
Highest voltage for equipment
420
24
12
1.1
Page: 25
Rated short time power frequency withstand

voltage (rms)
630
50
28
Rated lightning impulse withstand voltage

peak)
1450
125
95
Rated switching impulse withstand voltage
1175
3
-
4.4.2 Bushings
(1)
General
Bushings shall be of the outdoor type designed for areas with a very heavily polluted atmosphere.
They shall correspond to IEC 60137 and IEC 60815, shall be free from defects and shall be
thoroughly vitrified. Insulators shall be of top quality electrical grade porcelain, homogenous and
non-porous, and shall be in one piece. The glaze shall not be dependent upon for insulation and
shall be of a uniform shade of brown, completely covering all exposed parts of the insulator.
The bushings shall be arranged on the tank cover in such a manner, that removal of the same is
possible without lowering of the oil to such a level where the windings are exposed to the
atmosphere.
All bushings shall be at least of the same insulation level as that for the related windings and/or
neutral. The clearances in air between life parts of bushings and against ground shall exceed
those specified in IEC 60076-3 by at least 5 percent to withstand switching surges safely.
All bushings of voltage class 72.5 kV and above shall be generally of the condenser type (only
epoxy-resin impregnated paper type up to Um = 245 kV) equipped with test tap at the bushing
flange. Bushings of voltage class 52 kV and below may be oil-filled. All bushings shall be designed
for storage in horizontal position without any restriction.
Neutral terminals shall be designed for the highest over-current that can flow through the windings.
Bushing turrets, if any, shall be equipped with vent pipes which shall be connected to route any
gas collection through Buchholz relay. Bushings up to Um = 52 kV shall be arranged in an upright
position.
(2)
SF6 Gas Tight Bushings
Where required, the ends of the windings shall be led out by SF6 gas-tight bushings of the epoxy
resin impregnated paper condenser type and SF6 connection boxes with adequate flanges to
enable the direct connections to the tubes of an SF6 gas insulated switchgear.
The SF6 connection boxes shall be arranged on the tank cover in such a manner that removal of
oil/ SF6 gas bushing is possible without lowering the oil level to such a level where the windings
are exposed to the atmosphere.
Size and design of these bushings and flanges have to be done suitably co-ordinated with the
switchgear supplier.
(3)
Built-in Current Transformers
At 400 kV side of the ST / GT Unit Step up Transformers two CT at each phase shall be provided.
The CT will be used for the BAT Transformer protection 87T and the line differential protection 87B
to protect the SF6 bus ducts between the HV side of the transformers and the related 400 kV
feeder.
The CT's shall comply with IEC 60044 and shall be of class X.
Page: 26
Separate CTs, no multicore CTs shall be provided.

Actual burden have to match with rated burden.
4.4.3 Magnetic Core

The core and its clamping plates shall form a rigid unit structure which shall maintain its form and
position under the severe stresses encountered during shipment, installation and short circuits.
Care shall be taken to secure evenly distributed mechanical pressure over the whole laminations to
prevent settling of the core and to eliminate noise and vibrations when the transformer is in
operation. The core construction shall be such that removal and replacement of windings will
require removing of core laminations to a minimum extent. The core grounding shall be made
available outside the tank by means of a disconnectable link.
Core laminations shall be made from cold rolled grain orientated, high permeability silicon steel
free from burrs. The core joints shall be interleaved. Each lamination shall be insulated with a
material that will not deteriorate due to pressure and the action of hot oil.
The maximum flux density shall not exceed 1.7 Tesla at rated feeder voltage and 1.9 Tesla at
feeder voltage 1.1 times the rated voltage and under the condition that higher harmonics are
suppressed to the maximum possible extent.
4.4.4 Transformer Tank

The tank shall be of the bolted top flange type and shall be constructed of heavy mild steel plates.
It shall withstand filling with oil at vacuum without permanent distortion. All seams or joints shall be
continuously welded from both inside and outside the tank, etc. No stitch welding shall be
accepted.
Heavy structural steel members shall be welded to the bottom of the tank to form a rigid undersupporting base.
In order to prevent tank deformations during operation, a pressure relief device of sufficient size
shall be provided for rapid release of any pressure that might be generated within the tank, and
which might result in damage to the equipment. The device shall operate at a static pressure of
less than the hydraulic test pressure of the tank. Means shall be provided to prevent the ingress of
rain or dust. Exhausting oil shall be directed downwards into the transformer's oil collecting pit. A
drain valve at the lowest point of the transformer tank shall be provided.
The following moving and handling facilities shall be provided for each transformer:
Four (4) jacking lugs to enable raising and lowering the transformers completely filled with oil
by means of hydraulic jacks
Lugs for lifting the complete transformer
Lifting facilities for lifting the core, coils/ tank and/ or tank cover
Pulling eyes for moving the transformers in any direction
Minimum four (4) bi-directional wheels, as required by the maximum permissible point load.
The individual wheel positions shall be marked clearly on the carriage
Tank cover access ladder (for unit main and unit aux. transformers only)
Inspection holes of adequate number and size.
The scope of Works shall include all material required for fixing of the transformers in their service
position. Rails shall be provided up to the related roads to allow easy unloading, loading and
movement.
Page: 27
As required the tank shall be provided with suitable flanges for connecting of busduct enclosures
and/ or cable end boxes, respectively terminals for OHL connection, if applicable.
4.4.5 Cooling
The unit main and unit aux. transformers shall be equipped with detachable radiators in
independent groups connected to the tank by isolating valves so that each group may be removed
without taking the transformer out of service. Close and open position inlet and outlet valve for
each radiator to be distinctly marked with different colours.
Other transformers shall have steel radiators forming an integral part of the tank.
Radiators and coolers shall be designed and spaced, so that all painted surfaces can be
thoroughly cleaned by hand and subsequently painted on Site by suitable brushes or sprays.
Radiators and coolers shall be designed as to avoid pockets in which moisture may collect.
The tank and the radiators shall have sufficient cooling surface area to allow continuous operation
of the transformers with their self-cooled rating. The fans or group of fans shall have two sources of
power supplies, if not ONAN type. In this case automatic changeover to stand-by power supply
shall be provided in case of loss of main supply.
The oil filled transformers shall be provided with oil temperature and winding temperature indicator
with contact for alarm and tripping.
Forced air-cooling shall be provided for the transformers as specified by means of fan units
attached to the radiators. 20%, but at least two spare fan units beyond the 100% cooling capacity
requirement shall be installed.
Anti vibration mounting to be provided with fan units.
The cooling arrangements of all transformers, other than water cooled units, having ratings of 30
MVA and above, shall be such that failure of one part of the cooling plant will not result in the loss
of more than 50% of the total forced cooling capacity.
The radiators shall be assembled, framed and braced in such a manner as to provide mechanical
protection of them and to prevent vibrations. Radiators shall be pressure tested to ensure liquid
tightness. Radiator headers, if provided, shall be sloped so that they can be completely drained
and vented. All portions of equipment shall be accessible for inspection, cleaning and painting.
As applicable, the following accessories shall be provided:
One (1) inlet and outlet valve for each radiator or group of radiators for connection with the
transformer tank or header, respectively
One (1) drain valve at the lowest point of each radiator or group of radiators
One (1) thermometer pocket fitted with a captive screwed cap on the inlet and outlet of each
radiator group.
Thermometer pockets as required for heat run test as per applicable standards
Air release plugs.
4.4.6 Voltage Adjustment

Ratio adjusters shall be provided for voltage adjustment which shall be electrically and mechanically robust and arranged to ensure convenient inspection and maintenance. Design, arrangement
of lead and connection thereto shall withstand voltage surges, a continuous load current
corresponding to 125% rated capacity of the winding without excessive heating and full short
circuits without injury.
Page: 28
(1)
No-load Tap Changers
The manually operated no-load tap changers (NLTC) shall have 2.5% voltage steps.
The selector switch shall be gang-operated by a single handle from the ground at convenient
height when the transformer is de-energised. Hand-wheels or cranks shall have padlocking
provisions and may be interlocked with position micro-switch. Attempt to operate the tap changer
will generate alarm / trip signal.
A dial type indicator easily legible from place of operation with numbers from 1 to N shall be used,
where "1" is related to the position with the minimum number of turns.
The dry type transformer tap changing shall be performed by changing the respective bolted link
connections.
(2)
On-Load Tap Changers
On-load tap changers (OLTC) in conformity with IEC 214 and IEC 542 for manual and electrical
local as well as remote control.
The OLTC shall be based on the principle "Dr. Jansen", i.e. comprising a selector switch with
change over switch and a rotary type diverter switch of the high speed transition resistor type.
Transition current resistor of graphite elements are not accepted.
The tap changer shall be mounted from top into the transformer tank. The diverter switch shall
have a separate compartment of the tank with an oil system separate from the transformer oil, with
its own oil supervision, subsection in the transformer's oil conservator, and breather. The tap
changer oil compartment shall be protected against over-pressures, due to severe switching
operations by means of a spring-loaded relief device with trip contact.
A motor drive of sufficient capacity shall be mounted outside the transformer at convenient height.
The gear unit shall be provided with a register for local indications of switching operations and of
the tap positions, and with a crank for local hand operation.
Position and torque limit switches shall be provided to prevent overrunning of the mechanism. The
electrical control equipment may be arranged either in the same enclosure forming an integral part
of the motor drive or in a marshalling kiosk.
4.4.7 Oil
As far as applicable, transformers shall be supplied and shipped with their initial oil filling. Drained
oil resulting from parts removed for shipment shall be delivered in drums in sufficient quantity to refill the lowered transformer oil volume and to replenish losses during subsequent processing on
site. All transformers offered under the "L" Station shall have the same brand and type of oil. The
brand and type of oil shall be approved by the Employer / Engineer. The oil to be used shall
preferably be the Employer's reference type. The oil shall be of Naphtenic base.
Transformers for which the oil level has to be considerably reduced for transport reasons shall be
filled with nitrogen and kept under positive pressure. Pressure indicators / monitoring device shall
be provided during the transport and site storage, if applicable.
The oil shall be in accordance with the Technical Specification for Insulating Oils, document
number 1.5.1.9.0.05 Rev. 1 (see Annex 1 of this Part)
4.4.8 Filter and drain valves, sampling devices and air release plugs
Each unit shall be fitted with the following:
a.
One 50 mm valve at the top and one 50 mm valve at the bottom of the tank, mounted
diagonally opposite to each other for connection to oil circulating equipment.
Page: 29
b.
A drain valve together with such arrangements as may be necessary within the tank to ensure
that the tank can be drained of oil as far as practicable.
c. A drain valve fitted to each conservator,
d. Air release cocks connected to Buchholz relay to be conveniently located so that it can be
operated from ground level,
e. A robust sampling device at top and bottom of the main tank. The sampling devices shall not
be fitted on the filter valves specified under a) above.
f. Flanged type air release plugs,
All valves opening to atmosphere shall be fitted with blank flanges.
4.4.9 Piping and Valves

All necessary oil piping, oil drain and filling valves, sampling taps etc., shall be supplied in such
quantity as to correspond with the size of transformer.
All valves up to and including 100 mm shall be of gunmetal. Larger valves may be of gunmetal or
may have cast iron bodies with gunmetal fittings. They shall be of the full way type with internal
screw and shall opened by turning counter- clockwise when facing hand-wheel.
Means shall be provided for padlocking the valves in the open and closed position of the valve.
Provision is not required for locking individual radiator valves.
Every valve shall be provided with an indicator to show clearly the position of the valve. Close and
open position of inlet and outlet valves for each radiator shall be distinctly marked with different
colour, if applicable.
Every valve shall be provided with flanges having machined faces.
Air release cocks connected with the Buchholz relay shall be conveniently accessible, it should be
possible to operate from the ground level.
Padlocks shall be supplied complete with duplicate keys for all lockable valves. A key cabinet shall
be provided suitable sized to accommodate all the valve padlock keys.
4.4.10 Joints and gaskets

Oil resisting synthetic rubber gaskets of the limited compression type may be used. (subject of
approval)
4.4.11 Oil Conservator

A conservator vessel complete with sump and drain valve, filling and overflow facilities shall be
provided in such a position as not to obstruct the electrical connections to the transformer and
having sufficient capacity to allow oil expansion from 0 C to +110 C. The conservator vessel shall
be designed in such a way that it could be completely drained by means of the drain valve
mounted when in service.
If OLTC are provided, the oil conservator shall have either a separate section for this oil system or
a separate vessel, including as well separate breathers.
Oil conservators shall be fitted with magnetic type level indicator. Alarm contacts (max. and min.
level) shall be provided.
Each conservator or conservator section shall be fitted with a three-way valve connected to
dehydrating breathers.
Page: 30
4.4.12 Dehydrating breathers

Each conservator serving the main tank of Unit Step up Transformers and Unit Auxiliary
Transformers shall be fitted with a refrigeration type breather of an approved type (preferably
DRYCOL type breather).
Water effluent from the breather shall be piped to a convenient drainage point at ground level. The
pipework shall be positioned such that a collection vessel can be introduced should it be required
to monitor the output.
The electrical supply to the refrigeration unit shall be monitored and alarmed in the event of a
failure.
A temporary breather of the silica gel type shall be fitted following delivery of the transformer to site
until a reliable supply of the breather for the refrigeration unit and monitoring of this supply is
available. The temporary breather shall remain as stand by with the valve in the connection point
kept closed.
Where a separate conservator is provided for the tap changer, this shall be fitted with refrigeration
type breather or a breather with silica gel is the dehydrating agent. In this case the design shall be
such that the external atmosphere is not continually in contact with the silica gel. Breathers shall be
mounted as approximately 1.4 metres above ground level.
4.4.13 Pressure relief device

All oil filled transformers shall be provided with over pressure devices.
Pressure relief devices shall be provided of sufficient size and numbers for rapid release of any
pressure that may be generated within the tank, and which might result in damage to the
equipment. The device shall operate at a static pressure of less than the hydraulic test pressure for
transformer tanks. Means shall be provided to prevent the ingress of rain or dust. Pressure relief
devices of the type mounted below normal oil level shall be of the reset able type; once the
dangerous pressure has been reduced, to prevent unnecessary release of oil. Buffles shall be
provided where necessary to safely control the duration in which oil or gas is ejected.
Means shall be provide to direct the oil to the ground level through suitable pipework so that the oil
is brought to the oil pit in a proper way in the event of operation of the PRD.
Contacts shall be provided for alarm and trip initiation on operation of the device.
The relief device shall be mounted on the main tank and if on the cover shall be fitted with a skirt
projecting 25 mm inside the tank to prevent gas accumulation.
If a diaphragm is used, it shall be of approved design and material and suited above maximum oil
level.
One of the following methods shall be used for relieving or equalising the pressures in the pressure
relief device:
a.
An equaliser pipe connecting the pressure relief device to the conservator or
b.
The fitting of the silica gel breather to the pressure relief device, the breather being mounted in
a suitable position for access at ground level
Loss of oil on operation of the relief device shall be contained within the transformer oil retaining
area.
Page: 31
4.4.14 Transformer Terminals

(1)
General
Uncovered outdoor bushings on transformers are admitted for solidly earthed neutrals and
overhead line connected phase terminals only.
All other line terminals shall be provided with sealed cable end boxes, as follows:
Facilities are to be provided for the accommodation and connection of power cables together
with their sealing ends.
Isolation links are to be provided for easy test and maintenance of the power cables.
Facilities are to be provided for the connection busducts as specified.
Terminal contact surfaces shall be treated in accordance with the requirements of equipment to be
bolted thereto as to prevent corrosion and ensure adequate connection resistance.
(2)
Oil Filled Terminal Boxes
Where required, single-phase type, oil-filled terminal boxes of IEC standard class 72.5 kV and
above shall accommodate the outgoing terminals of the transformers to be connected to vertically
arranged single-core XLPE cables. The cable connecting boxes for line terminals shall also be
provided for direct connection of SF6-insulated surge arresters as specified below.
Oil filled cable connecting boxes shall be fully vacuum-proof and shall be arranged at the upper
part of the tank directly underneath the tank cover or on tank cover in such a manner that removal
of bushings is possible without lowering the oil level to such a level where the windings are
exposed to the atmosphere.
The oil level in the terminal boxes shall be maintained from the main conservator tank by means of
a connection to the highest point(s) of the chamber, and this connection shall be controlled by
suitable valves.
Connections between the cable boxes and to the conservator shall be made by means of pipes so
that any gas leaving the chamber passes through a twin-float Buchholz relay.
(3)
Air Insulated Terminal Boxes
Where required, air-filled cable connecting boxes (protection category IP 54) equipped with
outdoor bushings suitable for connections of cables with outdoor sealing ends up to 52 kV IEC
standard class shall contain the winding ends. Unless specified otherwise in the technical data
sheets the bushings shall be designed for areas with a heavily polluted atmosphere.
This box shall also contain internally supported cable termination busbars connected to the
bushings via flexible links in such a manner that any mechanical stresses on the bushings will be
avoided. An appropriate grounding bar for cable screens shall also be provided. A suitable
manhole for checking of oil tightness of the bushings shall be provided at a location easily
accessible from tank cover.
The cable terminal boxes shall also be equipped with cable glands and shall accommodate the
cable sealing ends. Appropriate grounding facilities for cable screens shall be provided. Formation
of condensate in the termination boxes must be prevented.
(4)
Neutrals
The transformer neutrals shall be equipped with bushing type current transformers for earth fault
protection. The current transformers shall comply with the general requirements as stipulated in the
General Technical Requirements and in the Electrical Control and Protection Specifications, as
applicable.
Page: 32
If the neutral bushing is part of a common cable or busduct connection box, a suitable cable gland
shall be provided for penetration of the neutral conductor.
Isolating facilities shall be provided within the terminal box for disconnection of the cables for
testing purposes.
(5)
Metal Oxide Surge Arrestors
In order to ensure safe operation at all considerable switching conditions, SF6 insulated surge
arrestors shall be provided for the unit main transformers. These surge arrestors shall be capable
to ease the strain on transformer windings when being switched off and to protect all related
equipment from lightning and switching surges. Further they shall be designed to prevent any
oscillating over-voltages during normal and/or abnormal switching conditions.
The arrestors shall comply with IEC 99-4, discharge class 4.
The design data of the arrestors shall be proven by calculations.
The arrestors shall have pressure relief devices and shall be fitted with operation counters legible
from ground level. If there is any chance that the surge arrestor may fail violently, it has to be
contained.
They shall be built-up from hermetically sealed units containing valve resistor blocks with nonlinear characteristics without spark gaps and shall be connected directly to the oil-filled cable
connecting boxes as specified above.
(6) Connections
In case of different suppliers for transformers and HV connections, both parties are to co-operate in
order to ensure a proper and complete boundary between these sectors, i.e. the Supplier of
transformers shall provide the SF6 gas-tight bushings and SF6 connection boxes including metallic
bellows (if required) and all connection parts at the transformer side or the complete sealed cable
terminating boxes including the stress cones and all parts for proper connection of the sealing
ends.
On the other hand, the Supplier of the cables or SF6 connections shall provide the complete pot
heads and cable sealing ends, or bus duct ends, respectively. It is hereby understood that
responsibility of the transformer supplier covers the oil-tightness.
Surface treatment of the termination point material/ surface shall be co-ordinated between both
suppliers.
4.4.15 Earthing Terminals

Terminals shall be provided on Neutral and Tertiary bushings and they shall be suitable for
duplicate earthing.
Earthing terminals shall be adequately dimensioned to receive the main earthing conductors.
Provision shall be made at positions close to each of the bottom four corners of the tank for bolting
the earth connections to the tank structure to suit local conditions. A similar terminal shall be fitted
to the tank cover.
4.4.16 Painting
Due to the unfavourable atmospheric conditions, particular attention should be given to the
protection of all ironwork.
As far as practicable, all exterior metal parts including tank and radiators shall be hot-dipped
galvanised, and be provided with adequate durable and weatherproof paint finish.
Page: 33
All surfaces shall be thoroughly cleaned of rust, scale, grease and dirt and other foreign matter and
all imperfections shall be removed by means of approved methods.
The following treatments shall be applied:
a)
External surfaces
All steel surfaces shall be sand-blasted in accordance with DIN 55928 Part 4 (equivalent to SIS
055900), and shall then be painted in the following sequence:
two (2) primer coats:
Binder: epoxy resin hardened with polyamide
pigment: titanium dioxide, zinc oxide, zinc phosphate, tinting additives
one (1) intermediate coat:
Binder: epoxy resin hardened with polyamide
Pigment: titanium dioxide, micaous iron oxide, tinting additives
one (1) top coat (polyurethane base)
Binder: polyurethane hardened with isocyanate
Pigment: titanium dioxide, micaous iron oxide, tinting additives
Coating thickness
approx. 2 x 35 m
approx. 40 m
approx. 40 m
Total minimum 150 m
The final coat shall be of a non-glossy uniform shade of colour code RAL 7031 (silica-grey)
If hot-dip galvanised radiators, etc., will be provided the same painting method shall be applied,
however, instead of two primer coats one adhesive coat and one base coat shall be applied. In this
case, the mean thickness of galvanising shall be approx. 55 m.
Mechanical damage shall be repaired at site.
b)
Internal surfaces
Inside the transformer/ reactor vessel, sand-blasting shall be performed in accordance with DIN
55928 Part 4, (equivalent to SIS 055900). After that, a solvent free, oil resistant coating shall be
applied.
Internal paint shall correspond to RAL 9002, white or equivalent.
The minimum dry film thickness shall be 40 m.
4.4.17 Rating, diagram and property plates

The following plates shall be fixed to the transformer tank at an average height of 1,5 metres above
ground level in such a way that it can be viewed from outside the transformer foundation:
a.
A rating plate bearing the data specified in IEC 76 or IEC 289 as applicable. Rating under site
ambient conditions shall also be stated.
b.
A diagram plate showing the internal connections and the voltage vector relationship of the
several windings and in addition a plan view of the transformer giving the correct physical
relationship of the terminals. When links are provided for changing the transformer group
symbol and / or ratio, means shall be provided for clearly indicating the group symbol and / or
ratio for which the transformer is connected. The transformer ratio shall be indicated for each
tap.
Page: 34
c.
A plate showing the location and function of all valves and air release cocks or plugs. This
plate shall also warn the operator to refer to maintenance instructions before applying vacuum
treatment.
d.
Numbered plates for all valves, cocks etc.
e.
A plate showing all electrical circuits and terminal blocks. This plate shall be located at the
inner side of the hinged door of the marshalling kiosk.
f.
A plate showing over voltage withstand capability (voltage versus time) curve. This plate shall
be located at the inner side of the hinged door of the marshalling kiosk.
g.
A plate showing through fault withstand (current versus time) curve. This plate shall be located
at the inner side of the hinged door of the marshalling kiosk.
4.5
4.5.1 Electrical Controls

Each auxiliary motor shall have its own motor starter of adequate size, fitted with thermal and
magnetic over-current release.
The electrical and/or mechanical control and monitoring equipment shall be complete in every
respect, the associated equipment including contactors M.C.B.s and all auxiliary devices shall be
accommodated in the marshalling kiosk as specified.
(1)
Fan Units
Power supply for the motors or group of motors shall be from two sources with change over
facilities in case of failure of one source.
Loss of power shall be detected on all phases, alarm shall be provided to indicate loss of
supply.
Provisions shall be made to protect each fan motor individually
Motors or group of motors shall be automatically controlled by a relay combination considering

the winding temperature from both windings and the oil temperature for ON and OFF control.
Sequencing the starting order may be grouped according to ON and OFF command as issued
by winding or oil temperature.
Provisions shall be made for sequencing the starting order for individual groups.
A group alarm per transformer shall be initiated, if any fan units fails.
Fans running shall be indicated in the local control cubicle and in the Control room
Electrical isolation of each motor circuit to facilitate replacement or repair of individual units
shall be provided.
Change-over from automatic to manual control and vice-versa shall be provided.
(2)
On-Load Tap Changers

The manually operated gear shall be interlocked with the electric motor drive.
Page: 35
Manual operation (MVR) from the local control kiosk and from the remote operation control
room shall cause one tap movement only unless the control switch is returned to the off
position between successive operations.
Simultaneous control from different control points shall be prevented.
Mechanical position indication locally and suitable electrical impulse shall be initiated for digital
indication in the central control room.
An alarm to the remote control room shall be initiated, if a tap change is incomplete or in case
of any failure. Additionally the mode tap changer in operation, reached highest / lowest tap
position shall be indicated in the control room.
(3)
Automatic Voltage Regulator
Unit Step up Transformers (BAT) of the GT units shall be provided with an automatic voltage
regulator (AVR) for maintaining the voltage on the LV side within adjustable limits. The AVR is in
operation only if generator circuit breaker is in OFF position. Whenever 400 kV Unit breaker is
open, the tap position should automatically reach nominal position. Before starting the
synchronisation of the generator the AVR function for the OLTC has to be switched off
automatically. During the generator is running the generator AVR will be in operation, manual
control of the transformers OLTC will be in service.
It shall be possible to select following operation modes:
Local electrical non- automatic
Remote electrical non- automatic
Remote automatic
A digital type AVR of an approved design shall be provided. The set point voltage shall be
adjustable between 90 % and 110 %.
The sensitivity of the AVR shall be suitable for adjustment at any value between 0,5 % and 6 % of
the set point voltage.
A time delay adjustable between the limits of 10 and not less 180 seconds shall be provided. This
setting shall represent the maximum operating time, which shall be reduced automatically as a
function of the amplitude and duration of the voltage deviation.
Additional, the AVR shall be blocked if the energising voltage becomes too low or to high. The low
voltage blocking shall be adjustable between 70 % and 95 % and the high voltage between 105
and 130 %. Overvoltage detection with tap changer high speed return to actual set voltage shall be
incorporated.
For remote control and monitoring through the DCS specified in the relevant part all required
interface facilities shall be provided (Reference is made to Clause 11.4.6 Transformer Supervision
and Control, Item (3) Transformer voltage regulation of this specification).
4.5.2 Measuring and Monitoring

All equipment shall be wired up to terminal blocks inside the marshalling kiosk. The dial type
reading thermometers and thermostats shall be provided with contact units of the snap action type
rated for 250 V DC All contacts shall be adjustable to scale and shall be easily accessible on
removal of the cover. Reading thermometers shall be arranged inside or nearby the marshalling
kiosk. Alarm and tripping signals shall be announced in the control room.
The following minimum scope of equipment shall be supplied for each oil filled transformer:
Page: 36
One (1) double float Buchholz relay with two contacts and accessories, with sampling tap and
shut-off valves at both sides
One (1) oil flow relay for the on-load tap changer oil system, if any
One (1) surge pressure protection device with trip contacts for on-load tap changer
compartments, if any
One (1) contact assembly for mounting on the diaphragm of the tank pressure relief device
One (1) dial type, float operated, magnetic type oil level gauge with one low level normally
open contact for each oil system.
One (1) prismatic type oil level gauge for each oil system.
Temperature monitoring Unit Step Up and Unit Auxiliary Transformer
One (1) dial type mercury thermometer for measuring the oil temperature, with adjustable
contact assembly for ON / OFF control of cooling equipment
One (1) image coil for measuring the winding temperature, with:
one (1) local resistance type thermometer
one (1) transmitter for remote indication in the control room
means for checking and calibrating the thermal assembly by external devices
One (1) thermal monitor with two normally open contacts, for oil temperature and for
temperature alarm and tripping.
Temperature monitoring of 11 /0,4 kV transformers:
One (1) dial type mercury thermometer for measuring the oil temperature, with two normally
open contacts for temperature alarm and tripping.
All meters mounted locally on the transformer shall be visible and readable from ground level at the
entry of the transformer compound.
For dry type transformer supervision refer to Clause 4.7 Special requirements for dry type
transformers.
4.5.3 Marshalling Kiosk, Wiring and Conduits

As far as applicable a rigid, weather-proof marshalling kiosk (protection degree IP 65) shall be
provided for each transformer for accommodation of electrical control, measuring and monitoring
equipment, alarm circuits, M.C.B.s and current transformer secondaries. The cable arrangement
inside of the marshalling cabinet shall not be crowded. The spare wires shall be terminated
keeping always 20% spare available.
Electrical connections between sensors, current transformers, and all other accessories and the
marshalling kiosk shall be enclosed in metal raceways or conduits of ample size securely fastened
to the transformer tank to prevent mechanical damage or vibrations. Special measures shall be
taken to prevent such connection leads from heating up by the tank surface.
The marshalling kiosks shall be suitably designed to prevent the ingress of water and dust and
shall be provided with hygrostatically and thermostatically controlled heating elements to prevent
condensation of moisture. The kiosk or the junction box shall have a Protection Class rating of IP
65.
Page: 37
A gland plate with suitable fittings for entrance of multicore cables shall be provided, duly sealed or
plugged during transport. The kiosk shall be lighted by hand controlled fluorescent lamps.
An adequately sealed, hinged door shall be provided with locking facilities.
4.6
NEUTRAL EARTHING OF TRANSFORMERS
Transformer neutrals shall be earthed as detailed in the single line diagrams. The earthing resistor
requirements are defined in the Electrical Protection Specifications (Clause 12).
4.7
SPECIAL REQUIREMENTS FOR DRY TYPE TRANSFORMERS
As far as applicable, the transformer shall meet all requirements detailed in this Specification.
Class F insulation material shall be used with the windings impregnated and cast under vacuum
into moulds of glass fibre reinforced epoxy resin. The windings shall not absorb any humidity. The
insulation material shall be barely inflammable and self-extinguishing.
All iron parts, except the core, shall be hot dip galvanised. he core shall be protected by a resin
coat.
The transformer shall be free of partial discharge up to at least 120% rated voltage and shall be
short circuit proof.
The transformer shall be designed for natural air cooling and be housed in a steel sheet enclosure
of adequate mechanical strength and protection class IP 23.
The following measuring and monitoring devices shall be provided:
Six (6) resistance type temperature detectors (Pt 100, 4 wire type) inserted in the HV and LV
winding, for local temperature measuring
LV temperature monitoring by two (2) thermistor systems, one for warning and one for tripping.
4.8
TESTS
4.8.1 Workshop Tests

Each transformer and its related equipment shall be subjected to acceptance tests to be performed
at the Contractor's workshop in order to verify the conformity with the guaranteed and other design
data. Tests shall include the following measurements, evaluations, etc.:
For detailed tests refer to Part G 5.6 Inspection and Testing
a)
a.1)
a.2)
a.3)
Factory Tests
Routine Tests
Type Tests and Special Tests
Tests on Transformer Tank and Accessories
4.8.2 Tests on Site
Oil tightness test on tank at 0.3 bar over oil level, 24 hours (power transformers)
Measurement of voltage ratio at all tap positions
Check of vector group by voltmeter method
Impedance measurement
Tan delta measurement for unit step up transformers and unit auxiliary transformers
measurement of excitation current (at reduced voltage)
Page: 38
Measurement of winding resistances at all tap positions
Measurement of the winding insulation resistances (R15, R60, R180)
Measurement of the insulation resistance (R60) between the core and tank (power
transformers)
Measurement of the insulation resistances on auxiliary wiring at 1000 V, DC
Chemical analysis of the insulation oil
Measurement of the dielectric strength of the insulation oil
Re-calibration and current injection test on winding temperature indicators (45 min.) (power
transformers)
Functional test on cooling plant, including check of rotation direction of motors (power
transformers)
Functional tests on control and supervisory equipment
Functional tests on OLTC equipment (power transformers)
Visual checks.
MEDIUM VOLTAGE SWITCHGEAR
5.1
SCOPE OF WORKS
For the power supply of the gas turbine units, steam turbine units and common auxiliaries of L
Station Phase I, 11 kV switchgear shall be provided as indicated in the overall single line diagram.
The MV switchgear as specified below shall be installed in the dedicated electrical switchgear
rooms in the control building. The ratings are given in the relevant data sheets are tentative
requirements and refer to standard IEC conditions. The Contractor is obliged to scrutinise the final
data and the number of feeders with respect to his requirements for the complete installation and
to provide all feeders, as required, not making use of the spare feeders as detailed below.
Any information/event, i.e. ampere, volt, any pre-alarm, alarm trip generated within resp. by any
protection system, etc. shall be indicated locally, in the central control room and by the alarm/
event recording system of the plant. Respective alarm windows shall be installed on each panel.
Trip Circuit Supervision (TCS) devices shall be provided for all circuit breakers and for all vacuum
contactors. Operation of the TCS shall block closing operation of the respective feeder (for further
details refer to 4.2.3 Circuit breakers).
Under normal operation condition with all GTs in service the unit auxiliary transformers BBT shall
be connected to the designated unit boards to supply the related GT-, HRSGauxiliary loads, the
11 kV desalination-loads, further 11 kV Sub--distribution Boards (if required) and partly the 11 kV
station service board loads.
Each 11 kV Unit Board shall be divided in two sections (BBA and BBB), the sectional breaker
between these both sections will be normally closed.
Each section shall be connected via coupling breakers and cables to one section of both other 11
kV unit boards (11BBA 12BBB; 12BBA 13BBB; 13BBA 11BBB). These breakers are
normally opened.
Voltmeters shall be provided on all incomer and bus ties. Ammeters shall be provided for the
coupling breakers. All meters shall be selected that at rated conditions the deflection is about 80%.
Page: 39
In case of power failure at one unit board these couplings shall be closed via high speed change
over devices. In dependence on the operational state of the power plant the change over devices
will operate in different ways:
If all three Unit Auxiliary Transformers will be in operation, than the section breaker of the
failed unit will be opened and each 11 kV section of the failed unit will be supplied by one of
the remaining Unit Auxiliary transformers. After success full change over the change over
devices of the healthy 11 kV Unit auxiliary boards has to be blocked to avoid the overloading
of the Unit auxiliary Transformers in case of a further failure in an other GT Unit.
If only two GT Units and two Unit auxiliary transformers are in operation, the 11 kV unit switch
board of the failed GT Unit will be supplied by the Unit auxiliary transformer of the healthy GT
Unit. In this case the sectional breaker remains in its closed position.
(reference is made Single Line Diagram Station L Phase 1)

Two 11 kV Station Service Switchboards (0BBA and 0BBB) will be provided. Each Switchboard
shall have two incoming feeders connected to the 11 kV Unit Auxiliary Switchboards
1BBA 0BBA, 3BBA 0BBA
2BBA 0BBB, 3BBA 0BBB
and a coupling feeder to connect 0BBA and 0BBB.

In normal operation the coupling breaker will be opened and one of incoming feeder of 0BBA and
0BBB will be closed.
A pre-selection facility shall select the incoming feeder (for 0BBA: either from 1BBA or 3BBA; for
0BBB: either from 2BBA or from 3BBA), which will supply the Switchboard. High speed change
over device shall be provided.
In case of power failure of one source for supplying one incoming feeder the related bus coupler
shall be closed via this high speed change over device to provide power to the lost system. In
general 2 X 100 % systems shall be provided according to the design concept.
The power supply for the 5 desalination units shall be foreseen from the 11 kV GT unit boards
properly distributed to achieve an acceptable load balance and limited short circuit rations. If
required by the contractor of package D, further 11 kV Sub--distribution boards as for example sea
water pumping station, screening plant and others shall be connected to the 11 kV Unit boards
also.
The design of the 11 kV switchgear shall be as follows:
Metal clad design, in which the various functional compartments (circuit breaker/fused
contactor, busbar, cable connection, control and monitoring) are separated from one another
(bulkhead design *1)
Protection class IP 31 in air conditioned rooms and IP 52 in all other rooms
The switchgear design shall be in accordance to IEC 60 298 and arc fault proof accordingly
3 seconds short circuit fault withstand current resistant
Single busbar system with the necessary voltage transformers
Feeders with SF6 or vacuum type of circuit breakers, anti pumping device shall be provided
Motor feeders < 1 MW with vacuum contactor and HRC fuses, anti pumping device shall be
provided for the contactor
Page: 40
Motor feeders > 1 MW with vacuum or SF6 type of circuit breakers, anti pumping device shall
be provided
Current and voltage transformers as required
Earthing switch in each fully equipped cubicle
Each section of 11 kV switchgear to be provided with bus bar VT and voltmeter
Each interconnector / bus coupler to be provided with VT and voltmeter
Provided with over-voltage protection devices
Quick-acting type earthing switch fitted to the busbars *2
Cable paralleling arrangement in cable connection compartment with auxiliary busbar

systems, connecting bars and support structures together with a sufficient number of earthing
studs, for all feeders with more than two parallel cables per phase
Fireproof closure to the floor of the switchgear panels to seal the outgoing power cables
Monitoring and signalling equipment, mcbs for protection and voltage transformers, switch
position indicators, reporting and operating facilities, mimic diagram on the front of each panel
Control Voltage 110 V DC
Multifunctional digital relays as required
Energy meter (Wh and VARh, 3 phase, 4 wire) with pulse output to be provided with each
incoming feeder
Test sockets / test plugs to be provided for all protection and metering devices
Visible trip circuit isolation link to be available
Capacitor and assembly kit for capacitive voltage monitoring at each feeder to be provided
DCS interface facilities
Alarm windows
High speed change-over equipment *3
Humidity plus temperature controlled heating units within the switchgear panels shall be
provided
Multifunctional digital relays as required
Cable feeders to 11 kV substations located outside the Control building shall have overcurrent protection relays including earth-fault device and line differential protection.
Motor feeders shall have over-current protection relays including earth-fault function,
Large motors shall have in addition differential protection.
Cable feeders to 11/0.4 kV transformers shall have over-current protection relays

including earth-fault function.
All remaining 11 kV switchgear panels such as bus coupler and interconnectors shall be
equipped with over-current protection relays including earth-fault device.
Page: 41
Synchro-check relays shall be provided for the in-feeds, bus couplers and section breakers of
the related 11 kV boards.
The voltage transformers (VTs) shall be protected with mcbs, which shall be monitored.
Remarks:
*1 The individual cubicles are to be bulkheaded from one another by double sheet metal partitions
or approved equivalent system.
The busbar compartments must be bulkheaded from panel to panel by arc barriers. Within the
cubicles, the compartments for circuit breakers, busbars, instrument transformers and cable
connections as well as the relay recesses must be bulkheaded from one another.
Sufficient pressure relief must be provided in the case of fault arcs. For each bulkheaded
compartment a separate pressure relief must be provided. Care must be taken that in the event of
arcing no hot gases escape to the front of the cubicle (operational side).
The type test certificates shall be submitted as required by the engineer. Type test certificates
shall also prove that the switchgear supplied is able to withstand internal fault arcing in accordance
with IEC 60298, Annex AA, criterion 1 to 6.
*2 For earthing and short circuiting the busbars, fault making earthing switches are to be provided
on each section. The earthing switch shall be interlocked with the circuit breakers with the circuit
breakers of all feeders connected to the relevant switchgear section.
*3 To enable the infeed breaker of the switchgear to be operated for inspection purposes, the
automatic transfer system shall be disconnectable locally and remote. Therefor a local / remote
selector switch shall be provided.
Additional requirements:
Overvoltages/ spikes in motor feeders which may occur in the event of switching high voltage
motors by vacuum circuit breakers / contactors shall be prevented by suitable measures
(voltage limiters). These measures shall be explained by the bidder.
Each 11 kV board shall have 20% spare capacity for extension. Space for extension shall be
provided on one side of each board.
The contractor has to ensure that after commissioning at least 20 % of completely equipped
and fully installed spare terminal board capacity is available in each cubicle.
The requirements for the local metering (kWh, kVARh meters) has to be considered as defined
in this specification.
Remote control for circuit breakers / contactors shall be carried out from the Central Control
Room via DCS.
Installation
All the switchgear cubicles must be mounted on subframes specially provided for this
purpose. The subframes shall be delivered by the manufacturer at a reasonable time prior
to erection of the switchgear building.
Each of the 11 kV board shall be housed in separate rooms for fire protection purposes.
The panels are to be so arranged that they can be installed freely in the room.
The switchgear building shall be provided with a cable basement.
Page: 42
Breaker / contactor lifting and transportation carts shall be provided, at least each type, which are
needed for handling of different breaker / contactor type for each switchgear room.
Breakers / contactors of the same size shall be interchangeable from one cubicle to an other of the
same size.
Trip Circuit Supervision (TCS) is to be provided with all circuit breakers and all vacuum contactors.
Operation of the TCS shall block closing operation of the respective feeder.
5.1.1 11 kV Plant Switchgear

The following main 11 kV switchgear shall be provided:
One (1) 11 kV Unit Board for each GT
One (1) 11 kV Station Service Auxiliary board
If applicable and necessary, all other MV switchgear needed for the power plant for, eg.
Compressor Station, Gas Reducing Station
5.1.2 Busbar Interconnector and spare Feeders

The above described 11 kV Unit switchgear shall be in two sections or shall be two switchgear
interconnected by a 3-phase busbar system, as defined in the applicable Specification.
In each switchgear section, one (1) spare feeder shall be provided and completely equipped as
follows:
Busbars
Outgoing circuit breaker including earthing switch
Relay recess complete with mcbs, terminals fluorescent tube, etc.
Complete bulkheaded of the busbar compartment, circuit breaker compartment, cable

connection compartment and relay recess
Fireproof floor covering
Heating arrangements
Insertion contacts for circuit breaker with shuttering to prevent accidental contact
Cubicle door with mimic diagram, operating buttons, control switches, position and alarm
indicators, breaker operating counter, cut-outs for ammeters with clear plastic windows, etc.
Completely wired
The spare switchgear cubicles shall be so arranged that future installation of equipment (protection
relays, CTs) can be carried out without long disconnection duration.
5.2
5.2.1 General
The switchgear, switchboards and all other equipment related hereto shall comply as far as
applicable with General Technical Requirements, shall have rated insulation level, impulse
insulation ratings and one minute power frequency withstand voltage and minimum fault level as
mentioned below:
Nominal system voltage
kV
11
Page: 43
Highest system voltage
kV
12
Symmetrical short circuit current (r.m.s. Value)
kA
40 (50)* / 3 sec at 11 kV
Asymmetrical short circuit current (peak value)
kA
100 at 11 kV
Impulse withstand test voltage (peak value)
kV
75
Power frequency withstand test voltage (r.m.s. Value) kV
28
* Note: Short circuit ratio shall be verified by the Contractor according to the results of the short
circuit calculation. If necessary 50 kA class shall be provided.
During normal operation all incoming feeders shall be closed and the busbars couplers resp.
sectionalisers shall be open. Any internal fault shall be cleared quickly by detectors sensitive to light,
pressure, heat or by the differential bus bar protection system.
Current ratings specified for standardised products shall refer to 50C ambient temperature. Such
equipment, however, shall be selected with due regard to the environmental conditions at Site, i.e.,
if upon the increased ambient temperatures a deduction of the standard current rating becomes
necessary such deduction shall be restricted to such an amount that a margin of 10% is still
maintained ahead of the actual requirement. In all such cases the Contractor shall state the
permissible current ratings under severest site conditions.
All components including protection and control as required have to be supplied installed and
commissioned.
5.2.2 MV Switchboards
The MV switchboards shall be of the type-tested horizontal draw-out type.
Circuit breakers shall be mounted on withdrawable trucks. The circuit breakers shall be designed
for maximum ambient temperature. The number of types shall be reduced to a minimum,
considering interchange ability and maintenance. There shall be easy access to the rear of the
panels.
The design of the individual cubicles shall be such as to obtain segregated compartments as
defined in the General Technical Requirements.
Arc protection shall be provided for each compartment of the MV switchboards. These pressure
relief devices shall prevent creation of impermissible pressures during heavy switching operations
and failures causing danger to personnel and/ or destruction or deformation of the relevant cubicle.
In the switchgear room, devices featuring pressure release to the atmosphere shall be provided.
Mimic diagrams and local indications
A coloured mimic diagram is to be provided on the front of each switchgear cubicle with the
necessary graphical symbols, control switches, push buttons, indication lamps, etc. (colour
code for 11 kV level: Carmine red, RAL 3002, reference is made to Part G5.2 General
Requirements, Electrical Equipment Clause 1.2.5 Colour coding for mimic diagrams)
Tripping of MCBs for voltage transformer protection shall be a separate indication.
The colour scheme for the indication lamps shall be standardised within the plant and has to
be approved by the Employer
The position of the circuit breakers shall clearly be indicated, supervision of control wiring
health condition and lamp test is required.
Page: 44
All circuit breakers and contactors shall be equipped with a switching operation counter which are
to be installed in the relay recess or on the circuit breaker.
Power supply for control, supervision, alarm and protection for each bus section of each
switchgear shall be via separate wire buses, each of them double fed via decoupling diodes from
the relevant DC board section.
The 11 kV switchgear shall be remotely controlled and monitored by the DCS from the central
control room. All equipment as required for interfacing with the remote control system shall be
provided.
5.2.3 Circuit Breakers

The three-phase circuit breaker shall be of the vacuum or SF6 type and shall be in compliance with
IEC60056.
The drive system shall be supplied by the 110 V DC system. Manual operation must also be
provided. A suitable spring energy storage system shall ensure uniform and reliable closing.
In any case, a spring must be mounted for opening, since opening must be guaranteed even after
a failure of the auxiliary power supply system. If the energy storage system is not fully charged, the
closing operation shall be blocked.
The control of the breakers (and the contactors) is to be carried out with 110 V DC. The circuit
breakers shall be able to operate satisfactorily in the range of 110 to 70 % of nominal control
voltage.
Each circuit breaker or contactor shall be capable of being operated locally by means of CLOSE
and OPEN push buttons which are covered in normal operation. If the control voltage fails, the
EMERGENCY OPEN operation of the breakers shall be possible. It must be possible to close the
circuit breaker without control voltage (for maintenance reasons) and such a closing device shall
be provided with a pad locking facility to avoid closure of breaker during normal operation. In the
test position of the truck, the circuit breakers must also be capable of being operated locally and
also remotely from the Central Control Room.
Key operated Local/Remote and Test/Operate selector switches be provided to define the correct
mode of operation of circuit breakers/contactors at the switchgear.
In the event of a protective trip of the circuit breaker or contactor, means must be provided to
prevent reclosing which can only be resetted from the switchgear cubicle. In order to avoid
transformer damage, an inter-tripping circuit is to be provided which trips the corresponding 11 kV
and 0,4 kV circuit breaker in the switchgear installation being fed in.
Trip coil supervisory system shall be provided for all circuit breakers to monitor healthiness of the
trip coil while the circuit breaker in close/open state. Control circuit schema shall be designed in
such a manner, that the fault trip circuit shall disable the breaker from closing. Necessary alarm
indication at local and at Central Control Room shall also be provided.
Anti pumping devices shall be provided.
All circuit breakers shall have local operation counters.
Service hour metering of motor feeders shall be performed via the DCS.
5.2.4 High Speed Transfer Equipment

High speed transfer systems from one incoming feeder to the other incoming feeder shall be
provided as described above. During the site tests of the transfer system, which shall be carried
out by monitoring the current of the respective circuit.
Page: 45
The high speed transfer system shall be started as follows:
Manual (local or remote through the DCS)
Automatic by protection relay
Each high speed transfer system shall comprise the following:
Logical analyser for all required control, interlocking and monitoring functions
Phase comparison device for continuously monitoring the phase angle, frequency and voltage
Test facilities for testing the complete transfer system up to the up to the closing and trip coil of
the circuit breakers whilst the system is ready for operation
According to the electrical system the high speed transfer system hall operate as follows:
High speed transfer the opening and closing command issued at the same time
Residual voltage transfer the individual circuit breakers will be closed at a residual voltage
adjustable between 20 and 50% of the rated voltage
Long time transfer the circuit breakers are closed after an adjustable time which insures that
the residual voltage is lower as at the residual voltage transfer
If in case of an high speed transfer the relevant circuit breaker does not open, e.g. due to
mechanical failures, the already closed circuit breaker shall be tripped within an adjustable time.
The transfer shall be blocked in following cases:
Short circuit on the relevant busbar
Incoming circuit breaker not in service conditions ( withdrawn, spring not charged, etc.)
If the relevant circuit breaker fails to close
MCB trip
Voltage on the stand-by source is not available
Each high speed transfer system shall be installed in free standing cubicles with the required
control and monitoring equipment on the front door (e.g. remote local selector switch, test push
button, fault indicating light, etc.) The control voltage shall be 110 DC with double infeeds, diode
decoupling and voltage monitoring.
5.2.5 Instrument Transformer

The rating of each instrument transformer shall comply with the requirements as specified, in
particular as far as adequate accuracy, saturation factor, rated burden and insulation levels are
concerned.
Particular reference is made to the relevant Protection Specifications.
Current transformers shall be designed for continuous thermal current rating equal to the current
rating of the associated switchgear plus 20% over-load as well as for a short time current rating
corresponding to the relevant kA fault level of the circuit.
Current transformers shall not be mounted on the CB truck but in the fixed portion of the relevant
compartment.
Current transformers are capable of withstanding (without sustaining any damage) a open circuit
while carrying rated current in the primary winding.
Page: 46
Actual burdens to be matched with rated burden of all CT respectively cores of CT. Saturation
factor of metering cores / CT to be less than 5.
Potential transformers of the cast resin insulated, single phase type shall be provided for each
phase.
Voltage transformers are capable of withstanding (without sustaining any damage) a short circuit in
the secondary terminals for 1 sec.
VT s shall not get up saturated up 1.4 Unom . Chances of ferroresence in VTs are to be eliminated.
5.2.6 MV Metal Oxide Surge-Arresters

Silicone type surge arrestors of the metal oxide (Zn0) type and equipped with surge counters shall
be provided if required. The Contractor shall elaborate the necessary details under consideration of
the particular equipment to be provided.
The arrestors shall comply with IEC 60099-4, line discharge class 4. They shall be capable of
resealing against the maximum TOV.
The surge arrestors shall be built-up from hermetically sealed units, each containing valve resistor
blocks. They shall be provided with non linear characteristic but without spark gaps, designed to
limit the voltage on AC power circuits.
Internal components shall be designed to minimise corona.
5.2.7 Interlocks
Electrical ON/ OFF interlocks of incoming feeders, bus bar sectionalisers, couplers, transformer
feeders and outgoing feeders shall be realised in the relevant switchboards. Electrical interlocks of
motor feeders shall be realised in the relevant relay cubicles, respectively the automatic control
system.
The basic interlocking principles shall be as follows:
All incoming feeders of a switchboard or a section of such board shall be interlocked against
each other or against the bus sectionaliser or the bus coupler, if provided, so that each
individual or through-connected bus bar section can be fed by one power source only.
Change over of any MV bus bar section to another supply source via either a sectionaliser, a
coupling or an incoming feeder (either voluntary or due to a failure) shall be effected by a quick
transfer device described in the Electrical Protection and Control Specifications. (Make before
break)
Each transformer feeder shall be interlocked in such a manner that the LV circuit breaker can
not be closed unless the MV circuit breaker is closed. If the MV breaker is tripped manually or
automatically the LV breaker shall be tripped automatically in every case. The necessary
signals shall be made available for the LV panel.
11 kV transformer feeder shall trip, if LV breaker is drawn out to test position. Closing of 11 kV
breaker will be prevented, if downstream LV breaker is not racked into service position.
5.2.8 Feeder and Busbar Protection

The feeder protection relays as defined in the General Technical Requirements and the Electrical
Protection Specifications, shall be mounted into the LV/ control compartment of the MV switchgear.
Selectivity of the protection system must be ensured to prevent any unnecessary tripping of a
breaker.
Arc protection shall be provided for each compartment.
Page: 47
5.2.9 Earthing Switches or Devices

Each incoming feeder, the busbars and each outgoing feeder shall be equipped with a hand
operated earthing switch.
An interlock shall be provided to enable closing only if the relevant MV circuit breaker is in the
draw-out position and the remote feeding circuit breakers are open. Moreover, it shall not be
possible to draw-in a circuit breaker truck when the earthing switch is closed.
5.3
LIST OF SWITCHBOARD COMPONENTS
According to its denomination, each individual switchboard compartment shall contain the following
main equipment (all remaining equipment as MCBs, terminals, etc. are to be included):
5.3.1 Incoming Feeders
One (1) circuit breaker, complete with control devices
One (1) earthing switch
Three (3) multi-core current transformers for measuring, metering and protection
Three (3) single-phase potential transformers
Three (3) ammeters
One (1) voltmeter with selector switch
One (1) watt hour meter, connected to the measuring CT, provided with test socket / test plug
One (1) var hour meter, connected to the measuring CT, provided with test socket / test plug
Protection relays as specified, provided with test socket / test plug
Alarm windows
Transducers 4-20 mA for remote measuring.
5.3.2 Bus Bar Sectionalisers and Coupling Feeders
Three (3) multi-core current transformers for measuring and protection
Alarm windows,
Three (3) ammeters
Transducers 4-20 mA for remote measuring
5.3.3 Outgoing Cable and Transformer Feeders
Transformer feeders: One (1) zero sequence CT (earth fault protection not to be connected to
residual branch of phase CTs), provided with test socket / test plug
Page: 48
Three (3) ammeters
Alarm windows
5.3.4 Motor Feeders
One (1) zero sequence CT (earth fault protection not to be connected to residual branch of
phase CTs),
Three (3) ammeters
Alarm windows
5.3.5 Measuring Cubicle
One (1) busbar earthing switch
Three (3) single phase potential transformers
Alarm windows
Transducers 4-20 mA for remote measuring
5.3.6 Control Voltage supply, remote control and Bus bar undervoltage monitoring
The control voltage shall be made available at least twice for each switchgear section in the
measuring cubicle. The contractor has to provide a diode decoupling of the control voltages; the
voltage shall be monitored.
The decoupled control voltage has to be permanently wired from panel to panel in a ring
connection.
Separate identified DC buses / wiring for control, protection and alarm shall be run all along the
panels.
In each panel, the control voltage is to be safeguarded by miniature circuit breakers and the
tripping of these is to be indicated locally. A further potential free set of MCB auxiliary contacts is
to be wired as a group signal to the Central Control Room.
The circuit breakers / contactors of the switchgear installations are also to be remotely controlled
from the Central Control Room through the DCS specified in the relevant part. Therefor the
required interface facilities are to be provided.
Page: 49
In each measuring cubicle an undervoltage monitoring device is to be provided for monitoring the
busbar voltage. The activation value of the monitoring device must be variable from 50 to 100 %
voltage and the delay time shall be variable from 0,5 to 15 seconds. This equipment is necessary
for the defined disconnection and reconnection of the high voltage motors - in the case of failure of
the busbar voltage - by the DCS.
5.3.7 Remote indications

The following remote indications shall be provided:
Breaker / Contactor truck not available for operation (in test position or not run in as a group
signal)
Earthing switch ON
Earthing switch OFF
Circuit breaker / contactor ON
Circuit breaker / contactor OFF
Circuit breaker / contactor tripped through fault
Miniature circuit breaker tripped (as a group signal)
No control voltage (as a group signal)
Protection activated (as a group signal)
No busbar voltage
Voltage transformer MCB tripped (as a group signal)
Trip coil / trip circuit fault (as a group signal)
5.4
TESTS

At least the following tests shall be performed in the manufacturer's workshop on the individual
apparatus and on the complete installation, respectively, all in accordance with IEC-Standards:
Visual inspection
Power frequency HV tests
Dielectric tests of the auxiliary circuits
Measurement of the main contacts resistance with dc
Temperature rise test on circuit breakers (type test certificate)
Test of mechanical endurance (type test certificate)
Measurement of the contact opening period (type test certificate)
Functional tests of the control circuits
Check of the operational sequence
Measurement of the instrument transformer's angle and ratio errors (according to

IEC-standards 60044 and 60186)
Page: 50
Check of the denominations.
5.4.2 Tests at site

The complete installation shall be tested at site as follows:
Dielectric test
Visual inspection
Contact resistance / torque test of bus bar joints
CTs, VTs ratio, magnetization characteristic and burden measurement
HV test
Mechanical functioning test
Test of the functional sequence
Testing of all interlocks
Testing of all protection relays and circuits by primary / secondary injection and functional tests
of the arc protection
Testing of high speed transfer systems
Testing of all alarms (local and remote)
LV POWER DISTRIBUTION SYSTEM
6.1
SCOPE OF WORKS
All switchgear and boards, i.e. main distribution boards, sub-distribution boards, MCCs, etc., as
required for the whole plant shall be supplied, installed and commissioned. The final number of
boards, feeders, etc., as well as the required capacities and assembly shall be defined by the
Contractor according to the requirements of equipment of his scope of Works. Reference is made
to the overall single line diagram, which is indicative only of the philosophy of the overall design.
The following shall be noted:
To match with the existing Jebel Ali LV installations the voltage level is 380 V AC and not 400 V
as required by IEC 60038.
For each GTG/STG Unit and all other electrical plant components of Package P the following LV
switchgear shall be provided:
all necessary main distributions
all necessary sub-distributions
key box/tool box inside every switchgear room
6.1.1 380 V AC System

The 380 V switchgear shall be of indoor installation design metalclad, bulkheaded type utilising the
plug-in principle with separate busbar and switching unit compartments and common cable
compartments. The short circuit fault withstand current design shall be for 1 second and the
protection class shall be at least IP 31 in air conditioned rooms and IP 52 in all other rooms.
Page: 51
The switchgear shall be equipped each with a single busbar system at the rear or top of the
panels. All switchgear shall be of the single row design. All main and coupling circuit breakers shall
be of the 4-pole type design for total isolation of the busbars. This is due to safety reasons in case
of a shut down and major maintenance works of the entire switchboard.
All low voltage main distributions shall be supplied by 2 X 100% transformers and shall be divided
into half-bars. A coupling circuit breaker shall be provided to connect both halfbars. During
normal operation this coupling breaker will be open and the incoming feeders will be closed. One
automatic change-over device shall be provided.
The half-bars shall be divided in two sections. The so known essential loads, which have to be
supplied by the emergency diesel generators in case of grid failures, shall be connected to this
section, which can be supplied from the 380 V emergency distribution board.
All necessary facilities, devices and interlocks to carry out automatic functions as change over to
emergency supply and change back to normal supply shall be provided in all 380 V Boards. (Refer
also to drawing 11 kV / 380 V Station Service Supply, drwg. no. CNE/0152002-W-00-E-D-00101
and to Part P2.10 Black Start / Emergency Power Supply of this specification)
The above mentioned basic LV main switchgear arrangement philosophy shall be valid for all other
main systems.
The individual plug-in units of the switchboards and distributions shall contain beside the switching
devices ( circuit breakers, MCBs, fused contactors / motor starters, fused load switches, etc.), the
necessary control and monitoring / protection relays, DCS interface facilities as well as the
necessary instruments. Control switches and signal lamps shall be mounted on the front panel.
The circuit breakers shall be provided with 110 V DC motor driven stored energy mechanism. The
circuit breaker panels shall also contain:
The relay recess with the protection (if not integrated into the circuit breaker unit) and
supervisory relays, complete terminal arrangements, meters, etc.
A mimic diagram on the front of each cubicle with circuit breaker position indicator, indication
lamps and operating buttons
Local and remote facilities
The connection compartment with current and voltage transformers, earthing facilities, cable
connections, etc.
Each switchgear section shall be supplied with busbar earthing facilities.

For cabling purposes a man-accessible cable basement or raised floor system shall be provided
below the switchgear rooms.
.Test kit for secondary injection test of protection relays of adequate rating to be provided.
6.1.2 Direct Current (DC) and Uninterruptible Power Supply (UPS)

The DC and UPS systems are important systems for reliable and safe operation of the plant as
well as the emergency facilities and special care has to be taken to ensure the availability and
reliability of its components.
The DC and safe AC distributions shall be designed as metal clad switchboards of similar design
as above mentioned LV switchgear with permanently mounted devices and all necessary signalling
and control accessories.
The following independent DC and safe AC systems, each with 2 X 100% capacity, shall be
provided.
Page: 52
110 V DC system for control of the switchgear
220 V DC for essential drives, infeed to the inverters of the UPS system and DC/DC converter
for 24 V DC system
24 V DC system for instrumentation and control
220 V safe AC system for instrumentation and control
220 V safe AC for emergency lighting
The 24V, 110 V DC and 220 V DC systems shall be connected to the 0.4 kV essential service
sections of the LV boards in the relevant building/area via rectifiers (2 X 100%).
For the power supply of 220 V safe AC consumers, 2 X 100% inverters shall be provided. A static
change-over switch shall be connected to each inverter feeder from the essential section of the
related 0.4 kV board.
6.2
6.2.1 General
The switchgear, boards and all other equipment related hereto shall meet the General Technical
Requirements, as specified.
A single failure shall not lead to a plant shut down. Double infeed shall be provided accordingly.
The allocation of auxiliaries to different sections of each busbar and the interconnections between
different boards shall be selected to achieve maximum plant availability and reliability.
The rated insulation level and power frequency withstand voltages shall be in accordance with
General Technical Requirements.
Current ratings for standardised products refer to IEC conditions with 50C ambient temperature.
Such equipment, however, shall be selected with due regard to the environmental conditions at
Site and cubicle design/ arrangement, i.e. if upon the increased ambient temperature a deduction
of the standard current rating becomes necessary such deduction shall be restricted to such an
amount that a margin of 10% is still maintained ahead of the actual circuit requirement. In all such
cases the Contractor shall state the permissible current ratings for both, IEC and site conditions.
The Contractor is obliged to submit a load evaluation for each individual switchboard and the entire
plant.
The fault current requirements of the individual distribution boards and components shall be
calculated by the contractor on basis of the design data of components under consideration of the
maximum acceptable tolerances of components according to standards.
Regarding inner lightning protection and transient over-voltage protection, particular reference is
made to the General Technical Requirements and the Lightning Protection Specifications.
6.2.2 Switchgear Assembly

The switchgear assemblies shall be designed as defined in the General Technical Requirements
and shall be type tested in accordance with IEC 60 439 and IEC 60947. The switchgear shall be a
type tested assembly (TTA) according to IEC 60439-1 form 4.
The individual board compartments shall be such as to obtain different zones fully insulated from
each other, namely:
the switchgear compartment
Page: 53
the busbar section compartment

the power and control cable compartment
Special means shall be provided for connection of the busbar systems between transformers and
boards as applicable.
6.2.3 Instrument Transformers

The completely enclosed, dry cast resin type instrument transformers shall be designed in
accordance with General Technical Requirements.
6.2.4 Remote Indication and Control

All electrical measuring systems requiring remote indicators in the control room shall be equipped
with transmitters, etc., as required.
All interfaces as required for remote control shall be provided.
6.2.5 Voltage Monitoring

The following voltage monitoring relays shall be provided in the measuring section of each bus
section of each:
LV/ AC Busbar Voltage Monitoring: Definite time delayed, three-phase undervoltage relay (27),
adjustable in steps.
DC Busbar Voltage Monitoring Instantaneous undervoltage relay (27) adjustable in steps.
6.2.6 Space Compartments

Each board, except the Main Unit and Main Common Distribution Boards shall be provided with
5% at least one, empty compartments of each outgoing feeder type completely wired as spare.
The main connection to the busbar and the outgoing side shall be completed except the withdrawal
parts. Such compartments shall be closed by steel panels/ doors.
6.2.7 Spare Feeders

At least 10% of the allocated cabinet units shall be provided as reserve cubicles for each main
switchgear and distribution.
The spare units shall be complete equipped except the withdrawable parts and fitted as follows:
With main connection to switchgear busbar and outgoing feeder terminals
with selection of sheet metal partitions
with busbar shutters
with the necessary doors and proportion of bulkheads
with arc protection covering
with heating
6.2.8 Terminal Boxes and Subsidiary Distributions

Field installed intermediate or collective terminal boxes as well as subsidiary distributions
comprising collective power and control circuits for electrically operated dampers, valves, etc. shall
be of the totally insulated type tested box type, with transparent cover and with protection class
IP55.
Page: 54
6.2.9 Interlocks
Electrical ON/ OFF interlocks of incoming feeders, transformer feeders, bus sectionalisers and
coupling feeders shall be realised in the relevant boards. Electrical interlocks of motor and valve
feeders involved in the main process functions of the plant shall be effected in relay cubicles,
respectively by the control system
The basic interlocking principles for the power supply systems are listed below:
All incoming feeders of a board or a section of such board shall be interlocked against each
other and against the bus coupler or bus sectionaliser, if provided, so that each distribution
board or section thereof shall be fed by one power source only.
Paralleling of infeeds of important boards being provided with two infeeds and/ or with bus
sectionaliser shall be possible for a few seconds if synchronism is ensured. In such case one
of the two relevant LV infeed circuit breakers shall be subsequently automatically tripped after
a pre-set period.
Tripping of protection device in one of two feeder circuits of any double fed switchboard (for
example tripping by transformer feeder protection, transformer pressure relief device or oil
temperature protection, but not the LV incomer protection) shall automatically trip the faulty
circuit and close the second feeder circuit (provided its feeding breaker is closed) via the
second LV incoming breaker or the bus sectionaliser, whatever is applicable.
Operational switching off of any infeed shall not actuate the second infeed. Manual changeover initiation shall be realised by a separate change-over switch.
Each transformer feeder shall be interlocked that the LV circuit breaker cannot be closed
unless the HV/MV circuit breaker is closed, and if the latter is tripped manually or automatically
the former shall also be tripped automatically.
Local control facilities are specified in the General Technical Specifications.
6.3
LIST OF SWITCHBOARD COMPONENTS
According to its allocation, each individual feeder respectively board-section shall contain the
subsequently specified main equipment.
If transmitters for remote indication are specified, the related remote instruments shall be provided
as well.
All interfaces as required for the remote control/ alarm/ event recording systems shall be provided.
6.3.1 AC Incoming Feeder, Bus Sectionaliser and Bus-coupling Feeder
Circuit breaker
Protection / AC Incoming feeders
Three (3) current transformer for protection,
One (1) Three phase over current protection including an earth fault element (connected
to the zero sequence CT at LV star point earthing) provided with test socket / test plug
Protection / Bus sectionaliser and bus coupling feeders
Three (3) current transformer for protection, if not incorporated in circuit breakers
Electromagnetic and thermal over-current release, with
Synchro check relay with test socket /test plug
Page: 55
control devices for local and remote control
Three (3) current transformers for measuring
Three (3) ammeters
One (1) Wh meter (3 phase, 4 wire) with pulse output without test socket/ test plug (incoming
feeders only)
One (1) VARh meter (3 phase, 4 wire) with pulse output without test socket/ test plug
(incoming feeders only)
Alarm windows
One (1) current transmitter for remote indication (for main boards fed by transformer only)
The above specified protection for incoming feeders will only be required for transformer incoming
feeders. Incoming feeder breakers of boards fed from the main distribution may be provided
without protection.
6.3.2 AC Outgoing Feeder to Individual Auxiliaries
One (1) circuit breaker with electromagnetic and thermal over-current release
One (1) current transformer for feeders rated 63 A and above
One (1) ammeter for feeders rated 63 A and above
Alarm windows
One (1) current transmitter for remote indication if required for process control.
For ratings of 25 A and below the above circuit breakers may be replaced by m.c.b. with electromagnetic and thermal over-current releases, if the fault capacity without additional pre-fuse will be
adequate.
6.3.3 AC Outgoing Feeder to Boards/Sub-distribution Boards

One (1) load switch with fuse or current limiting circuit breaker with electromagnetic and thermal
over-current release
In case that fuses as defined in the General Technical Requirements will be used, any fuse trip
shall inter-trip the downstream incoming circuit breaker.
6.3.4 AC Motor Feeders
According to the General Technical Requirements.
6.3.5 AC Valve Feeder
Three (3) fuses with load switch or current limiting CB.
Two (2) contactors
One (1) thermal overload protection device
Alarm window
Page: 56
6.3.6 AC Measuring Section
Three (3) primary fuses
Three (3) potential transformers
Three (3) secondary miniature circuit breakers
One (1) 3 phase voltage monitoring relay (27) (under voltage protection) provided with test
socket / test plug
Alarm window
One (1) voltage transmitter for remote indication (for transformer fed boards only)
6.3.7 DC Incoming/Coupling Feeder
One (1) circuit breaker with electromagnetic and thermal over-current release or fused load
break switch with key interlock
Alarm windows
One (1) shunt
One (1) ammeter
DC transmitters for remote indication (main distributions only)
One (1) voltmeter
One (1) C.T. for earth fault detection (main distributions only)
6.3.8 DC Motor Feeder
One (1) fused load break switch
One (1) main contactor with thermal over-current release
Alarm windows
One (1) starting resistor with start-up contactor combination
One (1) shunt
One (1) ammeter
Space for hook on CTs for earth fault detection
6.3.9 DC Outgoing Feeder to Boards
One (1) fused load break switch
One (1) shunt
One (1) ammeter
One (1) CT for earth fault detection
Page: 57
6.3.10 DC Outgoing Feeder to Individual Auxiliaries

One (1) m.c.b. with electromagnetic and thermal over-current release, if necessary with
individual or collective fuses
Space for hook on CTs for earth fault detection
6.3.11 Safe AC Outgoing Feeder

One (1) MCB with electro-magnetic and thermal over-current protection
6.3.12 DC Measuring Section
One (1) miniature circuit breaker
One (1) voltage monitoring relay (27)
One (1) voltmeter
One (1) DC voltage transmitter
One (1) earth fault monitoring device (64) with all required accessories (main boards only)
Alarm windows
One (1) lot injection and measuring facilities for selective e/f detection
6.3.13 Selective Earth Fault Detection System

The entire DC systems shall be equipped with a combination of fixed mounted and portable
detection systems to allow for easy and quick detec tion of any faulty DC feeder within the
unearthed DC systems. The detection system shall be based on a low frequency injection system
which shall become operational as soon as an earth fault is detected by the monitoring device (64).
6.4
TESTS
6.4.1 Workshop Test

In addition to the type tests for which certificates shall be submitted, at least the following tests
shall be performed in the manufacturer's workshop on the individual apparatus and on the
complete installation, respectively, all in accordance with IEC Standards:
Visual inspection
Power frequency HV tests at main circuit
Dielectric tests of the auxiliary and control circuits
Functional test of the control circuits
Check of the operational sequence
6.4.2 Tests at Site

The complete switchgear and the individual apparatus shall be tested on site as follows:
Visual inspection
Dielectric test
Contact resistance / torque test of bus bar joints
Page: 58
CTs, VTs ratio, magnetisation characteristic and burden measurement
Testing of all interlocks
Setting and testing of all protection relays and circuits by primary / secondary injection. Test kit
of adequate rating to be provided
Testing of automatic change over devices
Testing of all alarms (local and remote)
Functional test
Test of the functional sequence
Setting and functional test of protection devices (primary injection method). However, test plugs
and socket facilities for secondary injection tests shall also be made available. Tests kits of
adequate ratings shall be made available for the tests.
7
7.1
CHARGERS, BATTERIES AND INVERTERS

SCOPE OF WORKS
General
The DC and safe AC system shall serve all essential consumers of the plant as well as the
emergency features and special care has to be taken to ensure the availability and reliability of its
switchgear.
The DC and safe AC distributions shall be designed as metal-clad switchboards of similar type to
the low voltage AC switchgear except with fixed mounted equipment and all necessary switchover, signalling and control accessories.
All batteries, chargers and inverters/UPS systems shall be preferably from one manufacturer and
type.
All DC switchgear shall be from one manufacturer and type, which shall be the manufacturer of the
low voltage switchgear.
All switchboards fed with power from these DC installations shall be provided with duplicate DC
supply as required.
Based on Single Line Diagram, refer to drawing. No. CNE/015/2002-W-00-E-D-00100 the below
mentioned equipment shall be supplied, installed in the Compartments/Central Control Building
and commissioned. Final capacities of equipment shall be defined by the Contractor under
consideration of the requirements of the plant. Respective calculations shall be submitted for
approval.
The following independent DC and safe AC systems, each with 2 X 100% capacity shall be
provided:
220 V DC system for essential drives, inverters for safe AC systems, DC/DC converters,
emergency lighting, etc.
110 V DC systems for switchgear control
24 V DC system for I&C
220 V safe AC systems for I&C
Page: 59
220 V safe AC system for emergency (essential) lighting
The 220 V system, 110 V and 24 V systems shall be fed from the 380 V essential sections via
rectifiers and lead acid batteries.
(2 X 100%), each rectifier shall be sized to serve all the connected consumers and to charge one
battery.
The rectifiers shall be installed in closed steel sheet cubicles.
For the supply of 220 V safe AC consumers separate UPS systems shall be provided for all I&C
equipment and for emergency lighting.
2 X 100% inverters shall be provided to feed the 220 V safe AC distribution boards.
Static changeover switches (ATS) shall be installed for each inverter, which shall be supplied from
the 380/220 V essential section.
The capacity of all DC and safe AC equipment shall be in accordance with the power requirement.
A minimum of 20 % spare capacity shall be provided.
7.2
The 24, 110 and 220 V, DC and safe AC main distributions shall be provided as indoor switchgear
installation of metal clad, bulk-headed type, fixed mounted principle and single copper busbar at
the rear or top. In general the specification and construction requirements specified for low voltage
AC switchgear, shall apply for safe AC and DC switchgear also. The rectifiers and inverters are to
be arranged in sheet steel cubicles, which are to be matched to the distributions in respect of
height and other dimensions.
The rectifiers, inverters and converters should be designed preferably for operation with natural
cooling. If air-cooling is required, then 2 x 100% air fans with monitoring, control and alarm signal
must be provided.
The design shall take into consideration that in case of a power supply loss to a DC bus, power
back feeding through the UPS system shall be prevented.
Loads connected on the DC bus shall be protected under all operating conditions. However, DC
power supply to the emergency i.e. DC lube oil pumps of the turbines shall be assured under all
circumstances.
The 220 V DC system comprising one sectionalised main distribution, 2 X 100% rectifiers and 2 X
100% batteries shall be provided to supply for a period of 3 hours
(1 hour on one battery only), under conditions of loss of AC supplies the following loads:
a)
Emergency and essential lighting
b)
Essential drives (including 220 V safe AC) to shut-down the plant
c)
Each rectifier shall be designed for a capacity to supply the consumers and
to charge the connected battery set at the same time.

The infeeds and bus-couplers of the main 220 V DC distribution are to be provided with circuit
breakers equipped with motor driven stored energy mechanism.
The infeeds from the batteries are to be taken via isolating fuses to busbars for interconnection
with the rectifier, and from there to the infeed circuit breakers. Position and alarm indication shall
be provided in the Central Control Room for fuse links and circuit breakers.
Page: 60
For the 110 V, DC system the given design criteria for the 220V, DC system shall also apply.
The emergency duty of the 110 V, DC system shall be as follows:.
The 110 V, DC system comprising one sectionalised main distribution, 2x100% batteries and
2x100% rectifiers shall be provided to supply the following loads:
a)
Intermittent loads comprising power for circuit-breaker and contactor tripping and low power
closing (closing release) after the full period and superimposed on the continuous loads
specified below.
b) Supplies for turbine governor and Generator excitation control as appropriate for a period of 3
hours (1 hour with one battery only)
c) Miscellaneous loads for control, protection, and indication for the period 3 hours (1 hour with
one battery only).
For the 24 V, DC system the given design criteria for the 220V, DC system shall also apply.
Each 24 V DC system comprising one sectionalised main distribution, 2 X 100% rectifiers and 2 X
100% batteries shall be provided to supply for a period of 3 hours (1 hour on one battery only),
under conditions of loss of AC supplies the following loads:
a. Control and instrumentation equipment supplies
b. Alarm annunciation systems
c. Private automatic Telephone exchange
d. Paging system.
e. Miscellaneous loads for control, protection, and indication
The DC consumers shall be supplied from each bus bar section via 2 X 100% cable connections,
which shall be decoupled by diodes in the consumer cubicles.
The 220 V safe AC distribution shall be fed by 2 X 100% inverter with electronic change-over
device. Unrestricted parallel operation of two units shall be possible.
The infeed of the main 220 V safe AC distribution shall be effected via circuit-breakers. The
outgoing circuits in the safe AC main distributions shall be equipped with moulded case circuit
breakers (MCCBs) and contactors, mini-circuit breakers, etc.
7.2.1 Chargers
The chargers shall be designed to supply all connectable DC consumers and simultaneously the
demand for trickle charging of the batteries. The capacities shall be proved by calculations, subject
to approval of the Engineer.
The charger shall be short circuit proof at their output terminals.
Voltage ripple factor and current ripple factor (if any) to be available in the nameplate.
Each charger shall be accommodated in a cubicle with all control and protection devices. It shall
include incoming circuit breaker, transformers, fused thyristor rectifiers, control equipment, including voltage and current limiting devices with adjusting means, voltage regulator, outgoing feeders
to the battery and to the DC distribution board. It shall be ensured that rectifier trip does not affect
the battery supply of the relevant board.
The trickle charging process shall be effected by a constant voltage/ constant current (IU)
characteristic.
The constant voltage value shall be adjustable according to the requirements of the proposed
battery and the resulting charging current shall decrease with increasing battery capacity.
The constant current value shall be limited as required by the proposed, discharged battery
until the adjusted constant voltage value of the battery is reached.
Page: 61
Change over between I and U characteristic and vice versa shall be fully automatic whereby
the voltage set point shall be adjustable. Manual initiation shall also be possible.
For initial resp. boost charging of a battery, the DC distribution shall be disconnected and shall be
fed from the second battery/ charger system only. Boost charging shall be manually initiated and
automatically controlled thereafter.
The boost charging process shall be effected by an IUI - characteristic. After reaching the set
maximum battery charging voltage for a set time, change over to the normal IU characteristic shall
be performed. The relevant current, voltage and time data shall be adjustable according to the
requirements of the proposed battery.
In any case the voltage at the DC distribution busbar shall not exceed 1.1 p.u. at any trickle
charging condition and shall not become less than 0.9 p.u. at the design discharge end voltage of
a battery. The load voltage control devices shall be designed accordingly.
Alternatively to a load voltage control system the battery capacity and charge/ discharge end
voltage may be selected in such a way that additional voltage control facilities to keep within the
specified voltage range may not be required.
The recharging time of the battery after having reached the design discharge end voltage up to full
capacity shall not exceed 10 hours.
The feeding transformers shall be of the dry type with off-circuit tapping at the primary windings.
The rectifiers shall be of the thyristor controlled type and smoothing chokes shall be provided to
decrease the voltage ripple factor.
Each battery charger cubicle shall furthermore contain the following instruments and control
devices:
One (1) AC ammeter
One (1) DC ammeter for rectifier current
One (1) DC ammeter for battery current (+)
One (1) DC voltmeter for the battery
One (1) hand/automatic selector switch
One (1) lot control push buttons for charging process control
One (1) lot reference voltage adjusters for each charging characteristic
One (1) lot reference current adjusters for each charging characteristic
Signal lamps for alarm indication
One (1) DC high and low voltage monitoring device
One (1) DC earth fault monitoring device
One (1) rectifier output monitoring device
Set control devices as required to perform the specified operation modes
All individual alarms shall be indicated locally. Group alarms to the remote control system shall be
provided.
Page: 62
7.2.2 Batteries
For the DC systems, the Contractor shall supply maintenance free lead acid batteries or equivalent
supply systems with a life expectancy of 20 years or more. The batteries selected shall be of
Heavy Duty type "H".
The batteries shall be sized such that with each (1 x 100%) battery supplying the total load, the
battery shall have sufficient capacity to supply the above load for a period of at least one (1) hour,
however with 2 x 1 00% batteries in service serving the total load the capacity shall last for three
(3) hours. It shall also be guaranteed and proved by the Contractor that the cell voltage of each cell
in the battery system will not fall below.
1.8 V at the end of the above three hours period and that this voltage corresponds to the minimum
permissible voltage at the consumer terminals taking into consideration the voltage drop on cables.
Each battery capacity shall be 20% in excess of that required to achieve the specified emergency
discharge duty.
The intercell connections should be fully insulated. Welded intercell connections are not permitted.
The batteries shall be mounted on insulated subframes with the necessary consoles and fixing
material.
Dependent on the batteries size and location / size of the battery room all ventilation /air condition
/explosion proof conditions shall be considered in the offer and co-ordinated with the civil part of
this specification.
Maximum tolerable voltage and current ripple that the battery can withstand without sacrifice of
service life shall be mentioned in the offer. In the same way the expected degradation of life time at
operation with higher site temperature shall be stated.
Recommendation to carry out periodic discharge test in service life of the batteries and disposal
recommendation for a damaged battery shall be included in the offer.
The batteries should have a guarantee for proper function of at least 10 years after provisional
taking over.
The following facilities are to be provided for each battery room:
one (1) cell testing voltmeter
one (1) instruction card
one (1) battery earth fault locator
two (2) hydrometers
two (2) cell handling facilities (where batteries are mounted on more than one tier)
two (2) sets of protective clothing including eye glasses
one (1) record book for each battery
two (2) electrolyte level indicators when opaque cell boxes are provided.
Equivalent NiCd type of batteries shall be offered as an option. It will be decided during detailed
design stage which battery type (lead acid or NiCd) will be applied.
7.2.3 Battery Fuse Box

Each battery shall be protected by a lockable and electrically supervised fused load break switch.
The device shall be installed close to but outside the battery room into a totally insulated box.
Page: 63
7.2.4 Inverters with electronic change-over equipment

In order to be able to maintain an emergency supply in the event of network and machine failure,
for the dedicated systems inverters with electronic change-over equipment shall be provided. The
inverters are fed directly from the 220 V DC maim distribution and the change-over units from each
half busbar of the related 0.4 kV AC boards. For maintenance purposes a manual by-pass
designed as "emergency link" is to be provided. Each inverter shall supply 100% of the total load
required. In the event of failure of one inverter unit the second one shall be capable to meet the
total power demand.
The following loads shall basically be supplied from the safe AC busbars:
recorders
boiler flame monitors
emergency gate valves
event recorder
computer
fault printer
important actuators
Each static inverter must be suitable for 100% power or the power demand and plus 20% spare
capacity.
In addition, the Contractor shall provide the following devices for the
individual AC inverters:
radio interference suppression according to the appropriate IEC publications
local alarm lamp indication mounted on the front of the inverter
cubicle, shall be provided for the conditions of:
-inverter DC input voltage
low
-inverter output frequency
high and low
-inverter output voltage
high and low
-inverter output voltage
failed
-thyristor temperature
high
-cooling fan
failed
-over-current protection
activated
On activation of the above devices, switch-over to power supply from the AC bus shall occur.
The fault alarms are to be combined by the Contractor as a collective alarm - INVERTER FAULTand wired to the Central Control Room.
The inverters are to be protected on the input and output sides and are to be equipped with the
necessary isolating points. It must be possible to block the inverters on the input side in the case of
high rate battery charging or they shall be so designed that no damage will occur during this phase
of charging.
Page: 64
All the necessary control switches, measuring instruments etc. shall be installed in the front of the
cubicles.
Each inverter is to be equipped with a selector switch with positions: off-system operation - parallel
operation (bypass) - inverter operation.
In case one of the 2 X 100% inverters trips or is out of operation, the load must be taken over by
the second unit. The voltage dip on the safe bar shall not exceed 10%. The voltage dips must have
been corrected within 60 msec.
Each inverter shall be able to withstand without damage a short circuit at its output terminals.
In case of a short circuit at a consumer on the safe bar, the voltage tolerances in this case, should
also not be exceeded.
An electronic change-over device with network selection cubicle and transformer (if required) shall
be provided for the inverters and shall enable automatic, uninterrupted, synchronous switch-over to
the consumer busbar in the event of total inverter failure. For maintenance purposes a manual bypass switch shall be provided additionally. The network selection cubicle must be connected with
the 0.4 kV main switchgear.
All the switch-over procedures which are activated by the automatic system in the case of faults,
are to be so designed that they can also be carried out or locked manually.
The switch-over equipment provided is to be equipped with thyristor switches, control electronics
and a check-out system. The check-out system must make it possible to test the correct
functioning of the unit without disturbing the operation of the consumers.
The inverters and electronic change-over equipment of one supply system are to be installed in
common, steel-enclosed cubicles with front and rear doors of the same type as the DC main
distributions.
In the electronic change-over equipment in each case a selector switch is to be provided for the
change-over "Normal Operation - check-out". In the check-out" position, all fault criteria which lead
to activation of the change-over equipment can be simulated by button operation. The fault
condition leading to the change-over must be indicated by a signal lamp.
7.3
TESTS
Chargers and batteries shall be tested together in the factory. All factory tests to be repeated at
site.
7.3.1 Chargers
Visual inspection (to be repeated on site)
Functional tests (to be repeated on site)
Heat run (type test)
Output voltage stability measured for 25% load steps
Ripple voltage measurement without connected battery
Ripple measurement (voltage and current) with connected battery
Insulation test (to be repeated on site).
7.3.2 Batteries
Insulation test (to be repeated on site)
Charge test and discharge tests
Page: 65
7.3.3 Fuse Box
Functional tests (on site)
Insulation test (on site).
7.3.4 Inverters
Functional tests (to be repeated on site)
Heat run (type test)
Insulation test (to be repeated on site).
LIGHTING AND SMALL POWER
8.1
GENERAL
Description
This specification covers the rating, design, equipment requirements, supply, installation inspection
and testing of complete Lighting and Small Power for the Jebel Ali Station L Phase I Power Plant
Package.
All materials and equipment shall be provided as to ensure complete, properly functioning
installation and shall conform to the highest standards of engineering design and workmanship.
The number of suppliers shall not exceed two suppliers and the suppliers shall have an agency in
the UAE. In order to facilitate the approval of the material / equipment, samples of material /
equipment intended to be installed shall be provided to the Employer / Engineer.
The design and installation of lighting and small power shall be based on the following
Regulations/Standards.
Regulations relating to Electrical Installations in or about buildings in DUBAI
Regulations for Electrical Installations, as issued by the Institution of Electrical Engineers,

London, U.K. (IEE)
The Code for Interior lighting, as issued by the Chartered Institution of Building Services
Engineers (CIBSE) London, U.K.
IEC Standards as applicable
Local laws, rules and regulations including those of Statutory Authorities
Other Standards as detailed in the specification text.
Materials, workmanship and tests shall conform to the following Standards and Codes of Practice:
IEC 60364-5-54
Electrical installations of buildings:
Earthing arrangements and protective conductors
IEC 60064
Tungsten filament lamps for domestic and similar lighting purposes
Page: 66
BS 546
BS 1363
BS 5649
(BS 1840)
IEC 60598
(BS 4533)
BS 4533
IEC 60081
(BS 1853)
IEC 60920/60921
IEC 61195
IEC 61199
IEC 60929
IEC 60924
IEC 60188
(BS 3677)
IEC 60662
IEC 60898
IEC 60432
BS 4568
IEC 60922
IEC 60947
IEC 60502
IEC 60502-1

Two-pole and earthing-pin plugs, socket outlets and socket adapters
for circuits up to 250 V
Specification for 13 A fused plugs, switched and unswitched socket
outlet and boxes
Lighting columns
Luminaries
Luminaries
Part 101: Specification for general requirements and tests
Part 102: Particular requirements
Double-capped fluorescent lamps
Ballast for tubular fluorescent lamps
Double capped fluorescent lamps safety specification
Single capped fluorescent lamps safety specification
AC supplied electronic ballast for tubular fluorescent lamps
DC supplied electronic ballast for tubular fluorescent lamps
High-pressure mercury vapor lamps
High-pressure sodium vapor lamps
Electrical accessories Circuit breakers for overcurrent protection for
household and similar installations
Conduits for electrical purposes
Steel conduit and fittings with threads of ISO form for electrical
installations
Part 1: Steel conduit, bends and couplers
Part 2: Fittings and components
Auxiliary lamps Ballast for discharge lamps
(excluding ballast for tubular fluorescent lamps)
Low voltage and control gear
Power cables with extruded insulation and their accessories for rated
voltages from 1 to 30 kV
Power cables with extruded insulation and their accessories for rated
voltages from 1kV (Um=1.2kV) up to 30kV (Um=36kV)-
8.1.1 Main technical data

The lighting and small power distribution boards shall be rated 220/380 V, 50 Hz. Supplies shall be
taken from the related LV boards for normal lighting and socket outlet systems, from the 220 V
safe AC supply for essential lighting and from the 220 V DC system for emergency lighting.
Local distribution boards shall be constructed in form of separate panels:
One panel to feed all normal lighting circuits
One panel to feed all essential lighting circuits
One panel to feed all emergency lighting circuits
One panel to feed all ac socket outlet circuits.
The panel for normal lighting, essential lighting and emergency lighting shall be equipped with:
Four-pole incoming circuit breaker with residual current protection two-pole incoming circuit
breaker with residual current protection (220 V safe AC)
Page: 67
Two-pole incoming circuit breaker with earth fault monitoring alarm only for infeeds to the
emergency lighting panels (220 V DC)
Three-pole outgoing circuit breakers
Two-pole outgoing circuit breaker (220 V DC)
One-pole outgoing circuit breakers
Three-phase busbar system
Neutral bar
Earthing bar
Push-button, contactors, auxiliary relays, time relays, etc. As necessary.
The panel for socket outlet shall be equipped with:
Four-pole incoming circuit breaker
Four-pole outgoing residual current circuit breakers
Two-pole outgoing residual current circuit breakers
Three-pole outgoing circuit breakers
One-pole outgoing circuit breakers
Three-phase busbar system
Neutral bar
Earthing bar
Each panel shall be equipped with 20% spare feeders.

All equipment for lighting and small power system shall be suitable for 50C ambient temperature
and 100% humidity.
8.2
LAYOUT
The lighting and small power shall cover the whole area where the buildings and equipment
provided under this Contract shall be located.
8.3
SCOPE OF WORKS AND SERVICES
The lighting and small power systems are including but not limited to:
distribution and sub-distribution boards
cables
conduit and conduit accessories
cable trunking
socket outlets and plugs
lighting fittings
steel columns for street lighting
Page: 68
lighting switches
earthing and bonding
complete detail labelling of all installations
special tools and equipment for maintenance, inspection and repair
all standard equipment and accessories which are normally included in the supply schedule
but which are not separately listed
additional lighting and small power which is necessary for the safe operation and night-time
essential maintenance
detail design and calculations
training, inspection and supervision services by Contractor
spare parts
complete documentation as specified, etc.
8.4
EQUIPMENT REQUIREMENTS
8.4.1 General
Wiring systems for the control rooms, offices, electric equipment rooms and similar buildings, shall
be flush fitted installations. In all other areas circuits and cables shall be installed in surfacemounted galvanised steel conduits or trunking.
All fixings shall be of a type approved by the Engineer and all metalwork used in surface
installations shall be galvanised. Fixing to structural steelworks shall be with purpose-made
brackets or clamps. Drilling of structural steelworks will not be permitted.
Switches and push-buttons for lighting circuits shall be mounted 1400 mm above finished floor
level. Socket outlets shall be mounted 400 mm above finished floor level but those for use with
work benches shall be mounted 150 mm clear of the bench working surface. All lighting switches
shall be of a minimum 16 A rating with a 50% derating factor applied for fluorescent lighting loads.
Lighting fittings shall be attached to ceilings, walls, trunking or roof
steelworks or suspended therefrom as appropriate.
Final connections to all suspended lighting fittings shall be with heat resistant flexible cable
terminated in heat resisting connectors in the ceiling or junction box which shall also terminate the
main circuit cable. The cable length shall be such that the suspension unit supports the full weight
of the lighting fittings.
Where lighting fittings are mounted direct on walls or ceilings the main circuit cables may be
connected into the fitting terminal block provided that the cables are routed to avoid heat
generating components of the fitting. Where terminal blocks do not exist within the lighting fitting
flexible heat-resistant cable shall be used connected to a separate junction box.
8.4.2 Distribution boards

The distribution boards and all component parts shall be manufactured and tested in accordance
with IEC 60947 and be capable of withstanding without damage the mechanical and electrical
stresses set up by any fault current for twice the period required to disconnect such fault on any
circuit.
Page: 69
Each distribution board shall have a dustproof metal case of sheet steel with an enamelled finish
and shall have hinged doors complete with gasket seal with push-button handle incorporating a
cylinder type lock. The colour of the enamel finish shall match the colour of other switchgear. The
metal casing shall be provided with a gland plate for cable entry corresponding to the circuit
capacity of the distribution board and a suitable screened brass earthing stud.
Degree of protection shall be as follows:
IP 31 Indoors only in totally closed rooms
IP 52 Indoor, except as noted otherwise
IPW 55 Outdoors and indoors in areas subject to water spray or heavy
conditions.
Each current carrying component shall be so designed that under continuous rated full load
conditions in the climatic conditions at site the maximum total temperatures permitted under the
relevant Standards are not exceeded.
All normal and essential lighting distribution boards require residual current protection on the
incoming supply with tripping sensitivity 300 mA.
Outgoing circuits for socket outlets require residual current protection with tripping sensitivity
30 mA and air conditioning equipment with 100 mA.
Where a distribution board feeds critical equipment individual residual current protection shall be
used to avoid loss of all power supplies. The cables feeding the distribution boards shall be
connected directly to the incoming isolator or neutral bar as appropriate unless indicated otherwise
in the specification.
Neutral bars shall have an appropriate number of ways relative to the size of the board. The
neutral connection for each circuit preferably be isolating link type instead of direct connection.
The metal surface adjacent to any live part and all spaces between phases shall be protected by
barriers of fireproof insulation material.
The distribution boards for AC shall be either 3P+N+E or P+N+E types quipped with MCB, MCCBs
or RCCBs to provide overcurrent and short circuit protection to each circuit. MCBS, MCCBs or
RCCBs shall be removable without exposing live connections.
Protective devices on AC installations shall break the phase conductors only.
The 220 V DC distribution boards shall be L+, L-, PE type and equipped with MCBs or MCBs as
required.
Fuse bases and bridges where used shall be of an approved non-hygroscopic insulation suitable
for the receipt of HRC fuses.
The current rating of the busbars in each distribution board shall not be less than the sum of
maximum current rating of all outgoing circuits. The neutral connection for each circuit is to be
direct to the neutral busbar.
MCBs connected on the incoming side of a distribution board shall be mechanically attached to
the board with solid copper electrical connections between the units. A suitable insulated barrier
shall be supplied to prevent copper or carbon dust released under fault conditions passing from
one unit to the other.
Approved type labels shall be fitted externally on the front cover of each distribution board giving
details of the points controlled by each circuit. The circuit list shall be typed or printed stating the
location of the equipment served, rating of the protective unit and the circuit loading. The lists shall
Page: 70
be mounted on the inside of the cover door and shall be protected by an acrylic sheet slid into a
frame over the circuit list, the list and cover to be easily removable to permit circuit modifications.
Mixed capacity boards shall be employed and all contactors and time switches associated with the
respective outgoing circuits shall be accommodated within the distribution board.
8.4.2.1 Main switches

Air break switches, disconnectors and MCBs shall be used as appropriate. They shall be designed
and rated in accordance with IEC 60947 and IEC 60898 as appropriate for expected symmetrical
fault rating and shall be capable of breaking rated load current.
Interlocking shall be provided to prevent access to the interior of the unit unless in the off position.
Padlocking facilities shall be provided to enable the device to be locked in the off position and also
where applicable in the earth or test positions.
The position of contacts shall be externally visible. Alternatively, positively linked externally visible
mechanical indication for the on, off and where applicable, earth positions may be provided subject
to details having been submitted and approved.
Fuse switches and switch fuses may be used only with the approval of the Engineer.
8.4.2.2 Miniature and moulded case circuit breakers

All moulded case circuit breakers (MCCBs) and miniature circuit breakers (MCBs) shall be
constructed to BSEN 60898.
Circuit breakers shall be of the high-speed fault limiting, thermal/magnetic type with quick-make
and quick-break trip free mechanisms which prevent the breaker being held-in against overloads of
faults.
Tripping arrangements shall ensure simultaneous opening of all phases. Residual current circuit
breakers (RCCBs) Residual current circuit breakers shall be of the sensitivity given in the relevant
sections. They shall comply generally with the requirements of IEC 60947-2 and shall be of the
four-pole type or two-pole type as appropriate.
Where RCCB's are mounted remote from distribution boards. They shall be complete with a
suitably sized all insulated robust enclosure having entries for conduit or armoured cable glands
and a lift up transparent flap for access to controls and test facilities.
An ON/OFF operating switch and a test push-button shall be provided on each RCCB. Terminals
shall be suitable for the size and type of cable being installed.
Every RCCB shall be thoroughly tested by the Contractor and its operation proved to the
satisfaction of the Engineer.
8.4.2.3 Residual current circuit breakers (RCCBs)

Residual current circuit breakers shall be of the sensitivity given in the relevant sections. They shall
comply generally with the requirements of IEC 60947-2 and shall be of the four-pole type or twopole type as appropriate.
Where RCCB's are mounted remote from distribution boards. They shall be complete with a
suitably sized all insulated robust enclosure having entries for conduit or armoured cable glands
and a lift up transparent flap for access to controls and test facilities.
An ON/OFF operating switch and a test push-button shall be provided on each RCCB. Terminals
shall be suitable for the size and type of cable being installed.
Page: 71
Every RCCB shall be thoroughly tested by the Contractor and its operation proved to the
satisfaction of the Engineer.
8.4.2.4 Contactors
Contactors shall comply with IEC 60947, and shall be of the electrically held-in types contained in
heavy gauge sheet steel cases suitable for panel mounting. Each contactor shall be continuously
rated and suitable for thirty inductive switching operations per hour having utilisation categories
AC4 or DC4 as applicable.
Any changeover contactor for the emergency lighting shall be of the gravity or spring assisted
platform type where under supply failure conditions the coil would be de-energised and the main
contacts closed on to the standby supply.
8.4.3 Cables
8.4.3.1 General
The cables for indoor lighting and socket systems installed between distribution boards and final
connections shall be:
PVC or XLPE insulated -1, 3 and 4 cores with separate earth conductor Copper conductor - PVC
sheathed - 0.6/1 kV PVC or XLPE heat resistant (85C) insulated Single core - Copper conductor
(wire type) - 450/750 V EPR or silicon rubber insulated and sheathed flexible cable - 3 cores
(P+N+E) - Flexible copper conductor - 300/500 V for pendant cords of final connections to fixed
apparatus and shall be installed in:
cable trays and/or cable trunking
galvanised steel conduit (surface and flush installation).
The cables for outdoor lighting and socket systems installed between distribution boards and final
connections and all cables up to distribution boards shall be PVC or XLPE insulated 1, 3 or 4 cores
with earth conductor separate, steel wire armoured, copper conductor, PVC sheathed and
0.6/1 kV.
Fire resistant cables shall be utilised for essential and emergency lighting. The cables shall be
suitably protected if laid directly in the ground. All cables shall include a neutral conductor and an
earth continuity conductor. The cores of all cables shall be identified in accordance with IEE
regulations. All cables used for lighting and small power shall have copper conductors.
All cables shall be protected from direct sunlight.
The Contractor shall select conductor sizes for the respective final circuits to meet the
following conditions: the minimum conductor size for lighting and socket outlets circuits is 2.5
mm
the size is adequate for the current to be carried as set out in the cable manufacturers
specification taking account of the site ambient temperature
the size is sufficient to keep the voltage drop in the phase and neutral conductor to the farthest
lighting or power point under normal full load conditions to the final circuit limit specified in the
IEE Wiring Regulations. Diversity will not be allowed.
Outer sheath for all cables shall be flame retardant type to IEC 60332 standards.
Through wiring in luminaries will require the Engineer's approval and will be permitted only if it is
fixed clear of the control gear in the luminaries or if this is not possible high temperature wiring
shall be used. All holes through luminaries for through wiring shall be bushed and an insulated 2.5
mm 2 earth wire shall be run between all luminaries.
Page: 72
Cables shall run at least 150 mm clear of all plumbing and mechanical services. The space factor
for cables shall not exceed 40%. The method of Installation of buried cables shall be as specified
in the relevant Part of this specification - Cables and cable support system.
8.4.3.2 Cable terminations

Terminations for armoured cables shall comprise compression type of gland with armour and
bonding clamps to meet the requirements of type E1 to BS 6121 or equivalent and shall be
designed to secure the armour wires, to provide electrical continuity between the armour and the
threaded fixing component of the gland and to provide watertight seals between the cable outer
sheath and gland and between the inner sheath and threaded fixing component. The glands shall
project at least 10 mm above the gland plate to avoid moisture collecting in the cable crutch.
Shrouds shall be fitted to cable glands where exposed.
Earth bond terminal attachments shall be provided.
Terminations for non-armoured cables shall comprise compression type glands where the function
of the gland is to secure the outer sheath of the cable, in accordance with the requirements of type
A2 to BS 6121 or equivalent. A watertight seal shall be provided between the outer sheath and the
gland.
Conductors shall not be wrapped around stud terminals.
Only one cable shall be terminated in each gland.
8.4.3.3 Wiring to luminaries

Wiring to all luminaries shall be non-hydroscopic and heat resisting.
Circuit wiring in lighting trunking shall be looped into flexible terminal blocks suitable for the
temperature at which they will operate.
Circuit wiring in conduit shall terminate in connector blocks in conduit boxes to which the
luminaries are connected or plug in ceiling roses in false ceiling areas.
No single lighting circuit or luminary shall be supplied by more than a single phase i.e. different
phases shall not be mixed.
8.4.4 Conduit
8.4.5 General
All conduits and conduit fittings shall comply with IEC 60423, IEC 60614, BS 4568.
Open conduit systems will also be acceptable for indoor installation.
For outdoor installation, closed systems shall be provided.
Special attention to be paid for selection of materials for conduits, trunking junction boxes, panels
and cable trays in view of the highly corrosive environment especially in boiler, desalination plants,
water treatment plants and equipment located nearer to sea side.
8.4.5.1 Installation
Prior to erection all burrs and sharp edges shall be removed from the conduit together with any dirt
oil or paint which may be present. Bushes for use with conduits may be rubber, PVC or brass.
Corners shall be turned by means of hand-made bends or where this is impracticable by means of
conduit boxes. Factory-made bends, tees and elbows and inspection tees and elbows where
applicable shall not be used without approval.
Page: 73
Conduits, boxes and accessories comprising a circuit shall be erected, before any wires in such
circuit are drawn in.
Conduits necessarily exposed to the weather during building operation shall be protected against
ingress of moisture either by means of suitable brass stops or other means as the Engineer may
direct, and have their threads coated with petroleum jelly. Blockages occurring in conduits shall be
cleared. Conduits shall be swabbed through before commencing wiring.
Rusting of steel conduits occurring during building construction shall be removed with abrasive
paper and the conduit repainted.
Conduits shall not be installed in contact with plumbing and mechanical services, a minimum
separation distance of 150 mm being maintained wherever possible.
Conduits shall be so arranged that it is impossible for water from condensation or other sources to
lodge at any point. When this is not practicable, drain holes of 3 mm diameter shall be drilled at
the lowest points in the conduit runs of boxes or at any other points required by the Engineer.
In conduit runs containing cables of size up to and including 4 mm2 a standard draw-in box shall be
included at approximately 8 m to 10 m intervals. For cables of size above 4 mm2 suitably sized
adaptable boxes shall be installed in lieu of draw-in boxes to facilitate easy withdrawal of cables.
Conduit runs between draw-in boxes or adaptable boxes shall contain not more than two right
angle bends.
Where conduits terminate at distribution boards, adaptable boxes, switch and socket outlets, etc.,
the connection shall be made by means of a socket screwed on to the end of the conduit and a
smooth bore brass male threaded bush.
Surface conduits shall be made to harmonise as far as practicable with the architectural features of
the building. They shall be run only in vertical and horizontal directions except where it is desirable
to follow the line of a constructional feature, in which case approval shall be obtained.
In multiple runs crossing of conduits will not be permitted. Where a surface conduit turns through a
wall, a back outlet box shall be provided.
On flush installations conduit running from ceiling or roof positions to positions on walls shall be
connected by a solid coupling 300 mm below ceiling level.
Conduits shall be installed in wall chases and ceiling voids in such a manner that inspection and
draw boxes are accessible. Draw boxes shall not be fixed in plastered walls unless specified.
Extension rings shall be fitted to sunk conduit boxes to which lighting fittings or pull switches are to
be attached, if the distance between the conduit box and the finished ceiling or wall surface
exceeds 10 mm.
Boxes shall be erected so as to recess approximately 2 mm below the finished wall or ceiling
surface and in order that this requirement is met the finished thickness of all walls and ceilings
shall be verified on site.
On flush installations conduits running vertically on walls shall protrude at least 50 mm into the roof
space or floor void where applicable.
Conduits shall be installed in floor screed only when it is particularly specified and care shall be
taken to ensure that runs do not foul the position of any door spring boxes or other services.
Before any screed is laid the conduit shall be checked for rigidity and mechanical damage.
Page: 74
Cables conduits and ducts, which terminate in buildings shall be sealed with a permanently plastic
weatherproof sealing compound in conjunction with hardwood bushes to prevent the ingress of
water, foreign matter and vermin. Any spare conduits and ducts shall be similarly sealed.
Cables under roads shall be rum in conduits of either PVC or vitrified clay having a plastic sleeve
to form a push fit joint. The conduit shall have a minimum diameter of 100 mm, bends to suit the
cables and extend 1 meter on either side of the road. Conduit mechanical protection shall be
provided where necessary appropriate number, but not < 20% of spare conduits -shall be provided
at the road crossings.
Surface conduits shall be securely fixed to the building fabric by means of distance saddles to give
not less than 6 mm clearance between the conduit and the walls.
Steel conduits shall be supported at regular intervals not exceeding 1.2 m and the distance from
either side of any box or bend to the nearest saddle shall not be more than 150 mm.
Saddles and distance pieces shall have the same finish as the conduit for which they are to be
used, be single-way or multi-way as required and be fixed by means of screws in metal or other
approved plugs. Wood or fibre plugs shall not be used.
Conduit boxes to which lighting fittings are to be attached shall be fixed by substantial screws so
that the weight of lighting fittings will not be carried by the conduit.
Conduit runs in suspended ceilings shall be fixed to the building structure and not to the ceiling.
Where ceilings are fixed and the ceiling void is inaccessible after completion the outlet boxes on
the ceiling shall be supported from the structure.
Where ceilings are of the demountable tile type and capable of supporting module light fittings, the
outlet box for the light fitting shall be fixed to the structure with a cable connection from the outlet
box to the light fitting via 3-pin plug-in ceiling rose. Where the light fitting is not of the module type,
the outlet box shall be brought to the ceiling surface in the same manner as that for a fixed ceiling.
All boxes for other apparatus such as sockets and ceiling switches shall be supported as specified
for a fixed ceiling.
Conduit buried in plaster shall be fixed by crampets or equal and installed to allow a minimum
depth of plaster of 10 mm over its entire length.
8.4.5.2 Flexible conduit

Flexible conduit shall be used for the final connection of rigid conduit systems to the terminal boxes
of machines and to semi-portable equipment where a limited amount of movement is required for
cleaning and maintenance purposes.
Flexible conduit shall be watertight and oil-tight flexible metal conduit having an overall PVC sheath
complying with BS 731 - Part 1.
Earth continuity shall be maintained by means of a separate stranded earth conductor of not less
then 2.5 mm2 and generally equal to the live conductor and terminating at the first box on the
conduit system The earth wire shall be attached to the box at each end by means of a sweated or
compression socket, screw and spring washers.
8.4.6 Cable trunking

Trunking systems shall be designed and installed in accordance with good practice using the
relevant sections of the IEE regulations and manufacturer's recommendations. The finish of all
accessories shall match the trunking finish in all instances, irrespective of whether the trunking is
exposed to view or flush with the building fabric.
Page: 75
Trunking shall be sized with correct space factor for the total number of circuits involved plus 25%
spare capacity for future usage.
Trunking may be fixed direct to the building fabric or to the purpose-made bracket work dependent
on local requirements. Whichever method of installation is employed, trunking shall be installed in
the level and true in all axes and secured using round- headed fixing devices. Under no
circumstances shall fixing devices having a countersunk or similar sharp edged profile be used
within cable trunking.
Wherever possible, changes of direction or level in trunking shall be achieved using bends, tees or
similar accessories available from the trunking manufacturer. Gusset bends and tees shall be used
wherever possible in preference to ninety degree elbows and tee-offs to eliminate strain on cables.
Where site-manufactured bends or sets are unavoidable they shall be made by operatives skilled
in the handling of the materials involved. The resulting bend must allow the passage of cables
without damage or distortion and be painted to match the original finish of the trunking. Wherever
trunking passes through walls or floors which are to be made-up to their original thickness, a length
of trunking lid projecting 100 mm either side of the wall or floor shall be attached to the trunking
following its installation. A suitable draw-wire shall be provided in the trunking if deemed necessary
to facilitate subsequent Installation of cables.
Internal fire barriers shall be provided within trunking wherever they pass through fire
compartmented walls or floors. Barriers shall consist of fire stopping material approved by the local
Fire Prevention Officer and be installed for the full thickness of the wall or floor plus 100 mm on
either side of the same.
Cables shall be installed neatly within the trunking and retained where necessary using nonflammable cable retainers. Under no circumstances shall timber be used for this purpose or any
timber left in the trunking once the lids have been fixed.
Steel trunking shall comply with BS 4678 Part 1 and shall be hot-dip galvanised to Class 3 or
external graded trunking to IP 55 as specified elsewhere.
Trunking shall be constructed of substantial sheet metal not less than 1.6 mm thick with welded
joints and shall be provided with a removable cover.
The cover shall be flanged at the edges and shall be of the same size as the casing. Any trunking
used for the interconnection of switchgear, distribution boards, etc., shall be of a pattern of which
the lid does not overlap the sides of the trunking.
Where unprotected cables leave the trunking suitable bushings shall be provided.
Copper bonding links shall be fitted between all lengths of trunking, couplings, bends, etc., and
shall be located on the outer face and be visible prior to the final decoration.
For vertical runs of trunking the cables shall be supported at not less than 2.5 m intervals by
means of pin racks or other approved means.
Where conduits enter trunking flanged conduit sockets shall be used to terminate the conduit into
the trunking.
Due allowance shall be made for the expansion of long installed lengths of trunking.
All couplings, flanges, bends and tee pieces, etc., shall be formed from fabricated units designed
for the trunking specified.
Care shall be taken to ensure that. cables are not bent through a radius less then allowed by BS
7671 for the particular cable concerned. The maximum number of cables installed in any trunking
shall be such that a space factor of 40% is not exceeded.
Page: 76
Where trunking is to be routed external to the building, external graded trunking to IP 65 shall be
installed. Where the trunking is routed within plant rooms it shall be galvanised to Class 3
protection.
Where trunking is installed with the lid facing downwards and also where required on runs with the
lid on the side, cable retainers shall be fitted in the trunking at centres not exceeding 1 m. There
shall be no sharp projections inside the Trunking.
Where cables of different services are run in the same trunking, separate compartments shall be
provided in the trunking to provide segregation of the services where required by the current
edition of the IEE Wiring Regulations.
8.4.7 Socket outlets and plugs

8.4.7.1 General
A system of switch socket outlets shall be installed throughout all buildings and shelters, main
equipment as GTs, HRSGs, Desalination Units, etc. to provide power for office equipment and
portable tools.
The Contractor shall supply and install and test all power outlets, conduit,
trunking and accessories to form a complete power installation.
These outlets shall be:
125A, 380V AC 3-phase, neutral and earth IEC 60309 socket outlets for oil-filled transformer
bay areas -for connection to the mobile oil purification plant and other areas where similar
mobile equipment will be required. The Contractor shall check this against the actual oil purifier
being supplied.
63A, 380V AC 3-phase, neutral and earth IEC 60309 socket outlets in all plant areas for
connection to portable welding equipment
13A, 220V AC single-phase, neutral and earth BS 1363 socket outlets for general use as in
offices, control rooms, maintenance areas, etc.
All sockets installed in the plant areas and workshops shall be of the industrial type. The contractor
shall supply matching plugs for all types. The quantity of matching plugs shall be equal to the
number of plugs +20%.
Installation and/or samples of all socket outlets and plugs which the Contractor propose to
purchase shall be submitted to the Engineer for approval before using any suborders.
8.4.7.2 Socket outlets for oil-filled transformers

125A socket outlets are to be provided in oil-filled transformer areas for the connection of a mobile
oil purification plant. The socket outlets shall be located so that the mobile oil purification plant can
be positioned in front of each transformer bay using a maximum cable length of 20 meters.
125 A socket outlets are to be provided also in areas if similar mobile equipment will be required.
The socket outlets shall incorporate a load disconnector switch and a residual current protection
device rated at 30 mA including MCB.
The socket outlets shall be metal-clad to IPW 55, weatherproof and incorporate a spring return flap
cover.
The plug and socket shall be interlocked such as that the unit cannot be switched on until the
matching plug is fully inserted, nor can the plug be withdrawn with the switch closed.
Each unit shall be provided with the following:
facility for incoming supply cable looping and
provision for padlocking the switch in the off position.
Page: 77
8.4.7.3 Welding outlets

The Contractor shall supply and install welding socket outlets complete with matching plugs at
strategic points located on a normal 50 meter grid so that all parts of the plant supplied can be
reached using a maximum cable length of 35 meters.
Socket outlets shall be 380V, 63A, 3 phase, neutral and earth to IEC 60309. They shall
incorporate a load disconnector switch and a residual current protection device rated at 30 mA
including MCB.
The socket outlets shall be metal-clad to IPW 55, weatherproof and incorporate spring-return flap
cover.
The plug and socket shall be interlocked such that the unit cannot be switched on until the
matching plug is fully inserted, nor can the plug be withdrawn with the switch closed.
Each unit shall be provided with the following:
facility for incoming supply cable looping, and
provision for padlocking the switch in the off position.
8.4.7.4 13 A socket outlets

Socket outlets for offices, control rooms, and other similar areas shall comply with BS 1363, for use
with three-pin fused 13 amp plugs on a 220 V AC supply.
All BS 1363 socket outlets shall be fed via Residual Current Circuit Devices (RCCB). They shall
have a tripping sensitivity of 30 mA and a maximum operating time of 30 ms.
BS 1363 socket outlets shall be of a flush fitting pattern where the wiring installation is concealed.
In general the wiring installation for socket outlets and lighting shall be kept separate except where
run in common trunking.
2-gang socket outlets shall be installed in a density of one per 10 m and a minimum of 2 per room.
8.4.7.5 Portable safety transformers for handlamps

The Contractor shall supply ten portable safety transformers for handlamps and twenty handlamps,
each with 30 m extension cable. All handlamps shall be rated for 24 V AC service. The
transformation ratio shall be 220/24 V single-phase and the rated output 500 VA.
Transformers shall be of heavy-duty construction with encapsulated windings, enclosed in a steel
case. The steel case shall incorporate two metalclad 24 V socket outlets to IEC 60309. An
extension lead of 15 m shall be connected to the transformer unit complete with a plug for the 220
V supply.
The 24 V windings shall be fully insulated from the 220 V primary winding, the core and case of the
Transformer unit.
8.4.8 Lighting
8.4.8.1 General
High-pressure sodium luminaries shall be used for area floodlighting.
Low-pressure sodium luminaries shall be used for road lighting.
Page: 78
The design shall ensure satisfactory operation over the life of the station.
The lighting design shall take full account of the drop-off in performance of lamps and fittings over
their working life.
Appropriate access platforms or ladders shall be provided for working on high bay lighting and
street/outdoor lighting as applicable.
8.4.8.2 Lighting fittings

Illustrations and/or samples of all lighting fittings which the Contractor proposes to purchase shall
be submitted to the Engineer for approval before issuing any suborders.
Lighting fittings for interior and exterior use shall be manufactured and tested in accordance with
the IEC 60598 or equivalent and together with all components shall be suitable for service and
operation in the climate stated.
Lighting fittings for use in hazardous areas shall be designed and certified as suitable for use within
the area according to the Zone or Division classification and the nature of the inflammable gas,
liquid, vapour or dust concerned.
The lighting fittings and accessories installed in the water treatment plants and blending plants
shall be suitable for the highly corrosive environment due to chemical fumes, vapours and dusts.
Each fitting shall be complete with all lampholders, control gear, internal wiring, fused terminal
block, earth terminal and reflectors or diffusers as specified. The design of each fitting shall be
such as to minimise the effect of glare, and such that the ingress of dust, flies and insects is
prevented.
Preference shall be given to fittings with low maintenance and high efficiency. As far as possible,
such fittings shall be selected for which replacement fittings and their spare parts are available
locally or by such manufacturer who have local agents in U.A.E..
Fluorescent lighting fittings shall be of the high efficiency electronic start, having hermetically
sealed ballasts of the low noise level pattern. The power factor of the fitting and control gear shall
not be less than 0.9.
The electronic control gear for use with fluorescent lamps shall incorporate power factor correction
and interference suppression capacitors. Chokes shall be impregnated and solidly filled with
polyester resin or other approved high-melting compound and shall be manufactured to restrict the
third harmonic content to less than 25% of the not corrected current value and shall be silent in
operation.
Control gear for discharge lamps shall incorporate power factor correction and interference
suppression capacitors.
Internal connections shall comprise stranded conductors not less than 0.75 mm2 covered with
heat-resistant insulation to IEC 60245 or equivalent. All internal wiring shall be adequately cleated
to the fitting casing with an approved form of cleat. The finish of fittings for interior use shall have a
vitreous enainel, natural aluminium or galvanised finish according to the manufacturer's standard
product.
Lampholders as applicable shall be suitable for the lamps specified.
Lighting fittings shall be of the type specified. The type references used shall be repeated in the
Technical Schedules.
The lighting installations shall be designed to give the standards service illuminations. Control and
relay rooms, computer and electronic equipment rooms and offices shall all have the service
Page: 79
illumination measured at 850 mm above a finished floor level. All other areas shall have the service
illumination measured at floor level.
The Contractor should hand over to Employer software copy disc. he will use for the illumination
calculations within three (3) month after award of Contract.
The installations shall also meet the limiting glare index requirements specified.
The number of different types of lighting fitting shall be rationalised to keep the total to a minimum.
8.4.8.3 Lamps
The Contract includes the supply and erection of all lamps and tubes necessary to complete the
Installation together with one complete spare set for the first change.
Fluorescent lamps shall be manufactured and tested in accordance with IEC 60081 and shall have
natural colour rendering for internal use and daylight colour rendering for external use.
Tungsten lamps shall be manufactured and tested in accordance with IEC 60064 and shall have
Edison screw caps.
High pressure mercury vapour lamps shall be manufactured and tested in accordance with IEC
60188 or equivalent.
Mercury vapour lamps shall be fluorescent types having a 10% red ratio.
colour correction.
High Pressure Sodium (HPS) lamps shall have a hot restrike time not exceeding 1 minute. All
lamps should be of types and sizes available locally.
8.4.8.4 Poles for roadway and general floodlighting

Lighting poles shall be of hot-dip galvanised steel of octagonal shape and shall be approved by the
Engineer.
Poles for roadway lighting shall support the lanterns at a normal 10 m above ground level and
poles for floodlighting may exceed 10 m. The maximum spacing between poles shall be 50 m.
Hinged type poles for access to the light fitting shall be provided where floodlights are required to
be installed at high level.
Each pole shall be equipped with a weatherproof base section of sufficient size to house an
inspection trap, lockable door, fused cut-out, cable entry and termination for both the incoming and
secondary cables feeding the light source. Facility shall be included for cable looping.
All fittings shall be adequately earthed and all earth termination and fittings, fixing brackets and
supports shall be included.
The Contractor shall ensure that each pole is provided with foundations suitable for the ground
conditions existing at site.
The Contractor shall supply lowering devices for the hinged lighting poles.
Permanent illumination along the DEWA road outside station fence between N 2773400 / E
311600, N 2770500 / E 309000 shall be provided.
8.4.8.5 Exterior installations

All exterior lighting shall be automatically switched by photo-sensitive switches and have a time
delay between groups of circuits to even out the switching peaks. Manual override facilities shall
also be provides.
Page: 80
All external doors of buildings including switchgear rooms and stores shall have external lighting
fittings installed adjacent to the doors to provide illumination immediately outside entrances in
addition to the requirements for roadway and area floodlighting detailed in this specification.
Fittings shall be type J (Table 1, Clause 8.4.10) bulkhead fluorescent to the approval of the
Engineer.
8.4.8.6 Emergency and essential lighting

An emergency lighting system fed from 220 V DC shall be provided to allow for the safe movement
of personnel at all times in the event of a failure of the normal lighting system.
In case of failure of normal lighting, essential lighting fed from separate 220 V safe AC systems
shall provide sufficient illumination to allow a safe movement of personnel and operation of the
plant in a safe manner - at least 20% of the lighting in the following area shall be essential lighting:
GT areas
Switchgear rooms
Battery rooms
Computer rooms
Relay rooms
Diesel Generator rooms
Stairways, access ladders and platforms
GIS room
In the control rooms, however, 40 % of the lighting shall be essential lighting.

With the exception essential lighting of the control rooms for which safe AC supply is absolutely
required the essential lighting for the other rooms/areas can be fed alternatively from the essential
service board of the plant.
The emergency and essential lighting system shall comply with BS 5266 as amended and
supplemented by this specification.
Wiring systems for emergency systems shall be kept separate from the normal wiring system.
A method of testing emergency and essential lighting shall be provided.
Escape routes shall be clearly marked and lit to facilitate emergency escape in safety.
8.4.8.7 Security lighting

The Contractor shall supply, install and commission Security Lighting systems for the Perimeter
Fence as detailed below.
Perimeter Lighting
The Contractor shall provide perimeter lighting to illuminate a continuous area 10 meters outside
the perimeter fence to allow the patrol personnel to view the area without themselves being visible.
Perimeter lights shall be mounted 5 meters above ground level at the fence line.
The distance between lights shall not exceed 20 meters.
Lights are to be placed 1 meter inside the fence line, facing outward and illuminating the fence and
the outside.
Page: 81
The low edge of the beam may be adjusted by mounting a shield on the underside of the
luminaries.
Illuminance Level
The minimum horizontal illumination shall be 50 lux and shall exceed the lilumination of the
surrounding area, including street lighting.
The Contractor shall provide a computer plot showing grid results for any particular area of ground
along the perimeter fence. The grid size shall be based on a grid of 10 m square.
This plot shall provide an accurate check on the uniformity of light provided.
After erection and connection the Contractor shall supply all instruments and aiming devices
necessary and adjust, train and direct the individual floodlight beams to provide the specified level
of illumination over the perimeter area.
Lamps, Luminaries and Control Gear
Low-pressure sodium discharge lamps shall be used having the following characteristics:
the lamp shall be tubular horizontal burning, clear quartz
lamps, ballast and control gear shall be suitable for operation with a power supply 220 V,
50 Hz, single-phase
the lamps shall have a minimum lighting design output of 20,000 lumens
the restrike time on interruption of the power supply shall be not more than one minute
the lamp shall take not more than five minutes to reach full brightness.
Lumen output beyond 2000 hours operation shall not decrease by more than 2% per 1 000 hours
operation.
Lamps shall be mounted in luminaries having the following minimum specifications:
the body shall be of heavy-duty construction of a material which is corrosion resistant to

atmospheric elements present at the site. The body shall fully protect the optical and electrical
systems from outside elements. It shall be dust-proof and splash-proof to IP 54.
the reflector shall be contoured, polished and anodised and may form the back of the
luminaries body.
the mounting shall be a galvanised steel stirrup with mast clamp, for mast mounting, permitting
adjustment in two planes.
the wiring chamber shall have a gasket seal lid and the mains cable shall enter via a
weatherproof gland.
the front glass shall be heat and impact-resistant. The glass is to be both hinged and
removable. It shall be secured by quick release key operated screws.
the luminaries shall be suitably earthed.
The control gear and ballast are to be easily accessible to maintenance personnel. A remote
control gearbox or integral ballast tray may be used and both must be protected and secured
against unauthorised access. Where control gear is remote from the luminary, lamp/igniter
distances shall not exceed the manufacturers recommended maximum.
Electrical supply and switching
Page: 82
The system shall have robust fittings and armoured cables. Cables shall be buried underground,
rising inside masts, etc.
Each lamp shall be protected by a fuse to the manufacturer's recommended rating. The fuse shall
be located in the base compartment of each pole. This compartment shall be protected by a close
fitting vandal resistant door, secured, with a heavy-duty, minimum five-lever, security deadlock.
Separate ring main supplies or separate circuits shall be provided for the perimeter lighting.
A switch shall be fitted into the circuit to permit the use of alternate luminaries for 50% illumination
if required. 50% of the lamps shall be supplied from the emergency lighting supplies.
Switching of the perimeter lighting shall be performed automatically by photocells. Switches shall
be located at a suitable place. Back indication of the lighting state shall be provided in the plant
Central Control Room so that manual switching is immediately carried out if the automatic system
fails.
Poles
Poles for mounting perimeter lights shall be of galvanised mild steel construction and shall be in
accordance with the DUBAI Electricity and Water Authority current standard design. Precautions
shall be taken to protect the buried section of the mast from corrosion by ground salts and the
Contractor shall state this proposed method of corrosion prevention.
Poles shall be of sufficient height to allow the luminaries to be mounted at a height of 5 metres
above ground level at the fence line.
Each pole shall incorporate a locked compartment. This compartment shall be protected by a close
fitting vandal resistant door secured by a heavy-duty, minimum five-lever security deadlock and
shall be fitted with fuse holders, necessary terminal blocks, gland plate and control equipment if
required. Two keys shall be provided for each deadlock.
Poles shall be fully protected and sealed against corrosion and the ingress of water, dust or
vermin.
8.4.8.8 Aircraft warning lights

Aircraft warning lights shall be in accordance with ICAO and local regulations.
The aircraft warning lights are to be installed in the GT and HRSG stacks. Positions are to be
approved by the engineer. The lights shall be omni directional with light output intensity not less
than 1600 CD.
The lights are to be designed for continuous duty with a live expectancy of more than 5 years in
continuous duty conditions. The flashing rate shall be 20 60 times per minute.
If photo cells are used for control, these are to be fitted outside the lamp.
The contractor shall submit details of the lights, height of installation and other relevant information
for the approval of Department of Civil Aviation, Dubai.
8.4.8.9 Photocells
Photocells shall be mounted within a waterproof and dust-proof enclosure to IP 65 which shall be
fully corrosion resistant
Means shall be provided for adjustment of the ambient light threshold at which the photocell
actuates the lighting.
8.4.8.10
Page: 83
Lighting switches
Switches for use in AC circuits shall be rated for 16 or 20 A and shall be single pole type provided
with an earth terminal. Samples to be provided for approval.
Switches for use in areas designated for surface installation shall be quick-make quick-break fixed
grid industrial types mounted in sheet-steel weather-proof boxes with protected dolly and arranged
where necessary for multigang switching.
Switches for use in areas designated for flush installation shall be micro break types fixed to with
plastic cover plates and mounted in galvanised steel flush type boxes.
Switches for external use shall be of the surface mounting 16 A rotary quick-make quick-break
pattern housed in a cast iron galvanised weatherproof box to IP 65.
Push-button switches shall either be flush or surface types, contained in galvanised steel boxes
and be single pole rated for 5 A. Push-button shall be made of non-hygroscopic material, be nonswelling and so fitted as to avoid any possibility of sticking.
The terminals for all switches shall be adequate to accommodate 2 conductors, each 2.5 mm2 in
area.
Lighting circuits shall be designated such that no individual light switch is loaded to more than 50%
of the nominal rating of the switch. Shower rooms, toilets and toilet blocks shall have light switches
mounted outside the entrance doors.
Light switches shall be installed such that the operating dolly shall be pushed up for OFF and down
for ON. Similarly, rocker-operated switches shall be installed such that the upper portion of the
rocker is pushed for OFF and the lower portion for ON.
8.4.9 Earthing and bonding

All equipment being supplied under this Part shall be effectively bonded to ensure electrical
continuity throughout the system. A separate earth continuity conductor shall be included with all,
wiring in conduits. No reliance shall be placed on metal-to-metal joints in conduits for earth
continuity. The earth continuity conductors shall as far as possible be in one continuous length to
the furthest part of the Installation from the controlling switchboard, the earth conductor connecting
all metal cases housing electrical equipment. The branches shall be connected to the main
conductor by permanently soldered-on mechanically clamped joints.
8.4.10 Table 1 service illumination levels, glare index

Location
Service
Illumination
Local control and relay rooms,

desks
and control surfaces
Offices and first aid rooms
Workshop (General)
Computer and electronic
Equipment rooms, SCADA
room
Switchgear-rooms
Battery rooms
Building corridors and stairways
Type of
Fittings
Control
500
Glare
Index
16
PB/L
500
300
16
22
D
A,J
L
PB/L
500/800
19
300
200
200
25
25
25
A
B
D, J
L
PB
L
Lux
-
Type of
Page: 84
Location

Service
Illumination
Toilets
Locker rooms
All indoor areas not specifically
listed
Transformer bays and boiler
areas
Cable-ways and cable
basements
Outdoor plant areas not
specifically listed
Roadways, vehicle yard and
car park
Access road
Site perimeter fences
Access ladders, stairways and
platforms
Local control cabinets
Type of
Fittings
Control
200
100
200
Glare
Index
25
10
25
A,J
A
A,J
L
L
L
100
A,J
PB/L/PC
100
A,J
50
A,J
PC/L
30
KA,J
PC/L
30
50/100
50
K
X
A,J
PC/L
PC/L
L
200
25
A, J
Lux
-
Type of
The above levels shall be based on measurements being taken after lamps have operated for not
less than 100 hours. The method of measurement shall be in accordance with International
Commission on Illumination (CIE) Publication No. 29. Measurements shall be taken 0.85 metres
above floor level in control and relay rooms, electronic equipment rooms, and offices. Otherwise,
measurements shall be taken at floor level.
L
Double-Pole local switches
PB
Push-button for remote control
PC
Photocell.
8.4.11 Table 2 Schedule of Luminaries

Type Description
A
Totally enclosed corrosion-resistant fluorescent fitting, weatherproof and dust-proof to IP 65
with a glass reinforced polyester resin housing, acrylic diffuser, stainless steel diffuser retaining
clips and electronic control gear.
B
BASEEFA approved flameproof (type D) fluorescent luminary suitable for zone 1 areas.
Weather-proof and dust-proof to IP 65. Luminary to have non-sparking aluminium alloy body with
sealed borosilicate glass overtube and electronic control gear.
C
Low brightness recessed modular fluorescent luminary with specular Aluminium parabolic
reflector in the transverse and axial planes and electronic control gear.
D
Recessed modular fluorescent luminary with white stove enamelled sheet steel body and
prismatic acrylic controller and electronic control gear.
E
As type with high frequency fluorescent luminary.
F
250 W mercury halide high bay luminaire, with wide beam self-cleaning Aluminium
dispersive reflector and integral control gear, IP 54 enclosure.

G1
400 W mercury halide high bay luminaire as type F.
G2
As type Gl with narrow reflector.
Page: 85
J
Bulkhead type 2 x 8 W fluorescent luminaire with cast Aluminium or hot dipped galvanised
steel body and acrylic or polyester diffuser, weatherproof and dust-proof to IP 65.
K
Column mounted low-pressure sodium luminaries with semi-cut-off light distribution. Control
gear shall be integral or contained within the support column. Luminaire shall be weatherproof and
dust-proof to IP 65.
L
250 W high pressure sodium area floodlight, with corrosion-resistant cast Aluminium body
toughened front glass and stainless steel clips. Control gear should be integral or contained within
the support column. Luminaire shall be weatherproof and dust-proof to IP 65.
X
As specified under Security Lighting.
Metal halide light fitting for pole mounting. Protection degree IP 64.
8.5
SPECIAL EQUIPMENT AND TOOLS
Requirements for special equipment and tools are defined in Part G4.
One set of special tools shall be included in the scope of works.
8.6
SPARE PARTS
Works to be done under this Part include delivery of spare parts. Requirements for spare parts are
defined in Part G4 .One set of all lamps and tubes shall be supplied for the first change. In addition
for each type of luminaire a minimum of 10% extra fittings shall be supplied as spares.
8.7
INSPECTION AND TESTS
Testing shall comply with Part G4. Additionally the following tests are to be carried out:
8.7.1 Insulation tests

Insulation tests shall be carried out on all cables between cores and to earth after termination have
been made and before the cores are connected to the equipment, and records of these kept.
Tests shall also be made on complete circuits for lighting socket outlets, etc., between poles and to
earth and shall include associated switches, distribution switch and fuse gear.
8.7.2 Continuity tests

Earth continuity tests shall be made for each item of electrical equipment, lighting fittings, switch
and socket outlets to the main earthing connections for the installation. This shall be the point
where the main bonding conductor to the earth electrode system is connected to the main earthing
terminal on the main switch board.
8.7.3 Earth loop impedance tests

Earth loop impedance tests shall be made for all socket outlets in the installation and shall show
the complete earth loop impedance from the socket outlet to the sub-distribution fuse board.
8.7.4 Earth electrode tests

The resistance of all earth electrodes including those provided for main earthing anti-static
protection and lightning protection shall be measured, recorded and test certificates submitted.
Page: 86
8.7.5 Phase rotation tests

The phase rotation at each welding socket outlet and each 125 A socket outlet in oil filled
transformer pens shall be checked and verified to be standard- anti-clockwise phase rotation and
sequence R-Y-B.
9
9.1
CABLE SYSTEM
SCOPE OF WORKS
The scope of works shall comprise the supply, installation and commissioning of all high voltage,
medium voltage and low voltage power cables, control cables, pilot cables, cable terminals, sealing
ends, cable racks, trays and ladders, halfen rails, supports, conduits, cable fixing material, etc., of
the complete power station. It shall cover all equipment and works to form a complete, safe and
reliable Plant.
The Contractor shall perform all relevant design and engineering of the complete cable system and
prepare the cable installation drawings with cable routing, connection diagrams and cable lists,
details, etc.
The Contractor shall select the most suitable routes and raceways ensuring a minimum of
interference with other installations.
The maximum continuos current carrying capacity of each individual cable type and cross-section
used shall be determined, taking into account the site conditions. The resulting load reduction
factors are subject to the approval of the Engineer. The conductor cross-section of each cable,
shall be adequate for carrying the fault currents determined by the relevant short-circuit protection
device when operating under the specified load conditions, without deterioration of the dielectric
properties. All the above data and their calculation including the short-circuit calculations, shall
form part of the documents to be supplied by the Contractor.
The following general requirements shall be considered:
The cable system is to be segregated / protected in such a way that in any serious accident,
the integrity of the control room as the operational and communications centre of the plant is
preserved. A major incidence involving one unit shall not render other inoperable. It must be
able to be manned safely in the event of a fire in an adjacent area.
Insulation of the wiring shall have fire resisting properties.
Circuits of one panel shall be capable of isolation for maintenance purpose without affecting
the other circuits.
Terminals and terminal boards for wiring shall be accessibly located.
Circuits feed from a supply common to a number of panels to be avoided. Where it is not
possible to avoid, it shall be so protected that failure of a panel does not prevent operation of
the other panels.
Secondary circuits of CTs and VTs are to be protected against electromagnetic effects of
primary circuits in high voltage equipment. (Effectiveness of EMC measures may be assessed
by field measurement.
Under all foreseeable operating conditions undesirable surges and control circuits transient to
be limited to an acceptable minimum.
Control cables shall be kept on separate racks. Identification tags are to be fixed at a suitable
distance for easy identification.
Page: 87
9.1.1 Power Cables

The scope of power cables is as basically detailed below:
(1)
MV System Level
Unit Auxiliary transformer neutral connections
Connections between MV MV and
auxiliary transformers
MV motors
(2)
LV System Level
Connections between LV main distribution boards and
auxiliary transformers, as far as not provided by busbars, if specified
MCCs, distributions, sub-distributions as basically shown on the SLD and as required for
the plant
battery chargers
Connections between all MCCs, distributions, sub-distributions, etc., to all related auxiliaries
and consumers as required.
Connections of the complete DC systems
Connections of the complete safe AC systems
9.1.2 Control Cables

The scope of control cables shall contain, complete in every respect:
All electrical protection and control cables as required
All I & C, communication and control cables as required
9.2
DESIGN REQUIREMENTS AND DATA
9.2.1 General
The cables shall be as described in this Part and shall comply with the General Technical
Requirements, as far as applicable.
Cables shall never be exposed to direct sun radiation.
All cables shall be of armoured type. Conductor water blocking features shall be provided for MV
and HV cables.
The main electrical design data are as follows:
9.2.2 Main Data

(1)
MV Power Cables
U0/ U (Um ):
6.35/ 11 (12) kV
Operation voltage:
11 kV
Highest system voltage:
12 kV
Page: 88
Lightning impulse withstand
75 kV
Power frequency withstand
28 kV
Short circuit capacity:
as required by feeding sources
Neutral earthing:
earthed via earthing transformer
(2)
LV Power Cables
U0/ U (Um ):
0.6/ 1 (1.2) kV
as required by the feeding source and

the related protection system device
Neutral earthing:
effectively earthed
For consumers fed from building services distribution boards:
(4)
Design voltage:
300/ 500 V
Neutral earthing:
effectively earthed
as required by the design data of the MCBs
Control Cables
Operation voltage:
220 V DC/ 230 V AC
Design voltage
450/ 750 V
Operation voltage:
60 V DC
design voltage
200 V
9.2.3 Cable Sealing and Drums

The ends of any cable shall be sealed against the ingress of moisture, dirt and insects and the end
projecting from the drum shall be adequately protected against mechanical damage during
transportation, intermediate storage and site handling. Wooden cable drums shall be lagged with
closely fittings battens.
All cable drums shall be clearly engraved in English as follows:
1. Name of Manufacturer
2. Type of Cable
3. Sizes and Number of Conductors
4. Voltage
5. Drum Number
6. Length of Cable
7. Purchaser's Order Number
8. Weights - Net and Gross
9. Shipping - Identification Marks
10. Address
Page: 89
11. Direction of Rotation

Wooden cable drums shall be thoroughly impregnated with appropriate insecticide and wood
preservative.
9.3
(1)
CABLE CONSTRUCTION
General
Since there are no International standards defining the constructional design of 400 kV XLPE
cables, the cables shall be dimensioned by the manufacturer. Relevant calculations shall be
submitted for approval.
It is supposed that for design of particular cable components the relevant IEC standards will be
applied.
The applicable basic design requirements as defined in the subsequent specification "Cable
Construction, MV Power Cables", shall as well be applied for these HV cables.
9.3.1 MV Power Cables

The cables shall be of the single conductor, cross linked polyethylene n
i sulated type (XLPE),
designed for a solidly grounded system.
All cables and their accessories shall be designed in accordance with the latest issues of IEC
Publications or equivalent standards. All cables shall be of armoured type. They shall be
constructed to withstand the specified short circuit currents.
Where required, he sealing ends shall be suitable for outdoor installation. Conductor water
blocking features shall be provided. The Contractor is obliged to co-ordinate the layout of potheads
and sealing ends with the supplier of switchgear, transformers and other consumers to which the
cables are to be connected.
All cables and their accessories to be provided shall have insulation levels able to withstand any
voltage surge, due to switching operations, sudden load variations, faults, etc., which is normally
expected to occur in the power system in which the cable is to be included. The cables and their
accessories shall be constructed to fulfil the requirements when operating with full load or at any
load factor. Special reference shall be made to the prevailing climatic conditions. Contractors are
requested to submit:
calculation results of the continuous current rating of the proposed cables and their accessories
report on permissible overload currents of the power cables, starting from 50, 75 and 100% of
the above mentioned continuous permissible transmission capacity of 1, 2, 3, 4 and 5 hours
calculation of induced voltages in pilot and alarm cables installed in parallel with the power
cables
report of own site measurements of induced voltages on pilot and alarm cable
calculation of earthing wire cross sections.
The cross section shall be calculated by the Contractor subject to consideration of the following
conditions:
Maximum load current under most severe ambient conditions
Maximum fault currents/ periods.
Page: 90
The conductor shall consist of annealed copper wires, stranded and compacted to a circular
conductor. The conductor shall be in accordance with IEC 228.
Around the conductor, a semi-conducting layer shall be provided, followed by an extruded layer of
dry cured cross linked polyethylene (XLPE) of such a thickness that the minimum value as required
for the voltage class does not fall short at any point of the total cable length.
Over the insulation an extruded semi-conducting outer layer shall be provided. A water stopping
conductive material shall be applied over the insulation screen to stop water penetration in
longitudinal and axial direction, followed by a lead alloy or laminated sheath of adequate thickness,
and copper wires/ tapes for insulation/ shielding.
The outer jacket shall be an extruded finish layer of red coloured polyvinylchloride (PVC) or
polyethylene (HDPE) with a thickness of not less than 5 mm.
No MV cable shall be laid direct buried without prior approval of the Employer/Engineer.
9.3.2 LV Power Cables

LV power cables below 50 mm 2 core cross sections may be of the PVC insulated type. Those of
50 mm 2 and above shall be of the XLPE type.
The cables shall have cores for the phases and additionally one core for the protective earthed
neutral (PEN), or two cores for the separated neutral (N) and protective earth (PE), as applicable.
Higher rated three-phase loads may separately be connected to the plant earthing system. All
cables shall be armoured. Please refer in addition to the General Technical Requirements.
No LV power cable shall be laid direct buried without prior approval of the Employer/Engineer.
9.3.3 Control Cables

No control cable shall be laid direct buried without prior approval of the Employer/Engineer. The
cables shall be of armoured type.
9.3.4 Pilot Wire/Telephone Cables

All cables shall be armoured. Please refer in addition to the General Technical Requirements.
No pilot wire/telephone cable shall be laid direct buried without prior approval of the
Employer/Engineer.
For the pilot wire/ telephone cables to be provided, the following shall be applied:
(1)
Induced Voltages
All information and calculations on induced sheath voltages, cross-bonding arrangements and
influences on the parallel pilot/ telephone cables shall be submitted, giving sufficient information to
the Employer/ Engineer.
The pilot/ telephone cables laid in power cable trenches or in the vicinity of such power cables
have to be protected against damage by induced high voltages occurring in case of asymmetrical
power cable operation, e.g. during short circuits, etc.
The Contractor shall prove by calculation of the induced voltages that the sheaths and insulation of
the offered cables are sufficient for the given network configuration.
The following assumptions shall be taken into consideration for such design (and evaluation)
purpose only:
Cable arrangement as proposed by the Contractor
Page: 91
Maximum zero sequence currents in kA
Specific soil resistivities to be measured by Wehner Method at 20%, 50% and 80% length.
All further protection measures for the pilot/ telephone cables (e.g. isolating transformers to be
installed at certain pits within the cable run, or increase of insulation) shall be elaborated and
proposed, and the Contractor shall provide all necessary equipment and work.
(2)
Pilot Wire/ Telephone Cables
The cables shall be of the 7/ 54 type, i.e. 7 triplets 1.4 mm each for protection, plus 54 pairs
1.4 mm each for telephone, also written 7x 3 x 1.4/ 54 x 2 x 1.4. They shall conform in every
respect to VDE 0816 or approved equivalent standards.
The conductors shall comprise clean, smooth, compact, soft annealed, electrolytic copper wires
with standardised conductivity. The surfaces of individual wires shall be smooth and clean before
the insulation is applied.
The conductor insulation shall have various colours plus embossed numbers for easy identification
and termination.
The protection triplets shall be either colour coded or numbered 1X, 1Y, 1Z. to 7X, 7Y, 7Z, and
The telephone cores shall be either colour coded or numbered 1A, 1B to 54A, 54B.
The copper tapes of the conductor screen shall be lapped with a long lay, the second one covering
the butt space of the first layer. The armouring tapes, on the other hand, shall be lapped with a
short lay, the second one covering the butt space of the first layer.
The outer covering shall be preferably high density polyethylene, termite-resistant, vermin proof,
and suitable for the prevailing service conditions at site.
(3)
Pilot/ Telephone Cable Terminations
The pilot/ telephone cables shall be terminated in suitable terminal blocks inside watertight
marshalling cabinets at each end. If necessary, intermediate cabinets shall be provided along the
cable route.
The marshalling cabinets shall be designed in line with the requirements for electrical cubicles. All
equipment and work as required to complete the connected system shall be provided.
The marshalling cabinets shall further include:
Marshalling racks with terminations insulated for 15 kV AC for the protection wires
Marshalling rack with surge arrestors for the telephone wires and other unused cores
The pertaining wiring and connection work, comprising suitable cabling to the protection/ alarm
panels within the relevant station
Insulation transformer capable for a insulation not less than 15 kV (to be supplied triplicate for
each protection).
The terminal blocks shall have terminals with an insulated bridging plug, so as to allow a circuit to
be isolated. The plugs shall be colour coded and/ or numbered according to the appropriate cables
connected therewith.
The Contractor shall check through and identify the cores of the pilot/ telephone cables. He shall fit
numbered ferrules of an approved type at all terminals. The ferrules shall be of insulating material,
which shall be white and shall have a glossy finish. The ferrules shall be resistive against oil or
damp. Characters shall be suitably marked in black.
Page: 92
Only approved compression lugs or washers shall be used at the terminals.

All cable glands required for the terminals shall be supplied and installed.
The cables shall be sealed by compression-type armour gripping mechanical glands. These glands
shall be provided with an earth tag and PVC shroud.
(4)
Testing of Pilot Cabling
The following tests shall be provided, according to IEC 60229, 330, 332, VDE 0472, VDE 0816 and
VDE 0845, as applicable:
Dimensional tests
Conductor and insulation resistance tests
Capacitance/ unbalance measurements
Voltage test on cable plus marshalling cabinets (15 kV AC/ 1 min. between any conductors,
and between conductors and screens/ sheaths
Cross talk attenuation and frequency response
Voltage tests on cable section (water-immersion of full drum, 25 kV/ 5 min.) and on joints
(water-immersion at C/ 5 hrs, then 25 kV/ 5 min, afterwards natural cooling, seven cycles one per day)
Voltage test after installation of the complete cable (10 kV DC/ 1 min)
Site tests such as conductor and insulation resistance and capacitance/ unbalance measurements, identification and HV tests.
Hereby, all calculations evidencing the ratings under site conditions have to be submitted.
Single type tests may be waived if satisfactory type test certificates will be submitted.
9.4
CABLE TERMINATIONS AND ACCESSORIES
9.4.1 General Requirements

Every cable end of MV power cables shall be sealed and protected in an approved manner
consistent with the voltage level, kind of cable and place of installation. The spacing between
conductors and the earth shall be in accordance with the applicable Standards.
Where required, the sealing ends shall be suitable for outdoor installation. They shall be
constructed to withstand the specified short circuit currents.
The Contractor is obliged to co-ordinate the layout of potheads and sealing ends with the supplier
of switchgear, transformers and other consumers to which the cables are to be connected.
9.4.2 MV Cable Terminations and Joints

Suitable cable terminations for indoor respectively outdoor use are to be provided for every cable
end, as applicable.
The potheads shall be of the dry type and be consistent with the cross-linked conductor insulation
of the cables.
The Contractor shall supply, if and where required, all material necessary for jointing and
termination of cables, including cast resin cones, stress control cones, porcelain, as well as all
tapes, papers, plumbing material, solder and other consumable materials, and shall carry out all
Page: 93
work necessary for the proper jointing and sealing of all cables installed under this Contract. The
Contractor shall be held responsible for checking his jointing and sealing work and for putting the
completed cable installation into operation.
Where insulated glands are provided, the Contractor shall ensure that the insulation is maintained
after the cables have been jointed.
All cable terminations and joints must be able to withstand the specified design short circuit
current.
The Contractor shall detail the method of terminating the cable and of earthing the sheaths. The
outdoor type cable sealing end bases shall be insulated from the structural steel work and the
cable glands of gas immersed and oil immersed type sealing ends shall be insulated from the SF6
switchgear resp. transformers.
The arrangement to meet these requirements shall be subject to the approval of the Employer/
Engineer.
For outdoor sealing ends, porcelain insulators shall be provided, designed with a creepage
distance of 40 mm/ kV line-to-line operating voltage.
All terminations shall be made by using stress control cones. They shall consist of prefabricated
epoxy, silicone rubber, ethylene-propylene rubber or ethylene-propylene-terpolymer rubber and
joined to the cable afterwards or of stress control cones moulded in one piece together with the
cable insulation or made of crepe paper (elastic paper method) or of self-vulcanising insulation
tapes. The stress control cone material should have the same thermal expansion coefficient as the
cable. The sealing ends shall be filled with high viscosity polyisobutylene, silicone oil, or equivalent
and suitable expansion device shall be provided.
Supply and installation of the necessary hot-dip galvanised steel structures and non-magnetic
clamps, for supporting and fastening the cables at the gantries, switchgear and transformers shall
be included in the contract price. These structures must be designed to permit an easy jumping to
the terminations.
The arrangement of the terminations, the supporting structures including the cable fastening shall
be subject to the approval of the Employer/Engineer. A complete and detailed list of tools and
equipment required for terminating the cables shall be submitted with the tender.
For proposal of alternative methods which shall be equivalent in performance to the method
specified, the Contractor shall submit information necessary to demonstrate the performance and
experience with the method.
Joints will only be accepted if technically mandatory and are to be approved prior to execution by
the Employer/Engineer.
If cable insulating joints are required they shall be of the "taped" type. The conductors shall be
spliced by means of welding or equivalent. The intended method (e.g. Cadweld method) shall be
intimated in the tender. The Contractor shall explain in detail his proposed method of insulation
jointing, e.g. by winding of cross linkable polyethylene tape containing organic peroxides by means
of a special machine, etc.
The joints should be suitable for application to single-core XLPE cables as described in the
respective section. They should be designed to withstand the short circuit current as specified.
The insulation screen shall be linked with a semi-conductive plastic layer.
By placing the splice in a mould, a cross-linking method of heat and isostatic pressure treatment by
gas or silicone thermostatically controlled should be used for conductor screen insulation and
insulation screen.
Page: 94
The metallic shielding shall be connected by means of copper or lead tape, copper braid, tinned
annealed copper wire, copper wire netting tape, etc.
Finally, the outer covering shall be prepared with a copper or lead tube and protective glass fibre box
casing, filled with waterproof compound to the full satisfaction of the Employer/ Engineer.
For proposal of alternative methods which shall be equivalent in performance to the method
specified, the Contractor shall submit information necessary to demonstrate the performance and
experience with this method.
9.4.3 Grounding of Cable Screens

Cable screens shall be solidly earthed at both ends. The ground resistance shall not exceed 2 Ohm.
The metal sheath of the cables shall be connected to the station earthing system at both sealing
ends. or HV cables, reference is made to the relevant specification.
9.5
TESTS
The cables and their accessories shall be subject to acceptance tests, to be performed at the
Contractor's premises and at site as applicable. The latest issue of IEC and VDE standards shall
apply as far as not requested otherwise below.
The manufacturer shall be obliged to fabricate excess lengths of the cable if necessary for the test,
over and above those within the Scope of works. Before energising a cable circuit including all the
accessories, tests shall be performed on the complete installation as described.
The tests shall be performed as follows:
9.5.1 HV and Pilot Cables

As defined in the relevant specifications above.
9.5.2 MV Cables
Routine tests:
measurements of DC resistance (IEC 60 228) and dimensions of screen (if applicable)
partial discharge measurement according to IEC 60502 clause 14.3 nmax. voltage: 1.75
U0 - 10 sec measuring voltage: 1.5 Uo, max. permitted discharge level: 20 pC
power frequency test with 30 kV for 5 min. acc. to IEC 60502 Clause 14.4.
Special tests: (on 10 % of delivery lengths)
dimensional and constructional checks on the cable (thickness of insulation, outer sheath,
metallic sheath, and diameters)
hot set test of XLPE insulation acc. to:
IEC 60502 Clause 15.10
Type tests (may be waived if they have previously been performed and the Contractor produces
respective certificates to the satisfaction of the Employer and the Engineer):
electrical type tests acc. to:
IEC 60502 Clause 16.
non electrical type tests acc. to:
IEC 60502 Clause 17.

IEC 60332 Part 3
ASTM D-2843-93
Page: 95
Tests after installation:
AC test with 2.5 x U0, 15 min. between conductor and the metallic screen or an alternative
test with VLF (approx. 0.1 Hz)
AC test with normal phase to earth voltage of the system for 24 hours.
Megger test
9.5.3 LV/ Control Cables

As specified in the General Technical Requirements.
10 EARTHING SYSTEM AND LIGHTNING PROTECTION

10.1 SCOPE OF WORKS
The Contractor shall provide a complete earthing, potential gradient control (PGC) and lightning
protection system for all installations under his scope of works. Relevant design calculations and
reports shall be provided for approval to the Employer / Engineer.
The necessary soil excavation and refilling works for earth rods and conductors shall be performed
by the Contractor.
He shall supply, install and commission all required conductors and earth rods, connecting
material, protection equipment and all kinds of fixing material to form a complete, safe and reliable
system and shall provide an earthing materials list before starting the installation works.
10.2 TECHNICAL REQUIREMENT

10.2.1 General
Drawings and calculations shall be submitted for approval giving sufficient information on the
earthing, lightning protection and PGC system, the earthing of structure mounted equipment, as
well as on methods of measuring the earth resistance, respectively the earth - electrode potential
and the touch voltage.
All interconnections of the earth grid to equipment at the grid end and the connections between the
earthing grid and the earthing rods shall be made by the thermite welding process. Only those
connections that are located in earthing pits and occasionally intended to be opened for testing
purposes shall be of the bolted type.
All buildings (Control, switchgear) shall be provided with faraday cage shielding, subsequent
penetration of any foreign conductive materials (may be HVAC pipes, chilled water pipes, sprinkler
system pipes etc.) shall not nullify faradays shielding criteria of the building to be ensured.
The execution of work shall be performed in strict compliance with internationally recognised
standards.
Earthing conductors buried in the soil shall be of stranded copper. The minimum diameter of each
strand shall be 1.8 mm. Earthing conductors embedded in concrete shall be either copper cables
or galvanised steel tapes. Adequate corrosion protection shall be provided when conductors leave
the concrete, respectively the soil.
Earthing conductors laid on cable trays or similar shall be stranded copper.
Page: 96
10.2.2 Potential Gradient Control (PGC)

The Contractor shall provide a potential gradient control system for all locations where dangerous
surface voltage gradients may occur.
This will at least be applicable for:
Transformer areas
Substations
MV and LV switchgear rooms/ areas
Turbine/ generator floor
Cable floor
The required mesh-width shall be calculated by the Contractor in accordance with approved
standards such as VDE-0141 or IEEE standard 80 considering the design earth fault current of the
equipment and an admissible step and touch voltage as per the standard used for design.
The system shall be complete in every respect and shall include all necessary connections to the
plant earthing grid.
Within concrete structures (foundations, floors, trenches, columns) the Contractor shall either
provide copper cables or shall use reinforcement bars of adequate cross section interconnected to
a mesh net, with at least two connection terminals at diagonal points. The Contractor shall connect
such terminals with the other potential gradient control conductors via main earthing bars to the
earthing system.
10.2.3 Earthing
The Contractor shall provide a complete earthing system consisting of:
The main outdoor subsoil earthing system, with individual loops around each building,
foundation, structure, etc., of this plant extension.
Sub-earthing systems for buildings, foundations, structures, tanks, etc., being connected to the
subsoil earthing system as required.
All electrical equipment such as generators, motors, transformers, sub-stations, foundations,

switchboards, control boards, relay and auxiliary relay boards, all other subsidiary electrical
equipment as well as all metal parts of the civil construction or the mechanical equipment such
as transformer rails, pumps, pipes, steel structure, tanks, cable trays, etc. shall be connected
to the earthing system as specified in the General Technical Requirements.
At least two independent earthing connections are to be provided to each electrical device /
equipment. Those facilities that are most likely to supply or carry a high current, such as
transformer tanks, circuit breaker housing, base frames of switchgear and arrestor pads shall
always be connected to the earthing grid with more than one lead.
The leads shall preferably be run in opposite directions to eliminate common mode failures.
At least 4 interconnections between the new and the existing earthing systems after
successful testing of the P Package systems.
Sufficient bolted type interconnections between P Package - D Package and P Package

S Package earthing systems shall be provided after successful testing of the individual
systems.
Page: 97
Insulated earthing conductor connection between the main subsoil earthing system and the
I & C single point earthing system.
The cross sections of the various earth conductors shall be determined in accordance with
VDE-0141 or IEEE, however, the minimum copper conductor cross sections shall be as follows:
HV, MV and LV switchgear
150 mm 2
Turbo-generators
150 mm 2
MV motors
50 mm 2
Metal raceways and cable trays
35 mm 2
Intermediate terminal boxes
10 mm 2
Other metal parts as may be required
10 mm 2
The subsoil earthing conductors shall be buried into the soil in a depth of 0.6 to 1.0 m.
Earthing material list shall be provided in the offer.
10.2.4 Lightning Protection

The Contractor shall provide on basis of the relevant IEC standards and under strict observance of
the local safety regulations, all preventive equipment to minimise subsequent damage caused by
lightning for any buildings, structures, tanks, equipment, etc., of his scope of works.
The lightning protection system shall consist of the outer protection system (i.e. catching rods,
down conductors, sub-soil earthing system, etc.) as well as an inner protection system, as required
to prevent induced voltages and voltage differences that may damage electrical and/ or
electronically equipment.
Lightning catching rods and down conductors shall be stainless steel.
The following specific conditions shall be observed for the outer protection system.
Each outdoor tank shall be connected to 3 earthing electrodes evenly distributed around the
circumference as described above if it is not connected to the main earthing system described
in the former item
Unless otherwise protected by the shielding angle of another closely located lightning
protection installation, subject to the approval of the Engineer, each building roof, civil work,
protective cover or outdoor structure for which the Contractor is responsible shall receive a
lightning protection system composed of roof and down conductors sufficiently sized, spaced
and connected to the main earthing system.
No point of the roof should be more than 5 cm from the nearest horizontal conductor. Each
down conductor should be provided with an test joint. Plates indicating position number and
type of each electrode should be fitted above each test point.
Bonding of cables and pipes at the entry and exit to the building, the arrangement which will
be used, shall be supplemented by principle diagrams and to be part of the offer.
Material list shall be provided in the offer.
Inner Lightning Protection and Transient Over-voltage Protection

The inner lightning protection and transient over-voltage protection system as required to prevent
equipment failure due to over-voltages caused by direct and indirect lightning strokes as well as
switching of HV equipment shall be achieved by adequate measures, as, e.g.:
Page: 98
earthing and shielding,
Faraday's cage by use of earthed reinforcement bars of concrete walls/ floors/ roofs,
cover for cable trays, if required,
single point earthing of the entire I&C and electronic systems,
selection of I&C cables regarding screening, twisting, etc.
surge diverters and spark gaps, according to the standards/ regulations/ practices applied for
final design,
etc.
The relevant system concept shall be submitted for approval before detailed design of the LV
AC/DC and control system.
Reference is made to the relevant requests of the General Technical Requirements.
10.3 TESTS
The complete earthing and lightning protection systems shall be tested as follows:
The earthing system as a whole shall be tested and verified before putting any major
equipment into operation
Visual inspection of exposed elements
Measurement of the earth electrode potential UE by the voltmeter/ ammeter method, test
current 100 - 300 A or an equivalent, approved method if above will be proved to be not
feasible.
Measurement of the touch potential UB.
Measurement of step potential
11 ELECTRICAL CONTROL SYSTEM

11.1 GENERAL
This Clause includes the requirements for control of electrical systems, as far as not provided by
the process control system.
Automatic, respectively remote control of electrical plant and of individual electrical installations
shall be performed as required and as basically described below.
Manual control shall be as specified in the applicable Parts of the Specification.
Applicable general requirements are specified under General Technical Requirements for electrical
and I & C equipment.
11.2 SCOPE OF WORKS

The scope of works, installation and commissioning shall be of such an extent as to suit the
specified purpose and all requirements resulting from plant provided by the contractor. The main
equipment/ features shall be as follows:
Remote control and supervision from the CCR for:
Generators
Unit step-up transformers
Unit auxiliary transformers
400 kV GIS generator circuit breakers
MV distribution systems
LV distribution systems incoming and bus-sectionaliser feeders
Alarm indication for above systems
Data logging for above systems
Metering
MV transfer devices
LV transfer devices
Transformer control
Synchronisation
Local control systems for individual plant
Page: 99
11.3 LAYOUT
The layout and arrangement of the remote control facilities shall comply with the requirements of
the Technical Specifications for I & C systems. The layout and arrangement of the local and the
individual system control facilities shall comply with the relevant system specifications.
11.4 DESIGN AND CONSTRUCTION REQUIREMENTS

11.4.1 Remote Control and Supervision
Remote control/ supervision shall be performed via the DCS. All functions/indications/
measurements/ alarms, etc., available with the different plant/ systems shall be embraced into the
DCS as necessary for save operation and supervision of the plant.For back-up purposes, the
following devices shall be provided in addition at the control desk/ panel, as applicable. All devices
as defined below shall be incorporated into the mimic diagram, close to the relevant symbols.
(1)
Generators
Voltage meter
Phase current meter
Co-ordinates indicator (vectormeter) indicating:
generator capability diagram
active power vector
reactive power vector
Winding temperature indication
Cooling water temperature indication
Page: 100
Synchronising instruments (VV, ff, synchronoscope)
(2)
Unit Step-up and Unit Auxiliary Transformers
OLTC position indication
Temperature indication
Neutral current meter (unit auxiliary transformer only)
(3)
400 kV GIS Generator Feeder
Voltmeter
Phase current meter
Power factor meter
Active power meter
Reactive power meter
(4)
MV Distribution System
Transformer feeder current meter
MV incomer / tie voltmeters
Motor feeder current meter
Bus sectionaliser current meter
Bus voltage meter
(5)
LV Distribution System
For transformer fed distribution boards:
Incoming feeder current meter
Bus sectionaliser current meter
Bus voltage meter
For 220/110/24 V DC main boards and safe AC boards
incoming feeder current
bus voltage
11.4.2 Alarm Indication

Group alarms for the individual systems as mentioned above shall be indicated in the central
control room.
11.4.3 Data Logging/Event Recording

All alarms, all trips and changes of status of main equipment shall be recorded by the data logging
system. This shall include but shall not be limited to:
All individual alarms/ trips from HV feeder protection, generator - transformer unit protection
and MV protection systems
Page: 101
All individual alarms/ trips from all transformers
Group alarms/ trip indication from the LV power distribution systems.

information shall be indicated locally
Change of status of any HV and MV circuit breaker as well as the incoming feeder breakers
and bus sectionalisers of such LV boards.
The individual
11.4.4 MV Quick Transfer Device

This item should be read in conjunction with Clause 5.2.4 High Speed Transfer Equipment
The MV switchgear will normally be operated with separated busbars, i.e. each transformer will
feed one 11 kV Unit Auxiliary Switchgear.
The transfer equipment shall be designed with due consideration of the remote control
requirements and it shall include but shall not be limited to:
Push buttons arranged on the switchgear front panel and at the control room, as well as
control facilities for control via the VDUs for manual activation
High speed paralleling devices, taking into account the amount, vectorship and frequency of
the measured voltage of the circuits to be connected (like make before break!)
Push buttons, selector switches and C.B. position indicators on the front panel for testing
purposes
Fault and position indicators
The quick transfer device shall be actuated automatically as follows:
Any fault leading to a shut down of the feeding GTG unit - transformer system shall trip
the related MV unit auxiliary transformer feeder breaker and shall close the coupling
breaker to the other 11 kV Unit auxiliary boards.
Any fault of a unit auxiliary transformer shall trip the related transformer feeder breaker
and shall close the coupling breaker to the other 11 kV Unit auxiliary
Any trip of a 11 kV Unit Auxiliary transformer feeder breaker by MV switchgear protection shall
block the quick transfer scheme
Uninterrupted, manually initiated automatic change over to normal supply (i.e. 11 kV Unit
Auxiliary transformer feeder breaker open and bus sectionaliser open) shall be possible (make
before break change over) Manual opening of any related breaker shall block the quick
transfer scheme.
The quick transfer device shall include a high speed transfer device with adjustable settings for
maximum acceptable voltage differences and phase displacement. Further, long term transfer to
be initiated independently from phase displacement but actuating on adjustable residual voltage
shall be provided.
11.4.5 LV Transfer/Change-over
Transfer/ change over devices shall be provided for all LV boards equipped with two independent
infeeds.
Transfer initiated by protection devices may lead to a definite short time voltage interruption but
shall not result to a plant shut-down. Transfer, which would lead to switching onto a fault, must be
prevented.
Page: 102
Manually or process initiated change over between two feeding sources shall be provided without
voltage interruption (i.e. make before break with a definite short time overlapping)
11.4.6 Transformer Supervision and Control

(1)
Remote Temperature Monitoring
The temperatures of the unit main and auxiliary transformers and shall be indicated in the control
room.
(2)
Tap Changer Control
For the Unit Step Transformer automatic voltage regulating devices (AVR) shall be provided.
Manual control shall also be possible.
The design parameter shall be as defined below.
Remote control of the AVR and transformer shall be effected on the remote control desks/ panels/
VDU's by:
Manual/ automatic selector switch
Push buttons RAISE/ LOWER
Digital position indication
Set point adjuster and indicator.
Indication of automatic mode position as well as set point adjuster and indicator shall additionally
be arranged on the AVR panel together with the instrumentation as defined below. Any operation
on that panel shall only be possible upon liberation by a special key.
(3)
Transformer Voltage Regulation
The voltage regulator shall be equipped with devices to automatically control the on-load tap
changers GT Unit Auxiliary Transformers. The detailed description of operation and interlocks is
included in Clause 4.5.1 Electrical Controls, Item (3) Automatic Voltage Regulator.
The voltage regulator shall be installed in cubicles located in the relay room, together with the tap
changer position indicator and a meter for the respective busbar voltage as well as the manual tap
changer control. The tap changer control and check-back must also be possible from the central
control room.
All interface and wiring/ cabling from the plant control system and to the tap changer etc. shall be
via suitable terminal blocks with disconnection facilities.
The control shall follow the step-by-step principle, i.e. a single control pulse shall operate the tap
changer from one service position to the next. A RAISE or LOWER control signal shall be
generated by the voltage regulator and issued to the motor drive whenever the measured voltage
deviates from preset conditions.
11.4.7 Synchronisation Systems

This item should be read in conjunction with Clause 2.5.1.1 Synchronising
A separate, fully automatic synchronisation system as well as a semi automatic synchronisation
devices shall be provided for each unit.
The electronic type synchronisation apparatus shall be provided with the generator control panels,
installed in the control building.
Normally, the circuit breaker shall be synchronised by an automatic programme.
Page: 103
Synchronisation shall be actuated by key switches placed on the unit control desks, respectively
via VDU's. The key switch shall have four positions: local -test - off - automatic. Another selector
switch shall be provided at the local control panel and shall have four positions: manual - test - off automatic.
Synchronisation from the local control panel shall only be possible if the selector switch on the
control desk is in local position. At any other position of the control desk selector switch the locally
installed selector switch shall be by-passed.
In the manual position, of the synchronising key switch both voltage systems shall be connected to
the local synchronising instruments and then both systems shall be synchronised by manual
actuation of the speed and voltage setting and of the circuit breaker control device via a
synchrocheck relay.
In the automatic and test position of the activated synchronising key switch, the instruments for
manual synchronising - double voltmeter, double frequency meter and synchronoscope - shall also
be connected to the measuring circuits, but all synchronising functions shall be controlled
automatically.
In the test position all functions of the system shall be executed without the breaker closing control.
The closing signal shall be indicated by means of a LED.
The following equipment shall be provided, for each unit:
One (1) synchronising device with synchronoscope, double voltmeter and double frequency
meter, synchrocheck relay for manual synchronisation. The instruments shall be installed
locally and in the CCR
One (1) electronic system for automatic connection of two voltage systems, with set point
output for the generator voltage regulator and for the speed governor of the turbine. Means
shall be provided for adjustment of the circuit breaker closing time, the maximum admissible
frequency difference for breaker closing, and the control time, etc.
All auxiliary devices as push buttons, indication lamps, interposing transformers, relays, etc.,
as required.
12 ELECTRICAL PROTECTION SYSTEM

12.1 GENERAL
This Clause includes the electrical protection systems as well as particular design requirements
regarding HV surge protection and for instrument transformers, trip and control circuits, auxiliary
systems and devices, etc., as required for the protection of HV and MV systems of the plant.
12.2 SCOPE OF WORKS

The scope of works shall comprise all required studies, the supply, installation and commissioning
of all HV and MV protection systems of the plant, mainly:
ST Generator Transformer Unit Protection
GT Generator Transformer Unit Protection
MV switchgear Protection
Protection of the 400 kV system, refer to Package S

Protection of the LV systems is covered by the LV equipment specifications.
Page: 104
All necessary software and hardware (note book, connecting cables and others) for setting and test
of protection relays shall be part of supply. If different systems are provided for generator and MV
switchgear protection, the above mentioned equipment shall be provided for each system which is
used.
12.3 LAYOUT
The STG-Transformer unit protection shall be installed in cubicles in the protection relay room of
the Central Control Building/Compartment.
The GTG-Transformer unit protection shall be installed in the relay cubicles.
The MV - switchgear protection shall be installed in the LV compartments of the switchgear,
respectively in separate protection cubicles, as applicable.
Any event, i.e. any pre-alarm, alarm trip generated within resp. by any protection system shall be
indicated locally, in the central control room and by the alarm/ event recording system of the plant.
12.4 DESIGN/CONSTRUCTION REQUIREMENTS

The primary function of the protection system is to isolate the disturbed part of the system in case
of fault or abnormal operation conditions with utmost reliability, speed and selectivity. Tripping of a
faulty part of the system shall take place before adjacent mechanical and electrical parts of the
system are damaged and early enough to maintain the power system stability. These requirements
shall be considered as a minimum to be satisfied.
The supply shall include, whether explicitly mentioned or not, all elements and drawings necessary
to co-ordinate and ensure the correct function of the referred protection in compliance with the
specifications.
Along with all components the contractor shall supply the necessary documents, calculations and
settings, related to the relays and to the primary network, to prove the correct function of the
protection equipment acc. to the specifications. The protective relays shall be of the numerical type
with a documented passed service period of not less than five years.
The different components shall satisfy the following general requirements:
protection relays shall be suitable for operation in the local climate and EMC conditions
protection relays shall not be responsive to mechanical shocks
parts installed in the open air shall be protected against sun radiation, EMC, humidity and dust
protection relays and associated auxiliary equipment shall be of standard construction
protection relays shall be supplied by an experienced and reliable manufacturer
protection relays shall be fitted into protection boards as specified elsewhere
applicable type test certificates in accordance with IEC, VDE or other International standards
shall be part of the documentation of the relays
insulation of all the related circuits shall comply with IEC 60255 and shall not be less than 2 kV
for all the interfaces
protection class of the enclosure for all relays or protection systems shall not be inferior to
IP 52, when finally installed
relay equipment shall be arranged to produce a perfect contact.
Page: 105
manual operation of any relay shall not be possible without first opening it
each protection system that needs a DC/DC converter shall have its separate and
independent DC/DC converter.
fuses - if used - as well as MCBs shall be supervised, with local and remote alarm
protection equipment shall be designed not to produce any Over-voltage in case of switching
of contacts at secondary AC and/or DC control or supervisory alarm circuits.
internal auxiliary relays, switches, terminals, push buttons, etc., shall have clearly marked
plastic labels, fixed by screws
double stock terminals on the protection circuit will not be accepted.
terminal blocks shall include 20% spare of each type of terminal used (exception for test
blocks)
Reverse power, under excitation, negative phase sequence protection, etc. which operates at
fraction of the rated current values may be connected to CTs of metering class type. However, the
scheme shall be subject to approval by the Engineer / Employer.
A display shall be provided with negative phase sequence protection to show the percentage of
unbalance current in terms of machine rating.
All generator back-up protection shall be connected to CTs located in the neutral side of the
generator.
Test access for injecting voltage and current signals for maintenance testing shall be provided.
Required test kits shall be part of the supply.
Protection for synchronism / pole slipping shall also be provided.
Multifunctional generator protection system (MGPS) shall be provided. Additionally to the above
mentioned requirements the MGPS have to correspond with the following instructions:
At least two MGPS for each protection application to be available.
Two MGPS preferably to have different operating principles.
Separate CT and VT inputs to be used
MGPS to be integrated into the plant DCS, protocol conversion if necessary to be provided
Status of each MGPS to be determined by the DCS by cyclically interrogating the diagnostic
function via communication link.
Protective functions are to be partitioned into different micro processors or different boards.
Back up for critical components, particularly power supply to be provided
Evaluation test report by a third party to be available
Acceptance test to be made
Control circuits including potential and current transformer secondary circuits, all batteries, DC
controls, AC auxiliary power supplies, supervisory alarms and communication circuits connected to
the function of the protection equipment shall be protected against conductive, electrostatic and
electromagnetic influences of transients of neighbouring circuits.
Page: 106
All relays shall have the necessary number of auxiliary contacts able to handle the AC and DC
control, communication, alarm, monitoring, supervisory and tripping functions related to the
protection as well as having the capability to make and break currents that can flow in the circuits.
External relay connections to voltage and current trans former secondary circuits, all batteries, DC
control, AC auxiliary power, supervisory alarms, tripping and communication circuits shall be
marked with slip-over ferrules of different colours and numbering. A unified colours and numbering
system to adopted for the whole plant.
(1)
Relay Front Design
The front of all protection relays shall be clearly marked with important information. Using the
contractual language the function of the relay and the name of the protected feeder shall be clearly
recognisable. Additional indicators on the front of the relay, with an adequate description in the
contractual language without the need to encrypt manuals and documents, shall allow the
identification of the phase and the type of fault on every protection equipment as well as every
operation step if more than one exists. At all protection relays the actual setting at every part of the
relay, the tripping alarm as well as all the supervisory and monitoring alarms, the latter for
electronic relays, shall be clearly visible without opening the relays.
Indicators shall allow identification of the protection started, the alarm of the supervisory and
monitoring of the protection as well as the alarm of the auxiliaries at the alarm boards.
Each indicator, whether of the electrical or mechanical type, shall be capable of being reset by
hand without opening the relay.
Test plug / socket arrangement to be made available with each relay.
Each cubicle where protection shall be located shall be illuminated internally for maintenance
purposes. The fluorescent lamp shall be controlled by the door and an additional emergency light
fed from the station battery shall be supplied.
(2)
Tripping
The trip supervision of feeders protected by more than one protection equipment or relay shall be
performed independently for the two CB trip coils and cover the whole circuit between the trip
contact up to the trip coil.
The trip circuit of the principal and backup protection shall have completely independent trip
circuits or matrix. Two independent trip matrix shall be provided for the generator protection
systems. Visible link isolation facilities to be available.
All the relays used for tripping shall still operate if the DC supply voltage is reduced to 70% of the
rated voltage. Relays that are connected to complete the tripping of a circuit shall be provided with
an operation indicator. The entire tripping circuits of CBs shall be continuously supervised in both
CB positions. The design of this supervision shall prevent the CB tripping in case of a fault of any
component of the referred supervision circuit.
No time delay for the tripping contacts will be accepted. Master trip relays shall have a maximum
tripping time equal to 10 ms or less.
The tripping contacts of protection relays without autoreclosing shall reset automatically when no
further fault conditions are present, whereas the signalling and block of closing order to the CB
remain until the operator resets the relay manually. An exception shall be made for the event
recorder signalling contacts.
All tripping control circuits for the CB shall be interrupted for the qualitative and quantitative tests.
These circuits shall be located at the same test block provided to test the relay with currents and/or
voltages.

(3)
Page: 107
Voltage and Current Transformers
If modules of relays connected to the CTs current circuits can be removed, the design of these
parts shall prevent an open circuit at the secondary side of the CTs in any case.
Voltage and current transformers considered for protection and metering purposes shall be of the
electromagnetic type only. No capacitor diverters with amplifier sets will be accepted as a voltage
transformer for protection task.
(4)
Current Transformer Design Data Calculation
The characteristic of current transformers for the protection described in these specifications are a
minimum requirement to be fulfilled. Protective current transformer classes should be as per IEC
44-6 (latest revision). Future growth of the DEWA system to be taken into account in selection of
the time constant. Before production of the current transformers, the contractor shall submit for
approval a verifiable calculation based on the design short circuit of the substation and the power
station and a time constant not lower than 50 msec for the network and 150 msec for the power
station. This is necessary to demonstrate that the offered protection will be stable for faults outside
its zone, trips within the required tripping time and has enough sensitivity to work together with the
offered CTs. This requested calculation shall define the maximum admissible CT rated output,
knee point voltages for all taps, enabling changes of the current transformers without additional
costs, if necessary.
(5)
Diagrams
The contractor shall supply, before elaborating the wiring diagrams, block diagrams in one drawing
for each type of feeder protection. These block diagrams shall include schematic information
concerning the logic, trip circuits, control circuits, secondary circuits of voltage and current
transformers with polarity marks, DC power supply, supervisory alarms and tele-protection circuits,
etc. These block diagrams shall be updated during the factory test, erection and commissioning
phases.
CTs shall be specifically designed for high impedance protection schemes.
(6)
Setting
The setting of the protection shall be elaborated at least one month before commissioning of the
equipment. The necessary studies shall be performed by the contractor and shall be submitted for
approval. Preliminary setting report has to be presented at least 3 month before commissioning.
Zero-sequence impedance measurement shall be carried out for each cable or line for each
voltage level of the network at least one month before commissioning of each feeder to assure
correct setting and operation of the protection devices.
(Note: With reference to Item (1) relay front design the following requirement has to be considered:
If test socket and plugs are not included on the relay separate test socket / plug arrangement is to
be provided!)
(7)
Testing
The protection system shall be completely wired, tested and inspected at the Contractors factory
as defined in the applicable Clauses of this specification.
Under this contract it is the contractors obligation to check the protection under random conditions
together with the current and voltage transformers to fulfil the required stability, selectivity and
function availability of the protection at all included network levels.
Each protection equipment and/or relay shall be able to be tested through test sockets to be
provided with the relay. The test plugs of the test sets shall correspond with the test sockets
provided with the relays.
Page: 108
If the test plugs and sockets are not included on the relay or protection equipment module or box,
each of them shall have a pair of contacts, spring loaded, separated from its neighbour by
insulated barriers. The contacts shall loosen automatically when the test plug is removed.
The connection to the test plugs from the outside circuits, e.g. current transformer, voltage
transformer, trip circuits, etc. shall be performed on the lower part of the test plug and, on the
contrary, the connection with the relay shall be performed at the upper part. Where interposing
current transformers are used, test sockets shall be provided to test both sides of these elements.
All relays shall be able to be tested for quantitative evaluation of all incoming current and voltages
as well as times and the confirmation of the trip signal to other protection or communication
equipment.
(8)
DC-Supply
Power supply requirements of the protection system shall match with DC supply system specified
in the relevant Clauses of the technical specifications.
All feeders protected by more than one protection equipment or relay shall have a separately
protected DC power supply for the control and tripping of each of these relays. CB control circuits
shall in any case be fed by separately protected DC circuits.
All electronic relays shall be equipped with a self-monitoring alarm system, especially for DC
supply and abnormal level of stabilised DC voltages but not necessarily limited to only these two.
The DC supply of all the protection relays shall be monitored by means of an auxiliary contact of
the related MCB that will provide an alarm.
The supervision relays shall indicate a delayed, independent and separate alarm for each
supervisory relay and a local and remote alarm in case of a missing DC supply and/or interruption
in the trip circuit wiring.
12.4.1 Additional Requirements for Numerical or Mixed (Numerical, Electronic and

Mechanical) Protection Equipment
(1)
General
The rate of sampling for A/D converters shall vary between 600 Hz and 1000 Hz. The
representation inside the protection relays of currents among 0.1 and 100 x rated current requires
the use of a microprocessor with at least 14 Bit word length. Numerical protection shall always
display the latest event.
Reset of the display shall be possible on the relay front without opening the cover. Reset shall not
erase the memory of the relay. On the panel front in a visible place a label with the particular
designation of each LED in the contractual language is required. The software version shall be
displayed if manually requested.
The operational indication shall be saved in a non-volatile ring buffer, a four digit resettable counter
shall identify the individual faults by a number and the date of the internal fault shall be saved for
each fault.
The recording shall be started by an external signal e.g. CB closing related to an alarm relay and
wired to the binary input. At least the three latest fault events shall be loaded into the memory of
the numerical relays.
The basic and back-up protection (both if provided as numerical relays) requires double infeed by
independent DC/DC converters that shall be fed from independent DC sources.
Numerical protection shall be designed in such a way that in case of a failure of DC-auxiliary infeed
the full information need to be maintained during 24 hours. After recovery of the DC-auxiliary
Page: 109
infeed the last information and alarms shall be displayed and the alarm of DC-auxiliary infeed shall
be released.
(2)
Requirement for Hardware and Software
Necessary hardware (1x PC for each voltage level) and software used for commissioning shall be
provided. After commissioning, such equipment including all required software shall become the
property of the employer. All cables between the PC, test equipment and protection shall be also
supplied.
The software manuals shall give clear details of every action to be performed in its use. The
handling of the numerical relays by the service personnel shall be possible without manual.
A protocol with the parameter settings and addresses shall be supplied for each relay incl. drawing
as well as the proposed programming of alarms and output contacts. A copy of the protocol shall
be placed on the protection board defining the addresses, labels and parameters finally set on the
relays.
On the drawings addresses and input values for the binary I/O, LEDs and command relays are to
be included for the specific use of the relays on this project.
Hardware and software for setting, data collecting and programming of the protection in all aspects
shall be included. A numerical protection without the appropriate software shall not be accepted.
If the entire Substation Control Unit is delivered from the same supplier as the protection
equipment a Dedicated Private Bus (DPB) or a Multi Vehicle Bus (MVB) for the connection from
the protection equipment to the Bay Control Unit and/or Station Control Unit will be accepted as
alternative. The ultimate decision has to be made by the Employer/ Engineer.
The numerical protection supplied shall have a documented service experience in plants of at least
five years. Otherwise, an extended 5 years warranty covering all possibly necessary supply and
work including hardware, software, trans port, installation, commissioning, etc., shall be provided for
such a particular relay scheme.
(3)
Interface Requirements
The protection equipment shall have been submitted/passed a test to certificate compliance with
the VDEW/ZVEI serial interface where the connections are wired directly to the substation/bay
control unit.
If not, for numerical, electronic or mechanical relays where this serial interface does not exist, the
supplier shall include an interface programmable microprocessor LLC (Logical Link Control) and
MAC (Medium Access Control).
The above mentioned MAC shall have an interface to the channel control i.e., CSMA/CD with
additional telegram building acc. to VDEW/ZVEI requirements to the Substation and bay control
unit. It will also perform the task of the MAC to synchronise these relays to the time data valid for
the entire process.
In this way all the alarms, trips and interlocking of non VDEW/ZVEI relays shall be interfaced to the
substation control.
All relays are to be delivered with a serial interface for the PC and one additional interface for the
integrated substation control.
At least 50% of the alarms shall be programmable and able to be related to output contacts of the
numerical relays.
Analogue interface parts will be of non numerical relays shall be integrated in the relay itself.
Page: 110
In case of numerical relays the interface shall be able to set the parameters from a remote control
by modem and be able to request data from the relays e.g. faulty voltages and currents. In case
some of these input parameters can not be remotely set, the contractor shall show this in writing
during contractual negotiations.
Through this serial interface the PC shall be able to retrieve the following minimum information,
archive set or modified. The data integrity for data transfer inside the substation control unit shall
be assured by a Hamming distance 8.
(4)
Fault recording
On line analogue fault currents and voltages (for generator bays in the 400 kV substation (if
starting is initiated by neutral current) neutral current is to be used from CT connected to neutral of
the Generator Unit step up Transformer. Residual current is not to be used.)
Retrieval, analysis of service and fault annunciations
Parameterising of protection devices
On-line acquisition of measured process values (r.m.s. or peak values) of currents, voltages, active
and reactive power
Marshalling of relays input, output, LEDs
Configuration of protection relays
12.4.2 Requirements for Generator Protection Relays

Reference is made to following drawings:
Protection schema GT Generator, Unit Step up Transformer and Unit Auxiliary Transformer ,
drawing number CNE / 015 / 2002-W - 00- E - D 00103
Protection schema ST Generator and Unit Step up Transformer , drawing number CNE / 015 /
2002-W - 00- E - D 00104
The following protection functions shall be provided:
Loss of field protection (LOFP)
Reverse Power protection (RPP)
Stator earth fault protection (STFP)
Rotor earth fault protection (RTFP)
Over-flux protection (OVFLP)
Frequency protection (FRCP)
Over-voltage protection (OVVP)
Under-voltage protection (UVP)
Negative sequence protection (NSQP)
Minimum impedance protection (MIMP)
Over-current combined with undervoltage protection (OCCV) + (UVP)
Overall differential protection (DOP)
Generator differential protection (DGP)
Generator dead machine protection
Under power protection (UPP)
Earth fault protection of SFC
Breaker failure protection
Page: 111
Fuse failure supervision and monitoring of DC supply of all protection systems shall be provided.
(1)
Protection against Loss of Field
The specified protection shall avoid the generator going in asynchronous operation at a speed
higher than the rated speed to avoid severe voltage depression, overheating of damper cage and
shaft oscillations.
An internal angle relay shall detect the rotor pole slipping in connection with the necessary
adjustable time delay. The stator condition shall be combined with machine impedance detection
and level of excitation voltage detection as a rotor criterion for tripping of the unit in among 0.2 to
1.5 s. The protection shall allow through a small delay, the AVR to re-establish the stability if the
stator criteria have been fulfilled and still exist a certain level of excitation. During this delay the
signal stability border should be signalised by flashing. As long the AVR is functioning and
restoring stability the relay to be co-ordinated such that it does not trip the unit. If the AVR is not
functioning, reduced trip level shall be used.
This protection shall provide the additional detection of out of step condition supplied by an additional module being the final decision of the service personnel to co-ordinate the trip of this relay
with the time delay of the over-current relays and distance relays of the network.
(2)
Reverse Power Protection
The specified scheme shall protect the generator against intentional or accidental trip of the prime
mover whilst the synchronous generator is still connected to the network and against inadvertent
closing of the HV circuit breaker whilst the unit is stopped. No risk of incorrect operation caused
(for example) by rotor swing accompanying a system electrical fault to be ensured.
Power reversal following a turbine trip signal shall immediately trip the generator.
Power reversal without turbine trip shall trip time delayed.
This protection shall have adjustable pick-up values between 0.5 and 10%.
There shall be two independent time lag elements adjustable among 0.5 to 5 s and 2.0 to 30.0 s.
The reverse power relay shall be able to accumulate brief load surges and trip if a certain total
integration time has been reached.
Measuring angles shall be switchable between 0 and 90 .
The direction of operation will be able to be reversed in service.
(3)
Stator Earth Fault Protection
This protection shall provide protection of the stator of the generator connected in block with a
transformer.
The relaying equipment shall provide 100% earth fault protection of the generator winding.
The equipment provided shall include the over-current transformer or the injection voltage
transformer necessary for the external source.
Page: 112
Additionally besides the 100 % earth fault a second protection covering 95 % of the stator winding
shall be provided. This relay will be connected to the open delta winding of the VT installed at the
generator side of the unit step up transformer.
The necessary low-pass filter for harmonic (third etc.) shall be included in the protection relay.
The distribution transformer connected to the neutral of the generator will have a knee point
voltage not less than 1.3 times of the generator phase to phase voltage. The resistor connected to
the secondary side of this distribution transformer will have 10 minutes rating.
The protection shall be selective not to trip for phase-to-ground fault on the high voltage side of the
generator step-up transformers and shall be co-ordinated with the pick-up levels of the third
harmonic voltage or current distribution.
This relay shall be provided with an adjustable time lag in several steps among 0-5 s, providing the
possibility of a delayed or even a direct trip.
(4)
Rotor Earth Fault Protection
The rotor of the generator shall be protected against single and double earth fault. The former shall
be related to a rotor earth fault alarm to warn the operating staff of the faulty condition, whereas the
second one shall trip immediately and take the generator out of service. Filters shall be provided
on the input to eliminate signals outside the frequency range and providing a high degree of
immunity. This protection shall be adjustable between 500 ohm and 2000 ohm.
(5)
Frequency Protection
The frequency protection shall provide protection of the generator for active power deficiencies or
excesses that could lead to reduced cooling of auto-ventilated machines, turbine blades vibration
and fatigue damage.
These relays shall have several independent adjustable tripping stages with settings among 39
and 55 Hz with additional df/dt tripping conditions.
Additional time delays shall provide a setting range equal to 0.1 to 1.5 s at each stage.
Independent adjustable setting for over-frequency and under-frequency conditions shall be
provided.
Qualitative testing of the relay shall be possible by a push button. The frequency setting at
commissioning shall be performed by a frequency generator.
The accuracy of this relay shall be not less than +00.3 Hz at rated frequency.
An alarm for signalling the trip of each stage shall be provided.
(6)
Overflux Protection
This protection should provide a simultaneous monitoring of voltage and frequency expressed in
per unit values of rated quantities.
The inverse-time operating characteristic shall protect the own characteristic V/Hz of the transformer , so that in this way the equipment will be protected during system disturbances with abnormal
V/Hz ratio. Setting range on the level of 1.1-1.5 V/Hz.
Two selectable time units with outputs with multiple contacts shall be provided to give an alarm
with a selected time delay of about 0.5 till 30 s and a trip order among 2.0 till 30 s.

(7)
Page: 113
Over-voltage Protection
These three-phase relays shall provide a protection of the generator against an abnormal situation
of the generator excitation, providing an alarm that allows the intervention in the exciter and a
delayed trip for sustained over-voltage.
The range of setting shall be in the range of 1.0-1.6 UN , whereas the instantaneous limit shall in the
range of 1.4-2.1 x UN .
The relays shall provide an alarm for the starting as well as the other lamps indicating the trip
order, one for the delayed trip and the other for the instantaneous.
Time setting shall provide a delay among 0.03-2 s.
Reset ratio shall be 95% UN .
(8)
Undervoltage Protection
These three-phase relays shall provide a protection against severe voltage depression and supply
additional conditions to other protections for their logical interlocking, i.e. over-current, reverse
power.
The setting of the relays shall be among 30-80% UN with a reset ratio equal to 105%.
Time setting shall provide a delay among 0.03-2 s.
Visual alarms, indicating starting and trip, shall be provided.
(9)
Negative Phase Sequence Protection
This protection shall protect the generator against the increase of temperature due to the
appearance of a negative sequence current on the rotor. A display/indication device shall be
provided with the Negative Phase Sequence Protection to show the percentage of unbalance
current in terms of machine rating.
The negative component shall be filtered and the positive sequence shall be blocked.
The accuracy of the current transformer used for this protection shall be defined by the contractor.
It is assumed, that this protection function will be incorporated in the MGPS.
Setting of this protection shall be between 1 and 5% of the rated power.
The starting and trip alarms of these relays shall be visible on the front of the relay.
A proper characteristic beneath the rotor I2t thermal limit curve shall be provided.
(10)
Minimum Impedance Protection
If a fault has not been cleared by the main protection the fault shall be isolated by the action of a
non-directional three-phase impedance measuring relay with a circular characteristic on the
resistance/ reactance diagram.
Under fault conditions when the voltage drops to zero, the current required to operate the relay
shall be at least 5% of the rated current. A built-in timer with adjustable settings shall be provided
for co-ordination purposes. In addition to the separate time-delayed output for each phase
separate instantaneous output contacts shall be provided. The same impedance for phase-phase
and three-phase fault shall be adjusted on this relay.
If the 400 kV side CB is closed first zone setting to cover 80 % of the Unit Step up Transformer
winding. If the 400 kV breaker is open, first zone setting to cover 100 % of the Unit Step up
Transformer winding. Second zone - if used will cover 100 % of the Unit Step up Transformer
winding.
Page: 114
Selective alarm signalling for each phase for the starting and tripping shall be provided.
The protection shall be applied additionally together with a logical trip order (protecting the
generator against an open power circuit breaker flash-over).
(11)
Over-current Combined with Undervoltage Protection
The over-current relays for the generator shall work together with the undervoltage protection to
provide proper protection for static excitation.
(12)
Overall Differential Protection
Three-phase biased differential protection relays with variable bias ratio shall be provided .
Interposing transformers or transductors with the possibility to perform, by means of switches
located on the front plate, compensation of phase and amplitude differences due to transformer
group of connection shall be provided. It should be possible to confirm the group by measurement.
Relays without this possibility shall be delivered with the necessary interposing CT's and test
terminals.
The corresponding current transformers shall be calculated so that any delay caused by the
saturation detector will be prevented.
The relay shall be insensitive to inrush current restraint the operation of the relay by using
harmonic, detection of the conductor current or other reliable means. It must be capable of rapid
tripping in the event of energising onto a fault.
Tripping time of less than 40 ms with differential currents equal to 5times the nominal setting
current shall be guaranteed.
Several legs will be required for differential protection scheme, dependent on its location.
(13)
Generator Differential Protection
High impedance type differential protection shall be provided.

(14)
Generator dead machine protection
To avoid accidental energising of the generator, while at stand still or on turning gear, due to
operational error, breaker head flash over or control circuit malfunction, a dedicated protection
schema shall be proposed to detect inadvertent energising. This schema shall provide protection
when the generator is off- line.
(15)
SFC Start up over current and over voltage protection.
If SFC is going to be used for start up of the GT unit, dedicated over current and over voltage
protection (operating range 5 to 50 Hz) shall be provided to work during start up operation.
12.4.3 Requirements for Step-up Unit Main Transformer Protection

The following functions shall be provided:
Transformer differential protection (DTP)
Line differential protection (HV Side SF6 bus ducts)
Restricted transformer earth fault protection, 400 kV (REFT)
Inverse time phase over-current protection, 400 kV(OCP)
Sensitive earth - over-current protection, 400 kV(SEFP)
(1)
Page: 115
Signalling/ alarms of transformer supervisory/ protection devices

Transformer differential protection
A three-phase biased differential relay with a variable bias ratio is required. This ratio must be such
that with maximum mismatch between the HV and MV CTs due to tap changing, the relay will
always securely restrain in the presence of maximum through-fault current.
The relay must not operate in the presence of magnetising inrush current yet must be capable of
rapid tripping in the event of energising onto a fault.
A tripping time of less than 40 ms (including main tripping contactor) with a differential current
equal to five times nominal setting current is required. Setting of bias and basic sensitivity must be
adjustable in steps during service.
All necessary interposing transformers with test terminal facilities must be provided which shall be
adequately rated to ensure correct relay performance during maximum through fault conditions.
Trip and indication output need not be on a phase segregated basis.
(2) Line differential protection (HV-Side SF6 bus ducts)
As protection for the phase bus ducts between the 400 kV terminals of the unit transformers and
the related 400 kV feeder in the substation a line differential protection shall be provided.
Measuring principle shall be current comparison between the related CT at both sides by use of
two relay units. The communication between these relay units shall be directly through fibre optic
links.
The complete protection, cubicles with relays including the fibre optic cables will be provided by the
contractor of Package S. One relay unit will be installed in the relay transformer protection cubicles
in the relay room of the power plant, the second one (remote end relay) will be installed in separate
cubicles in the relay room of the 400 kV Substation. All these cubicles will be provided by the
contractor of Package S. The installation works in the Package S area shall be done by the
Package S Contractor.
Specification for the design of the CT cores in the 400 kV feeder shall be provided by the
contractor of Package P and submitted to the contractor of Package S to avoid any mismatching
of this protection.
The current comparison protection shall have a high fault sensibility even under high through
current conditions. The measuring principle shall guarantee, that the load current flowing prior to
fault inception shall be eliminated from the measuring quantities for a short period after fault
inception.
The pick up value of this dynamic measuring shall be 20 to 100% Inom . After two periods the
measuring function shall change over to a steady state phase comparison.
The communication with the remote end shall use one 64 kbit/s standard channel and shall by
itself measure the signal transmission time and automatically compensate the signal prolongation
time. The protection system shall provide an integrated direct transfer trip channel that can be
independently used for signal transmission.
The signal transmission shall be based on IEC 870-5. For direct communication through optical
links mono-mode fibres shall be used. Suitable optical interface shall be provided.
The signal transmission shall be monitored continuously. In case of transmission failure, the
current comparison protection shall be blocked and the relay shall switch over to a back-up over
current mode.
Page: 116
(3)
Restricted earth fault protection (HV-Side)
An independent high impedance circulating current protection scheme is required for each winding
being provided with earthed neutral. It shall be connected to dedicated CT cores on the HV resp.
MV and neutral connections of the transformer, as applicable. These CTs shall have equal ratios,
identical magnetising characteristics and identical secondary resistances. The magnetising current
shall be the minimum practically available in order to maximise the sensitivity of this protection.
The relay shall have an operating time of less than 40 ms (including main tripping contractor) when
set to ensure complete security in the presence of through faults and when the CT knee point
voltage is applied. The relay shall be tuned so that it is insensitive to the DC component of fault
currents.
A current transformer, located at the neutral point, with one core of class X and the same magnetising
characteristic, ratio and output as the current transformers located at the line terminal side and with a
second core for the sensitive earth fault protection shall be provided.
(4 )
Sensitive earth fault protection (Earthing point)
An independent over-current relay with a definitive characteristic, a low current setting (0.5% to
15%) and a low basic burden shall be provided.
A timer with a long time delay adjustable among 0.5 till 10.0 sec. and a thermal dimensioning that
allow the service of this protection in this network with a high single phase fault level.
(5)
Inverse time phase over-current protection
Three independent single-phase normal IDMT relays shall be provided for over-current protection,
covering the through-fault withstand capability of the power transformer. These relays shall comply
with BS 142/1966 respectively IEC 60255-4 and with the standard characteristics requested in
these standards.
Each relay shall provide means for at least five selectable characteristics.
The over-current relays shall have current ranges from 50% to 200% in steps of 25%.
The time settings for this relays shall be continuously variable from 0 to 1.0 or, as an alternative,
with steps of at least 0.01 from 0.05 to 1.0.
Each over-current relay shall be supplemented with an instantaneous element having a range 5 to
16 times nominal current. It must also be capable of being set to infinity.
Tripping shall occur from the instantaneous unit in less than 40 ms including main tripping
contractor when two times the setting current is flowing.
The instantaneous and IDMT elements shall have separate trip and alarm contacts and separate
trip indicators.
Non volatile memory for the time delayed and instantaneous LED indicators
(6 )
Signalling/ Trip of Buchholz Relays ,Oil and Winding Temperature Protection
All signals provided by local protection/ supervisory devices of the power transformer as
signalling / trip of Buchholz relays of transformer tank and OLTC
oil temperature signalling / protection
winding temperature monitoring / protection
pressure relief for main tank and OLTC compartment protection
pressure relief for off load tap changer protection (if applicable)
oil level signalling / protection
transformer cooling system monitoring
further protection / transformer protection and supervision facilities if applicable
Page: 117
shall be wired to the binary I/O input units (in the case of numerical relays) and to a separate alarm
panel placed on the transformer protection board. The designation/ labels of the LED/ Alarm panel
shall define clearly the origin of the signal.
12.4.4 Requirements for Unit / Main - Auxiliary Transformer Protection

The following protection functions shall be provided:
Earthing resistor dimensioning and protection
Transformer differential protection
Inverse time phase over-current protection, Ugen (kV) side
Restricted Earth Fault relay
Inverse time phase and earth over-current protection, 11 kV side
Signalling/ alarms of transformer protection / supervisory devices as signalling / trip of

Buchholz protection; oil temperature signalling / protection; winding temperature protection.
Identical protection as with the unit main transformer shall be considered.
(1)
11 kV earthing resistor protection and dimensioning of the earthing resistor
An earthing resistor in accordance with the ANSI/IEEE Std 32-1972 with following data shall be
included in this contract
11 kV earthing resistor shall be rated for 10 minutes.
The element materials shall possess a balanced combination of properties, uniformity of
resistance, and mechanical stability over the intended operating temperature range, without any
injurious effects to the element and the associated insulation.
All conductor termination shall be bolted, welded or brazed. Low-melting alloys to join connectors
would be adversely affected by the resistor operating temperature and shall not be used.
The reference ambient temperature is equal to the design ambient temperature.
Temperature rise test, standard impulse test and dielectric test shall be performed at the workshop.
The protection scheme of the resistor shall consist of a sensitive earth fault protection with a
definitive characteristic and long time delay to co-ordinate with the 11 kV network protection, an
inverse characteristic over-current relay to protect the resistor thermally and an instantaneous
element with a very long time delay to co-ordinate with the continuous (long time) design current.
If this last element will not be possible a voltage relay with a single phase voltage transformer shall
be provided for this aim.
A current transformer with two cores shall be provided with the earthing resistor. One of the cores
shall be designed for the above detailed protection and the other shall be of class X with the same
magnetising characteristic, ratio and output as the current transformers located on the line side for
the restricted earth fault protection.
Page: 118
(2)
Restricted earth fault protection (11 kV)
An independent high impedance circulating current protection scheme is required for each winding
being provided with earthed neutral. It shall be connected to dedicated CT cores on the line and
neutral connections of the transformer. These CTs shall have equal ratios, identical magnetising
characteristics and identical secondary resistances. The magnetising current shall be the minimum
practically available in order to maximise the sensitivity of this protection scheme.
All signals provided by local protection/ supervisory devices of the power transformer shall be wired to
the binary I/O input units (in the case of numerical relays) and to a separate alarm panel placed on
the transformer protection board.
The designation/labels of the LED/Alarm panel shall define clearly the origin of the signal.
12.4.5 MV Switchgear Protection

The following protection features shall be provided, as applicable:
Overall busbar protection
Bus sectionaliser protection
Protection of Cable Feeders to 11 kV Sub-distribution boards
Motor feeder protection
LV transformer feeder protection
(1)
Overall Busbar Protection 11 kV
This protection shall operate on the differential circulating current principle employing high
impedance relays of voltage calibrated type.
A supervision device for the current transformer circuits shall be provided.
The operating time of the busbar protection, including trip relays, shall not exceed 50 ms at 5 times
the setting.
The rated stability limit of each fault detecting system shall not be less then the rated short time
current of the associated switchgear.
Limiting voltage devices for internal faults will maintain the level of voltage on the secondary side
down to 2 kV and will not cause a split current for more than 300 mA at the knee point voltage of
the current transformers.
Both trip coils of the circuit breakers are separately energised by the busbar trip relay.
The high impedance relay may be of either voltage calibrated or the current calibrated.
(2)
Bus Sectionalise r, Inverse Time Phase and Earth Over-current Protection
Three independent, single-phase, normal IDMT relays shall be provided for over-current protection.
These relays shall comply with BS142/ 1966 resp. IEC 255-4 and with the standard characteristics
requested in these standards.
An earth fault element connected to the residual secondary circuit of the current transformer in the
corresponding feeder with the same curve specification than the phase relay shall be provided.
Each relay shall provide means for at least five selectable characteristic.
The over-current relays on the phase shall have current ranges from 50% to 200% in steps of 25%
and the earth fault relay shall have current ranges from 20% to 80% in steps of 10%.
Page: 119
The time setting for this relays shall be continuously variable from 0 to 1.0 or, as an alternative,
trip indicators.
Non volatile memory for the time delayed and instantaneous LED indicators.
(3)
Cable Feeders to 11 kV Sub--distribution boards
Over current and line differential protection for 11 kV interconnecting cables between the 11 kV Unit
auxiliary boards and the 11 kV Desalination Boards 1, 2, 3, 4, 5 and cables between the 11 kV Unit
auxiliary boards and 11 kV Sub distribution boards in the desalination plant shall be provided in
addition to the Inverse Time Phase and Earth Over-current Protection described in the above
mentioned item .
The line differential protection shall be of the same relay system as described for the protection of
the 400 kV bus ducts (please refer to 12.4.3 Requirements for Unit Step up Main Transformer
protection).
The complete protection including the fibre optic cables shall be provided by the contractor of
Package P.
One relay unit shall be installed in the control compartment of the 11 kV feeders in the 11 kV Unit
board, the second one shall be handed over to the contractor of Package D Desalination plant to be installed in the control compartment of the related incoming feeder cubicles.
Specification for the design of the CT cores in the incoming feeder of the 11 kV Subdistribution
boards in the desalination plant shall be provided by the contractor of Package P and submitted to
the contractor of Package D to avoid any mismatching of this protection.
(4)
Motor Feeder Protection
Multifunctional digital over current relays shall be provided. During the starting condition the motors
need to be protected by a long-time phase over-current relays (definitive characteristic) with
instantaneous element. An over-current protection function with an extremely inverse characteristic
shall provide a locked-rotor protection, the relay curve shall be set below the motors locked-rotor
thermal limit curve for voltages among 80 per cent and 100 per cent. As an alternative the
contractor may provided for the locked-rotor protection an impedance sensing relay that will
monitor the voltage, current and phase angle without requiring access to rotating parts.
Controlling the number of consecutive starts and protection function for too long starting time shall
be included.
Earth fault protection function connected to separate zero sequence CT (CT residual connection
are not to be used !) shall be provided.
A negative sequence protective function shall be provided to protect the motors against single
phase operation and imperfect transposition of feeders.
A thermal overload protection function shall protect the motor against overload.
Differential protection for large motors (P> 1 MW) shall be provided.
Page: 120
For induction motor the torque developed is approximately proportional to the square of the applied
voltage therefore an undervoltage relay with a time delay shall be provided.
(5)
MV/ LV Auxiliary Transformer Inverse time phase and earth over-current protection
Three-phase normal IDMT relays shall be provided for over-current protection. These relays shall
comply with BS142/ 1966 and IEC255-4 and with the standard characteristic requested in these
standards.
An independent earth fault element connected to the zero sequence CT (CT residual connection
are not to be used !) in the corresponding feeder with the same curve specification than the phase
relay shall be provided.
Each relay shall provide means for at least five selectable characteristic.
The over-current relays on the phase shall have current ranges from 50% to 200% in steps of 25%
and the earth fault relay shall have current ranges from 20% to 80% in steps of 10%.
The time setting for this relays shall be continuously variable from 0 to 1.0 or, as an alternative,
trip indicators.
Non volatile memory for the time delayed and instantaneous LED indicators.
Restricted earth fault protection and phase over-current relay and standby earthfault protection
feeding from zero sequence CT (not from CT residual connection!) shall be provided at the LV side
of the transformers.
12.5 TESTS
12.5.1 General
All components of any protection system shall be workshop tested in line with the respective
standards as well as the requirements of the applicable specifications. The contractor shall prepare
comprehensive test programs, commissioning and test schedules for each system as required to
prove correct design, installation and operation.

All relays and compost relay systems shall be subject to routine tests as specified in the relevant
IEC publications or other applicable standards.
The testing procedure for ready assembled boards shall prove the correctness of the assembly, its
settings and the range of operation.
The performance of type tests will not be required in those cases where the Contractor can submit
the required type test certificates for identical equipment.
Page: 121
12.5.3 Site Testing Procedures and Commissioning

(1)
Procedure
Prior to start of commissioning, lists and schedules for the protection system detailing the precise
commissioning tests to be carried out on the various types of protective relays shall be provided.
Each relay has to checked over the full range by secondary injection. As per approved setting,
each relay has to be checked by secondary injection. Overall system to be verified by primary
injection finally.
The test schedules shall confirm that the equipment has been erected and operates satisfactorily
under the conditions defined in the specifications.
The Contractor shall employ only experienced and highly qualified commissioning and test
personnel and shall provide all necessary test equipment.
The time schedule for testing shall be agreed between the Contractor and the Engineer.
Overall tests involving more than one manufacturers equipment shall be co-ordinated by the
Contractor.
(2)
Standards and Methods
The method of testing shall be agreed with the Engineer.

Details of the test equipment and instruments used shall be noted in the test sheets in cases where
the instrument or equipment characteristics can have a bearing on the test results.
The Contractor's test equipment shall be of satisfactory quality and condition and, where
necessary, shall be appropriately calibrated by an approved authority or standard at the
Contractor's expense.
(3)
Wiring
Insulation resistance tests are to be carried out on all AC and DC protection, control, alarm and
indication circuits.
Static equipment which may be damaged by the application of test voltage shall have the
appropriate terminals short circuited.
Burdens are to be checked and recorded for each CT and VT.
Inter-relay, inter-unit and cubicle wiring carried out at site shall be checked to the appropriate
circuit and/or wiring diagram.
Loops resistance measurements shall be made and burdens shall be checked on all current and
voltage transformer circuits. All measurements are to be recorded on lead resistance diagrams.
Pilot cable impedance and phase angle measurements shall be made when pilot cables are to be
used.
(4)
Mechanical Inspection
All boards and relays are to be examined to ensure that they are in proper working condition and
correctly adjusted, correctly labelled and that the relay case, cover, glass and gaskets are in good
order and properly fitting.
(5)
Secondary Injection
Secondary injection shall be carried out on all AC relays using voltage and current of sinusoidal
wave form and rated power frequency.
Page: 122
For circulation current protection employing high impedance voltage operated relays, the points of
injection for relay voltage setting tests shall be across the relay and stabilising resistance. The fault
setting for this type of protection is to be established by secondary injection, where it is
impracticable to ascertain this value by primary injection. Injection is to be made across the
appropriate relay bus wires with all associated relays, setting resistors and CT's connected.
(6)
Current Transformer Magnetising Tests
The magnetising characteristic of all current transformers shall be checked to identify the current
transformers with reference to the manufacturer's estimated design curve, and to determine the
suitability of the current transformer for its intended duty. Special measures may have to be taken
to ensure that the core is fully demagnetised before commencing the test.
(7)
Primary Injection
Primary current injection tests are to be carried out with all protection relays and systems including
the protection of the LV switchgear by the Contractor. Appropriate teat kid shall be provided. The
primary injection methods employed for a particular installation shall be agreed upon with the
Engineer.
Tests are to be carried out as follows:
a)
Local primary injection to establish the ratio and polarity of current transformers as a group,
care being taken to prove the identity of current transformers of similar ratio.
b)
Primary injection tests shall be carried out for all protections including the LV switchgears.
Appropriate test kits shall be made available for the tests. Overall three-phase primary
injection to prove correct interconnections between current transformer groups and
associated relays.
c)
Fault setting tests to establish, where practicable, the value of current necessary to produce
operation of the relays. If not practicable, these tests are to be carried out by secondary
injection applied at the wiring close to the current transformer.
13 CATHODIC CORROSION PROTECTION

13.1 SCOPE OF WORKS
The scope of works shall include all studies, design, supply, installation and commissioning of a
cathodic corrosion protection system as required to protect all steel and steel structures, which,
due to their installation or duty are in contact with sea water or are buried into the ground. This
shall include:
Co-ordination with other metallic parts, e.g. the earthing system, etc., buried into the ground
All material and works required for the implementation of the cathodic protection system.
13.2 DESIGN REQUIREMENTS AND DATA

13.2.1 General
Cathodic protection, either by a sacrificial system or by an impressed current system shall be used
as required to ensure long-term corrosion protection. The system design shall consider the
following:
Sea water and soil resistivity prevailing at the Site
Ten years minimum service life of anodes for impressed current cathodic protection
Page: 123
Five years minimum service life of anodes for sacrificial cathodic protection
The impressed current protection system shall automatically maintain a voltage level as
required by the design of the system and the anodes utilised. However, in the event that
alterations to the voltage may be desirable when reviewing actual protection performance, the
equipment shall be capable of being readjusted to new figures.
The criteria for protection shall be in accordance with the applied standards and code of practice
as to be proposed by the Contractor for approval.
13.2.2 Sacrificial Cathodic Protection

In plant areas where the risk for fire and/ or explosion hazards is inherent due to materials handled
in such area, sacrificial anodes shall be provided.
13.2.3 Impressed Current Cathodic Protection

In plant areas where sacrificial cathodic protection is not mandatory, protection by impressed
current shall preferably be provided.
13.2.4 Design Particulars

The design and the selection of material and methods shall consider that beside steel structures
and pipes other metallic parts as cables, earthing conductors, etc., will be buried into the ground.
That equipment shall not be affected by the cathodic protection system.
Design life time of the system shall be 25 years. Material characteristics, material lists and
dimensioning of the system shall be provided by the contractor in the offer.
The AC and DC systems, as well as control and monitoring devices shall be designed in
compliance with the relevant electrical and I&C Specifications.
Ground anodes for buried structures shall be suitable for the intended environment including the
prevailing soil and ground water conditions.
Sacrificial anodes shall preferably be of zinc or aluminium alloy.
Impressed current anodes shall preferably be copper cored titanium, continuously plated with
platinum. Anodes shall be protected against physical damage in service.
Reference electrodes shall preferably be of high purity zinc or aluminium.
The reference electrodes shall have adequate surface to prevent the polarisation.
Sensing electrodes shall be incorporated to provide a feedback to the automatic voltage regulation
equipment.
Reference electrodes shall be provided for all areas under protection.
Adjustable, automatic control of impressed current protection shall be provided to allow the level to
be set to match developing site conditions.
The anodes shall be spaced sufficiently far from the structures to prevent crud build-up and high
local current flow. In addition, an extra thickness of protective coating shall be incorporated
between the adjacent parent metal and the anode.
The control equipment shall be so arranged that each group of equipment will be controlled
independently of other equipment.
Page: 124
The supply and distribution cubicles shall be located in relation to the equipment being protected.
Monitoring of the individual distribution cubicle supply and anode voltages as well as alarm
facilities shall be provided.
Failure of individual anode system, of distribution cubicle supply and of protection coating shall be
monitored individually locally and groupwise in the CCR.
Link / junction boxes to have a protection degree of IP 65 and shall be provided to enable testing of
the galvanic current.
All buried steel pipework to be protected shall be provided with electrically isolating flanges where
it emerges from the ground and no connections between the buried pipework and the electrical
earthing grid shall be made unless required through polarisation cells, to maintain safe potential
gradient control.
Protective coatings shall be employed on buried pipes and structures to minimise protection
current requirements and non-welded joints shall be bonded to provide good electrical continuity.
All pipe joints shall have protective coatings applied.
Excavations for pipe runs shall be lined with sand or fine grit and the backfill shall be suitably
graded and applied to minimise damage to the pipe coating.
Each pipe run shall be supplied with a cable cad-welded in place for subsequent connection of the
cathodic protection system.
Cathodic protection of steel in structures which include titanium components shall not be used to
exclude that titanium will suffer hydrogen embrittlement by the accidental application of excessive
potential differences. Such steel components shall be protected by suitable coatings.
The Contractor shall arrange his time schedule as required to ensure that cathodic protection is
operational prior to flooding of seawater equipment.
13.3 TESTS
All equipment shall be workshop and site tested in line with the applied Clauses of these
specifications and the relevant standards.
Functional tests at site shall prove that the criteria as to be elaborated by the Contractor by his
design study are complied with.
DEWAs MMS/DMS Functional Requirement Document for L-Station
Attachment to the
Particular Technical Specification
P2.27
MMS/DMS Systems and

IT Facilities
At L Station
WORKING DOCUMENT
Page 1
A. Introduction:....................................................................................................................3
Q. Network & Connectivity Specifications .........................................................................4
Q.3 Backbone Cabling .................................................................................................4
Q.4 Telecommunications Closet..................................................................................5
Q.5 Horizontal Cabling................................................................................................5
Q.6 Work Area .............................................................................................................5
R. LAN/WAN ......................................................................................................................5
R.1 Minimum specifications for the switches are as follow: .......................................6
R1.1Core Switches.......................................................................................................6
R.1.2 Workstation Switches. ........................................................................................6
R.3 Monitoring and Management software .................................................................7
U. IT Facilities ....................................................................................................................9
U.1 Computer Room Layout ........................................................................................9
U.2 Raised floor ..........................................................................................................9
U.3 Electricity connections ........................................................................................10
U.4 AC units ..............................................................................................................10
U.5 UNINTERRUPTIBLE POWER SUPPLY SYSTEM ........................................10
U5.1 General Requirements....................................................................................11
U5.2 General Design and Construction ..................................................................12
U5.3 Inverters .........................................................................................................14
U5.3.1 Performance ...............................................................................................14
U5.3.2 Operation....................................................................................................15
U5.3.3 Alarms ........................................................................................................16
U5.3.4 Isolating Devices........................................................................................16
U5.4 Mains Bypass .................................................................................................16
U5.5 Rectifier/Charger............................................................................................17
U5.5.1 Performance ...............................................................................................17
U5.5.2 Operation....................................................................................................18
U5.6 Batteries .........................................................................................................19
U.6 Fire detection and extinguisher system. ..............................................................20
U.7 Access control and monitoring system. ..............................................................20
U.8 Furniture..............................................................................................................21
U.9 Telecommunication Closet..................................................................................21
U.10 Communication Cabinets ..................................................................................21
Page 2
Maintenance Management System Document Management

System
IT Facilities at L Station
A. Introduction:
This Section of the Specification defines the functional requirements for the new
MMS/DMS System. The specific requirements are described under the following sections
Software functional requirements
Hardware Equipment requirements (Quantities of hardware and technical details)
IT Facilities
Page 3
Q. Network & Connectivity Specifications

New Administration building and other all buildings in L - station must adhere to
international standard of Structure cabling system as follow.
Structure Cabling system
Q.1 Building Entrance

Building entrance facilities provide the point at which outdoor cabling interfaces with the
intra-building backbone cabling. The physical requirements of the network interface are
defined in the TIA/EIA-569-A standard.
Q.2 Equipment Room
The design aspects of the equipment room are specified in the TIA/EIA-569-A standard.
Equipment rooms usually house equipment of higher complexity than
telecommunications closets.
Q.3 Backbone Cabling
The backbone cabling provides interconnection between telecommunication closets,
equipment rooms and entrance facilities. It consists of the backbone cables, intermediate
and main cross-connects, mechanical terminations and patch cords or jumpers used for
backbone -to-backbone cross-connection. This includes:
-
Vertical connection between floors (risers)

Cables between an equipment room and building cable entrance facilities
Cables between buildings (inter-building)
Other Design Requirements

- Star topology
- No more than two hierarchical levels of cross-connects
- Bridge taps are not allowed
Page 4
Main and intermediate cross-connect jumper or patch cord lengths should not
exceed 20 meters (66 feet)
Avoid installing in areas where sources of high levels of EMI/RFI may exist
Grounding should meet the requirements as defined in TIA/EIA-607
ANSI/TIA/EIA-568-B1, 2, 3 to be met
Q.4 Telecommunications Closet

A telecommunications closet is the area within a building that houses the
telecommunications cabling system equipment. This includes the mechanical
terminations and/or cross-connect for the horizontal and backbone cabling system. Please
refer to TIA/EIA-569-A for the design specifications of the telecommunications closet.
Q.5 Horizontal Cabling
The horizontal cabling system extends from the work area telecommunications
(information) outlet to the telecommunications closet and consists of the following:
- Horizontal Cabling
- Telecommunications Outlet
- Cable Terminations
- Cross-connections
Q.6 Work Area
The work area components extend from the telecommunications (information) outlet to
the station equipment. Work area wiring is designed to be relatively simple to
interconnect so that moves, adds and changes are easily managed.
R. LAN/WAN
All Design drawings and Diagrams for the LAN/WAN have to be submitted for approval
to DEWA prior to any implementation.
Network redundancy to be highly considered in the design on the levels of power
supplies, cable route, switches, communication cabinets location and servers network
adapters in order to guarantee 100 % network availability with no single point of failure
for the LAN/WAN.
Minimum 24 Core fiber optic cables to be laid for any route (Out Door / In Door) in the
proposed design.
Minimum 10 Gigabit Ethernet standard proven technology to be provided in the LAN to
build high-speed redundant connections between switches and between switches and
servers.
No redundant connection is required for client PC.
Minimum 1 Gigabit Ethernet to the desktop.
Number of ports is to be determined from the structured cabling formula used for the
buildings in the campus in order for covering the entire work area.
All switches must comply with the standard of Layer3/Layer4 switching techniques.
Page 5
Upgrading the existing JAPS network from FDDI technology to Gigabit Ethernet
technology and connecting the new L Station network with D, E, G, K, H Stations and
the Head office through NAJMA and SATWA. Upgrading of the backbone
protocol/cabling from existing FDDI Technology to support Giga switching, latest ATM
or latest Standard Technology, Network equipments (Switches Routers,etc) shall be
included in the upgrading. Please refer also to Block diagram under section E of this
document.
R.1 Minimum specifications for the switches are as follow:
R1.1Core Switches.
High Performance, scaleable, high availability core switch for campus Backbones.
Switch provides scalable bandwidth and increased network reach with support of Layer
2/ Layer 3/ Layer 4-7 intelligent services with a performance reach up to 210 Million
packets per second.
- Redundant Load-Sharing Power Supplies.
- Redundant Supervisor Engines, uplinks & system clock.
- Redundant Switch Fabrics.
- Eleven Hot Swappable Switching slot modules.
- LAN, MAN & WAN convergence support.
- Supports various WAN modules (E1, HSSI, E3, ATM & PoS) thru Flex WAN
module option.
- IP Telephony, Voice Gateway, Intrusion Detection System, NAM and ATM OC-3
module options are available.
HSSI = High Speed Serial Interface
E3
=34.368 Mbps
POS =Packet-over-SONET
R.1.2 Workstation Switches.
High Performance, scaleable, stackable and multi-layer switch that will provide high
availability, quality of service (QoS), and security to enhance network operations.
Range of Fast Ethernet and Gigabit Ethernet configurations.
Allow you to deploy network-wide intelligent services with the simplicity of traditional
LAN switching
Extends a set of Layer 2-to-Layer 4 features IOS Software- IP routing, QoS, rate
limiting, access control lists (ACLs), and multicast services- to the edge.
Simplifies access layer and small backbone deployment with the embedded Cluster
Management Suite Software
Delivers powerful Gigabit Ethernet connectivity with a full suite of Gigabit Interface
Converter (GBIC) devices
Redundant Load-Sharing Power Supplies.
Page 6
R.3 Monitoring and Management software

Enable the enterprise to plan, provision, configure, and monitor. Through an intuitive
user interface, the solution should eases and accelerates deployment, enables efficient
operation of large network environments, and streamlines the provisioning process.
Provides device-specific element management for Fault management-Provides status
updates on chassis, module, interfaces and the mapping of system log (syslog) messages
and MIB traps to alarms.
Fault and network performance management solution that can be deployed across the
entire enterprise, eliminating bottlenecks in the network, making sure the network is
available to users and responding to hardware and software malfunctions.
Network & Server Uptime/Downtime Monitor to monitor network using various
protocols (e.g. ping, http/https, SMTP, ftp, pop3, DNS) and notifies the staff in various
ways as soon as an outage occurs.
Provide network engineers with portable network analysis solutions for quick
identification and resolution of network performance issues.
Easy-to-generate reports that make it possible to quickly display key network statistics.
QOS (Bandwidth) monitoring.
Support for Voice (VoIP) monitoring feature option.
Support for Application Response Time (ART) monitoring feature option.
LAN management tool that can spot security risks in real-time
Network traffic sniffer and logger that allow you to monitor all internet and network
traffic on your PC and view the actual content of the packets, showing you exactly what
was transmitted and to where which includes all traffic initiated by software products,
web sites etc.
The capability to audit what flows in and out of every piece of software.
Show the history since boot time of every TCP, UDP or RAW port opened through
Winsock.
Affordable, easy-to-use TCP/IP port scanner tool for network administrators and
computer security professionals.
Network mapping and monitoring tool that allows administrators to receive immediate
notification of network problems.
Manage a network by providing a visual diagram interface that allows you to
interactively add and test network resources, including not only components, but also
shared resources and performance data.
Monitors all TCP/IP activity to and from the Internet or other network connections and
shows the communication speed in real time.
Allow you to determine how fast data is really transmitted over your network.
Monitor and display file system activity on a system in real-time.
A tool for exploring the way how Windows works, seeing how applications use the files
and DLLs, or tracking down problems in system or application file configurations.
Page 7
Show precisely when every open, read, write or delete, happens, and to tell you the
outcome.
Page 8
U. IT Facilities
U.1 Computer Room Layout

Room 1 located in the 4th
floor of new L-Station Admin.
building
A/C 1
Storage
DMS
System
Comm.
Cabinet
2
Comm.
Cabinet
1
A0 size
Scanner
A/C 2
MMS
System
Printer
A/C 1
Storage
Comm.
Cabinet
2
Optical
Disk
A3 size
Scanner
Operation
Work
Space
Plotter
Room 2 located in
K-Station or G Station
Layout Diagram
Work
Station
Comm.
Cabinet
1
A0 size
Scanner
Plotter
Work
Station
DMS
System
A/C 2
MMS
System
Optical
Disk
A3 Size
Scanner
Operation
Work
Space
Plotter
work
Station
work
Station
The above layout provides for a highly available DMS/MMS system to the user by
means of having a fault tolerant data replicated system with an off-site online data
replica. The user should get uninterrupted access (99.999% of the time) to the
systems regardless of failures that may occur in the background. This is the reason
why there are two rooms with the same equipment in each room. If one of the rooms
fails (due to power loss, natural disaster etc.), then the other takes over. Likewise, in
each room, if either the DMS or MMS system fails, then the other one takes over.
U.2 Raised floor

The raised floor panels should have the following properties:
1. Excellent rolling load performance
Page 9
2. Interchangeable with other panel strengths

3. Painted finish for lifetime protection
4. Solid and quiet
5. Superior ultimate load performance
6. Completely non-combustible
7. Excellent grounding and electrical continuity
Following are the minimum specifications required:
System
Type
Under
Structure
Corner
lock
Bolted
Stringer
System
Weight
Static Loads
Concentrated Uniform
Loads
Loads
10.5
lbs./ft^
51 kg.
/m^
11.5
lbs./ft^
56 kg.
/m^
Rolling Loads
Impact
Ultimate
10
10,000 Loads
Loads
Passes Passes
1500 lbs.
680 kg.
375 lbs.
170 kg.
4600
lbs.
2087 kg.
1500 lbs.
680 kg.
375 lbs.
170 kg.
5100
lbs.
2313 kg.
1250
lbs.
567
kg.
1250
lbs.
567
kg.
1000
lbs.
454
kg.
1000
lbs.
454
kg.
100
lbs.
45 kg.
150
lbs.
68 kg.
U.3 Electricity connections

The connections must be supplied from two different sources and designed to
support a load of 100kVA, and must be through UPS. The A/C units must have
separate power connections from the other equipment. All electricity outlets
should conform to Industrial Standards.
U.4 AC units
Dual heavy-duty A/C units with automatic switching over mechanism between
the units preferably under floor air flow type. The temperature within the rooms
should be maintained at 21 2 C and the humidity should be maintained at 50
5 %.
U.5 UNINTERRUPTIBLE POWER SUPPLY SYSTEM
Page 10
The Administration building should have overall UPS protection for all the electronic
equipment in them. The UPS should have a stand-by time of 12 hours and must support
a load of 100 KVA.
U5.1 General Requirements
An Uninterruptible Power Supply (UPS) System shall be provided and located
at the Administration building at the L station support all essential
computing and networking equipment.
The power supply equipme nt detailed herein, including batteries, chargers,
inverters, static switches, transformers, distribution feeders, etc., shall be
supplied as a fully integrated package and whilst various principal components
may be from a number of different manufacturers , the Contractor shall be
responsible for ensuring that all such items are fully compatible with each other
and perform safely and efficiently and conform to the requirements of the
Specification.
The UPS System shall be configured to the Contractor's detailed design so as to
meet the overall availability requirements of the MMS/DMS Computer
System.
The UPS, shall be rated to supply the total demand of the following:
(a)
All equipment provided under this Contract is to be powered from the

UPS System.
(b)
Lighting, small power and other circuits within the Administration

building are to be connected to the UPS System.
(c)
40% spare capacity for future expansion.
The Contractor shall provide a UPS System that will supply the total demand
as defined above.
The associated battery systems shall have sufficient capacity to supply the
worst-case load (including inverter losses) for a period of 12 hours following
loss of the incoming AC supply to the UPS system under the worst case
environmental conditions.
The UPS equipment shall comply generally with the requirements of the IEC
146 series of publications.
The Contractor shall ensure that the provision of ventilation in the rooms
housing the UPS System adequately meets the requirements of the equipment.
If necessary, the Contractor shall provide an air-conditioned environment for
Page 11
the UPS room where the air conditioning units are supplied from the UPS
output.
Where air conditioning is to be provided the air conditioning plant shall
comprise duplicate units either one of which can support the full duty.
U5.2
General Design and Construction

Each UPS is to be housed in a suite of cubicles. The cubicles shall be of robust
sheet steel construction, finished in a durable paintwork to an approved colour.
The enclosure standard shall be at least IP 41 to IEC 529.
These cubicles shall incorporate a System mimic and all necessary controls,
indications and alarms as required for the safe and efficient operation of the
equipment, together with any further items called for in this Specification.
Natural cooling is preferred and any forced cooling arrangements shall be
described in detail by the Contractor.
There shall be provision for top and bottom cable entries via standard glands
and removable gland plates. Each gland plate shall have sufficient capacity to
accommodate a full complement of power and control cables.
Each cubicle shall be supplied with an integral earthing bar, all metalwork shall
be bonded to earth and there shall be an earth strap making a positive
connection to each cubicle door.
It is preferred that the chargers, inverters, etc., shall be fully segregated so that
any one item may be isolated and maintained whilst other parts of the UPS
remain in service. Spares and test equipme nt shall be identified on the basis
that major elements will simply be replaced under failure conditions and the
defective element examined in detail once the UPS has been returned to a fully
operational state.
All equipment is to be clearly labeled and all wiring clearly identified
All live equipment is to be suitably arranged, shrouded and shielded to allow
on-load testing and trouble shooting to be carried out safely by qualified
personnel.
A local alarms annunciator shall be provided, either in respect of each
functionally separate item (eg. charger, inverter, etc.,) or for the system as a
whole, which shall be equipped with audible and flashing visual annunciators,
Page 12
accept, reset and lamp test facilities. Alarms shall latch until accepted. A
muting facility shall be provided for the audible device.
Summary alarms shall be connected to the Auxiliary Plant Annunciator. There
shall be a specific alarm to show that a UPS is not in its normal operational
configuration.
Alarms shall be inhibited from operating during transient conditions, eg.
temporary overload and mains disturbances.
Shutdown or disconnection of any section of the System due to, for example, a
low battery voltage or equipment over temperature, should be pre-alarmed to
give prior warning of this condition. Nevertheless, all equipment will be
expected to operate continuously at rated output under the worst case
environmental conditions stated in this Specification.
All equipment shall be suitably protected against overloads and short-circuits,
with the protective devices selected so as to minimize damage which would
result from a fault condition, but ensuring proper discrimination with other
protective devices under all credible conditions.
A distribution board shall be provided as part of the UPS System. All UPS
loads shall be connected to appropriately rated outgoing ways of the board.
The Contractor shall ensure that circuit protective devices (fuses or circuit
breakers) are rated to ensure clearance of faulty circuits without dis ruption to
the operation of equipment connected to healthy circuits.
The Contractor shall demonstrate that all circuit protective devices are suitably
coordinated to contain circuit disconnection to the minimum commensurate
with safely isolating the fault or faulty feeder.
The worst case (loudest) noise level at 1 m from any part of the equipment
shall not exceed 65 dB(A).
Due consideration shall have been given in the equipment design to ensure that
any vibrations generated within the cubicle suite have no deleterious effect on
the equipment mounted therein.
A general lamp test pushbutton shall be provided for all indicating lamps not
covered by the annunciator System.
Deviation from the requirements for alarms, indications and controls may be
allowed if it can be shown that the equipment offered provides the same level
of information and control.
Page 13
A panel inscribed with a detailed description of operating procedures for the

UPS System, including start-up procedures, shall be provided and mounted in a
suitable position on one of the cubicle front panels.
The UPS ac output shall operate as a solidly grounded System.
All maintenance requirements shall be fully detailed by the Contractor ,
including recommended replacement periods for components of known limited
lifetimes.
U5.3
Inverters
U5.3.1 Performance
The inverters may be 3-phase or single phase, depending on the Contractor's
detailed design, and shall meet the following performance specification for the
full range of conditions to be encountered at the dc supply terminals, including
allowance for voltage drop in the battery cable connections and operation with
the battery charger only (ie. battery disconnected). Power supply to be from
essential board.
Output voltage regulation
380/220 V + 1% over full load range
Frequency tolerance
50 Hz + 1% (+ 2% when synchronized to
mains supply)
Frequency slew rate
0.1 Hz/s (adjustable)
:
:
5% maximum
3% maximum
Voltage transient response
+5% for a 100% load step. Recovery

within 10 ms.
Overload capability
120% for 10 minutes

150% for 1 minute
Harmonic distortion
-
total
individual component
However, the Contractor shall satisfy himself that the inverters are entirely
suitable for supporting the connected loads.
The inverter shall have its own internal frequency reference, but with a facility
for automatically synchronizing with a mains source. The synchronizing range
shall be at least + 2% of the nominal frequency. Should the mains frequency
Page 14
deviate from the allowable frequency limits of the inverter then the inverter
shall automatically revert to its own internal reference, nominally 50 Hz.
U5.3.2 Operation
The control circuits necessary for operation of the inverters shall operate
independently for each inverter such that a control circuit failure in one inverter
shall not cause failure of any other inverter. Failure of any one inverter shall
result in automatic isolation of the defective inverter.
If the Contractor's design includes dual redundant UPSs , it is required that the
two UPS inverters should normally operate in duty and standby mode. Failure
of one of the inverters shall result in automatic transfer of all load to the
healthy inverter, without disruption of the load.
An inverter shall shut down under the following conditions:
(a)
Inverter failure
(b)
Overload (time delayed)
(c)
DC input voltage out of limits
(d)
AC output voltage out of limits
(e)
Over temperature (for units using forced ventilation).
Transfer of the load to the mains bypass shall be automatically initiated upon
shutdown of an inverter when it is the only one operating.
Operational controls shall include the following:
(a)
Inverter start/stop
(b)
Transfer load to inverter
(c)
Emergency stop.
It shall not be possible to stop an inverter under normal conditions unless an

alternative supply is available.
Operational indications shall include the following:
(a)
DC switch closed
(b)
Inverter on/off
Page 15
(c)
Inverter supplying load
(d)
Inverter output switch closed.
Instruments shall be provided to display the following parameters:

(a)
AC output voltage
(b)
AC output frequency
(c)
AC output amperes (rms).
U5.3.3 Alarms
Alarms to be annunciated at the UPS control panel shall include the following:
(a)
Fuse/breaker operation
(b)
Overload (time delayed)
(c)
DC voltage outside limits
(d)
AC voltage outside limits
(e)
Loss of synchronization
(f)
Mains supply out of limits
(g)
Over temperature (for force ventilated units only)
(h)
Fan failure (for force ventilated units only).
Alarm annunciators shall have auxiliary contacts to enable alarms to be

repeated to the Auxiliary Plant Annunciator.
U5.3.4 Isolating Devices
Isolation switches shall be provided at the dc input and ac output sides of the
inverters for maintenance purposes.
U5.4
Mains Bypass
A mains bypass shall be provided of sufficient capacity to supply the fully
expanded UPS system load. The bypass shall include a transformer and/or
filter, if necessary. The transformation ratio shall be adjustable 5% either side
Page 16
of nominal, in steps of 2.5%, by means of bolted links or terminal selection.

The primary and secondary sides of the transformer shall be protected by HRC
fuses sized to discriminate with downstream protective devices. The mains
bypass shall be complete with a static bypass switch and isolating switches at
the input and output. A manually operated bypass switch shall also be
provided.
The mains bypass control logic shall automatically initiate a transfer of load
from the inverter to the bypass in the event of failure of all inverters. The
transfer shall be inhibited in cases where the mains voltage or frequency is out
of limits.
It shall also be possible to manually initiate a transfer from inverters to bypass,
but the transfer shall be inhibited if the inverters and bypass are out of
synchronism or the mains supply is out of limits.
The bypass control logic should incorporate the facility to automatically
parallel the bypass with the inverter(s) for a short duration during transient
fault conditions of the UPS load. This facility is designed to ensure rapid
operation of protective devices in the load distribution System, during fault
conditions, whilst minimizing transient effects imposed on equipment
operating normally. The bypass shall be automatically switched off again and
the UPS System restored to normal inverter operation upon clearance of the
fault. This requirement does not override that for inverter fault clearance
capability detailed above.
Indications of the operational states of the bypass and isolating switches shall
be provided.
Alarm annunciation of mains supply out of limit and static switch fault
conditions shall be provided.
An instrument shall be provided for display of mains supply voltage.
U5.5
Rectifier/Charger
U5.5.1 Performance
In addition to supplying the full inverter load, each charger must be
independently capable of recharging the battery at a minimum initial current
equivalent to 0.1 C3 (ie. at a rate equivalent to 10% of the 3-hour discharge
rate of the battery). If charging current limitation is recommended by the
battery manufacturer, then this shall be automatically controlled by the battery
charger. The battery charger output current shall be limited electronically to
the maximum capability of the charger.
Page 17
The battery charger shall be suitable for operation from the mains supplies
detailed in Clause 3.
Charger output shall be entirely suitable for float charging of the specified
battery and simultaneously supplying dc power to the associated inverter. The
ripple content of the output shall be controlled to permissable limits both for
the battery and the inverter.
Charger output voltage shall be controlled to + 1% over the full range of the
specified ac input conditions. The output voltage shall be independently
adjustable in both the 'float' and 'boost' modes, if applicable.
U5.5.2 Operation
The battery charger shall be of the constant potential type suitable for float
charging the specified battery. Preferably, the battery charger should also be
capable of automatically 'boost' charging the battery following a significant
discharge. The 'boost' charge end condition shall be automatically controlled
by the battery charger. The 'boost' charge voltage shall be entirely suitable for
the specified battery and 'boost' charging shall not cause a reduction in battery
life.
The battery charger shall incorporate devices to monitor battery charger faults,
status and battery condition. As a minimum requirement, the following
conditions shall be monitored and alarmed:
(a)
Battery charger voltage high
(b)
Battery charger voltage low
(c)
Battery charger failed
(d)
Mains failure
(e)
Battery voltage low
(f)
End of battery discharge
(g)
DC earth fault
(h)
Battery fuse/circuit breaker operated
(i)
Over temperature (Force ventilated units only)
(j)
Fan failure (Force ventilated units only).
Page 18
Operational controls shall include the following:

(a)
Boost charge selection (manual) - (if applicable)
(b)
Charger on/off.
Indications shall include:

(a)
AC supply isolating switch status
(b)
AC output isolating switch status
(c)
Charger status
(d)
Float/boost charge indication
(e)
Battery output switch status.
Instruments shall be provided to display the following parameters:
U5.6
(a)
AC supply voltage (with selection switch)
(b)
DC output voltage
(c)
DC output current
(d)
Battery current (charge and discharge).
Batteries
Batteries of the Ni-Cd type, of proven design, shall be supplied. They should
have a minimum design life of 10 years operating in the environmental
conditions detailed in Clause 8. In order to achieve this lifetime, it shall only
be necessary to maintain the cells in a clean and correctly charged state.
The battery cells shall be constructed of proven robust and fire retardant
materials. Only bolted intercell connectors of high conductivity shall be
supplied. All intercell connections shall be fully shrouded, but readily
accessible for routine maintenance.
The cell electrolyte shall be fully absorbed in the material of the plate
separators in the form of a gel; damage to a cell case shall not result in the
release of corrosive material. The cell shall be fitted with an automatically
Page 19
resealing pressure-operated vent to permit the safe release of small quantities

of gaseous products.
Battery capacity shall be selected to ensure the required standby period is
achieved for the specified load over the design life of the battery under the
worst conditions of environment. Allowance shall be made for the specified
operating temperature range and losses of the inverters.
The internal resistance of the batteries shall not impede correct operation and
discrimination of protective devices within the dc and inverter load circuits.
The batteries shall operate unearthed and an earth fault-monitoring device shall
be provided as part of the battery charger equipment. A DC System earth fault
shall be alarmed.
Provision shall be made to automatically disconnect the battery from the load
at the limit of permissible discharge. This may be accomplished by switching
off the inverters if, following this, the remaining load on the battery is
negligible.
The battery shall be installed on multi-tier racks in a space-efficient
arrangement commensurate with allowance for adequate maintenance of all
cells. The cells shall be numbered.
A double pole fused switch or circuit breaker shall be located in close
proximity to the battery to provide short-circuit protection and isolation
facilities. The status of the battery output switches (or circuit breakers) and
fuse failure (or MCB trip) condition shall be wired to the UPS units for
indication and alarm, respectively.
U.6 Fire detection and extinguisher system.

Reliable fire detection and extinguisher are required for the computer Center which
complies with the international safety standard and it should contain the following:
Fire alarm control panels.
Smoke detection subsystem.
Heat detection subsystem.
Early warning smoke detector/air sampling smoke detector and relevant devices.
U.7 Access control and monitoring system.
Page 20
The entire 4th floor physical access must be thru access control system
And monitoring system that prevents unauthorized people from the entry
into the computer Center and keeping track of the authorized access timing
with excellent audit trail of the system activity and alert conditions.
U.8 Furniture
Furniture should conform to the following specifications:
It should be functional, ergonomic and innovative, and be open to
continuous change in the design of organizationa l systems. It should
display versatility for different applications, flexible layout configurations,
and modular design and have all the advantages of a future-proof
workstation system. Add-ons and superstructures should provide options
for expanding the work surface of systems workstations. The furniture
should provide a structured, expandable cable management system to
accommodate ever -increasing cable volumes. Even very large cable
volumes should be accommodated out of sight in all horizontal and
vertical cable ducts without tiresome loops.
U.9 Telecommunication Closet.
Each floor must be equipped with centrally positioned
Telecommunication closet with the following specifications.
Dimension:
Floor:
Ceiling:
3m X 3m
Raised floor type.
False ceiling equipped with cable runners to
computer room and other users work area
where computer network is required.
Separate Distribution panels to be fed from
two different sources.
Air condition for the TCs to be controlled
separately not with the main building A/C.
The UPS for the computer room should
supply the TCs.
The TCs for all floors must be vertically
aligned and connected through 30cm cable
Raisers. (ANSI/TIA/EIA/569-A) standard
to be applied for TCs Locations and
specifications.
Power:
A/C:
UPS:
U.10 Communication Cabinets

Standard 19 communication cabinets to be provided with minimum of the
following accessories
1.
Shelving.
Page 21
2.
3.
4.
5.
6.
7.
8.
Minimum 12 position power bars.

Cable management vertical and horizontal.
Patch panels for both fiber and copper UTP.
Dual power supply.
Cooling fan and the associated assemblies.
Locking side panel.
Front/Rear doors.
Page 22
CNE/015/2002
P2.27
Instrumentation & Control System
WORKING DOCUMENT
Part P2.27 Instrumentation and Control Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
1
PAGE

1.1
SUMMARY........................................................................................................................ 1
1.2
GENERAL ......................................................................................................................... 2
1.3
SCOPE OF WORKS......................................................................................................... 2
1.4
FIELD INSTRUMENTATION............................................................................................ 3
1.4.1
Local Measurements.................................................................................... 3
1.4.2
Field Instrumentation for the Remote Control and Supervisory System3
1.5
1.6
DISTRIBUTED CONTROL SYSTEM (DCS).................................................................... 4
1.7
OPEN-LOOP CONTROLS ............................................................................................... 7

1.7.1
Plant and Unit Co-ordinator........................................................................ 7
1.7.2
Start-up Preparations................................................................................... 7
1.8
CLOSED-LOOP CONTROLS .......................................................................................... 9

1.8.1
General .......................................................................................................... 9
1.8.2
Plant Master Controller (PMC).................................................................. 10
1.8.3
Boiler Stress Evaluator and Lifetime Counter ........................................ 11
1.8.4
Steam Turbine Control............................................................................... 11
1.8.5
Desalination Plant ...................................................................................... 12
1.8.6
Feedwater Control for HRSG and Auxiliary Boiler:................................ 12
1.8.7
Control Performance.................................................................................. 13
1.9
PLANT AND EQUIPMENT PROTECTION SYSTEM.................................................... 13

1.9.1
Gas Turbine................................................................................................. 13
1.9.2
HRSG and Steam / Water Cycle ................................................................ 13
1.9.3
Back Pressure Steam Turbine (BPST)..................................................... 14
1.9.4
Generator and Electrical System.............................................................. 14
1.9.5
Desalination Plant ...................................................................................... 14
1.10
GAS TURBINE CONTROL EQUIPMENT...................................................................... 15

1.10.1
General Design Criteria ............................................................................. 15
1.10.2
Sequencing System................................................................................... 15
1.10.3
Governing System of the Gas Turbine .................................................... 16
1.10.4
Speed & Load Control................................................................................ 16
1.10.5
Control of Other Systems .......................................................................... 17
1.10.6
Gas Turbine Protection System ............................................................... 18
1.10.7
Alarm System for the GT -Units................................................................. 19
1.10.8
Performance and Condition Monitoring System.................................... 20
1.11
HRSG SUPPLEMENTARY FIRING BURNER MANAGEMENT SYSTEM (BMS):...... 20
1.12
AUXILIARY BOILER CONTROL, BMS AND PROTECTION SYSTEM:...................... 21
1.13
BLACK BOX CONTROL:............................................................................................... 22
1.14
PLANT MANAGEMENT SYSTEM (PMS):.................................................................... 22
P2_27Instrum_and_Control_Working_Doc.doc
Page: ii
1.15
CONTROL OF ELECTRICAL MOTORS IN CASE OF POWER FAILURE..................23

1.15.1
Resuming of Power ....................................................................................23
1.15.2
Emergency Shut Down...............................................................................24
1.16
CENTRAL CONTROL ROOM ........................................................................................24

1.16.1
CCR Layout and Design.............................................................................24
1.16.2
Central Control Room Equipment.............................................................24
1.16.3
Software, Tasks and Functions.................................................................25
1.16.4
Furniture.......................................................................................................28
1.17
COMPUTER ROOM........................................................................................................29
1.17.1
Central Programming and Configuration Station ...................................29
1.17.2
Central Diagnostic Station.........................................................................29
1.17.3
Scope............................................................................................................29
1.17.4
Furniture.......................................................................................................29
1.18
LOCAL CONTROL ROOM .............................................................................................30
1.19
CENTRAL AND LOCAL ELECTRONIC ROOMS.........................................................30
1.20
DEMINERALISED WATER PLANT CONTROL AND MONITORING ..........................31
1.21
OPERATOR STATIONS MONITORS............................................................................31
1.22
LARGE SCREEN MONITORS .......................................................................................31
1.23
PROGRAMMING AND DIAG NOSTIC DEVICES FOR THE PLANT ............................32
1.24
SIGNAL EXCHANGE WITH THE LDC ..........................................................................32
1.25
WEATHER STATION......................................................................................................34
1.26
I&C POWER SUPPLY ....................................................................................................34
1.27
TESTS AND INSPECTIONS...........................................................................................34

1.27.1
Factory Acceptance Test (FAT).................................................................34
1.27.2
Site Test .......................................................................................................34
1.28
EMPLOYERS STAFF I&C TRAINING ..........................................................................34

1.28.1
General.........................................................................................................34
1.28.2
Content.........................................................................................................35
1.28.3
Instructor Qualification ..............................................................................35
1.29
INSTRUMENTATION AND CONTROL WORKSHOP...................................................35
1.30
CONTINUOUS EMISSION MONITORING SYSTEM (CEMS).......................................35
COMMUNICATION AND CLOCK SYSTEM ..............................................................................36

2.1
TELEPHONE SYSTEM ...................................................................................................36

2.1.1
General.........................................................................................................36
2.1.2
Particular Requirements ............................................................................38
2.2
MAINTENANCE TELEPHONE SYSTEM.......................................................................43

2.2.1
General.........................................................................................................43
2.2.2
2.3
LOUDSPEAKER SYSTEM / PUBLIC ADDRESS SYST EM .........................................43

2.3.1
General.........................................................................................................43
2.3.2
Page: iii
2.4
CLOCK SYSTEM............................................................................................................ 51
2.4.1
General ........................................................................................................ 51
2.4.2
Particular Requirements............................................................................ 51
2.4.3
Scope of Works .......................................................................................... 52
2.5
LOCAL AREA NETWORK (OFFICE LAN) AND COMPUTERISED MAINTENANCE

MANAGEMENT SYSTEM (CMMS) ............................................................................... 53
2.5.1
Local Area Network / Office LAN .............................................................. 53
2.5.2
Computerised Maintenance Management System (CMMS).................. 54
COMPUTER SYSTEM ................................................................................................................ 55
1
1.1
Page: 1

SUMMARY
The plant instrumentation and control equipment shall be selected and designed in such a way that
the operation as described below and the following functions will be performed for each unit and for
the Desalination plant.
Start-up, generator synchronisation and loading of the GT units, ST, the HRSGs, Auxiliary
Boilers, the Demineralisation plant and all auxiliary equipment from the Central Control Room
while using all the main full automatic start-up sequence step and automatic function group
programs with one pushbutton operation. Semi-automatic and manual modes shall also be
provided for operator selection.
Full automatic start-up sequence will also be provided for the seawater system, blending plant,
potable water system and all auxiliary equipment in the plant.
Full automatic start-up and shutdown sequences will be provided for the desalination units
based on function group control. Minimum preparation work which consist of filling of lines and
establishment of the recirculation system can be carried out by the operator from the CCR
operator stations prior to the full automatic sequence.
Plant / Unit Master Controller-co-ordinated Unit operation, capable of handling unscheduled

load swings as well as scheduled load ramps.
Complete supervision of the whole plant, including the GTs, STs, Boilers, the Desalination
plant and auxiliary systems in the plant
Safe operation in case of Unit island/house load operation
Automatic contribution to grid frequency control
Safe shut-down of the Unit/Plant. Full automatic shutdown sequences shall also be provided
for all plant units and auxiliary equipment including unloading, breaker opening and shutdown
The DCS system shall be applied as a total solution, providing the necessary control means
basically for the whole plant, including also the controls for the Gas Turbines Steam Turbines,
Boilers and for the Desalination plant. The Man Machine Interface in the Central Control Room
shall be uniform, using DCS standard workstations. Workstations from proprietary systems shall
not be accepted.
As a part of the Plant Master Controller, Plant Master Sequence (PMS) programme shall be
provided. This programme shall co-ordinate in a sequence of priorities the start-up and shut-down
of the whole plant including which system/unit to be started/shutdown first and which one second
and so on. This shall be displayed in the DCS monitor and to include instructions to the operator
with indication and feed back indications of the status of the plant units/systems.
The use of black box systems with PLC's or local controls for ancillary plants or systems is not
acceptable. Only some special cases can be considered subject to the Employer/ Engineer's
approval. PLCs or digital control systems shall be of uniform type, compatible with the main DCS
system and shall be built redundant. The application and the manufacturer/type of the control
system is subject to Employer/Engineer's approval.
The remote central operating and monitoring facilities will be installed in the Central Control Room.
The Plant common auxiliary systems will be controlled by the DCS workstations in the CCR.
Page: 2
The plant shall be interfaced with the LDC, with the Dubai Supply Authorities (DUSUP) for Gas
metering and with the potable water system Master SCADA station at the DEWA Head Quarters in
Dubai for limited amount of signals.
The DCS basic configuration is shown on the Tender Drawing No. CNE/015/2002-W-00-G-D00007.
One unified DCS system of the same make and type shall be provided for the entire plant of
Package P and Package D. Make and type of the overall DCS shall be offered by the contractor
of package P and the contractor of Package D will provide the same make and type of the DCS
for all package D units and equipment, All DCS hardware and software required for Package D
units and equipment will be within the scope of supply and services of the Contractor of Package
D. The integration of Package D part of the DCS into the overall DCS as well as the coordination work and the merger of Package D data base with Package P data base is under the
scope of work of Package P Contractor. The overall automation of the entire plant of Package P
and D as well as their operation and control by the Plant Master Controller shall be within the
scope of work of Package P Contractor.
1.2
GENERAL
The instrumentation and control equipment shall fulfil the general technical requirements. The type
and make of equipment shall be internationally proven in similar power plants and shall be
approved by the Employer/Engineer.
The scope has to be complete in every respect for a functional system, i.e., cable connections,
software and programming works, filling of database, etc. are to be included when not explicitly
excluded from the scope of works.
Only basic and minimum instrumentation and control requirement have been indicated on the
Process Flow Diagrams (PFD) and described in the Specification and should not be considered as
the limiting factor. Any items that are not shown on the Process Flow Diagrams (PFD) and
specified elsewhere shall also be included in the scope of supply.
Specified instrumentation and control systems are only basics, detailed design may be different.
Only basic and minimum instrumentation have been specified and it should not be considered as a
limiting factor. Any items not included hereunder but specified elsewhere for this Lot shall also be
included.
The Contractor shall complete the scope of supply with such items not specified, but found as
evidently necessary with the Contractors proper design and/or ensure a reliable and safe
operation of the power plant. If during design, construction, testing and/or completion of the work
any additional instrumentation and control equipment becomes evidently required and is
considered to be essential to the operation of the Plant and it is considered by the
Employer/Engineer to be essential for the safe and reliable operation of the plant, it shall be
provided at no extra cost to the Employer. If the Contractor proposes or supplies any additional
plant/equipment, all corresponding instrumentation and control equipment shall be included in his
scope, along with all necessary special tools and product specific configuring and diagnostic
devices.
The numbers and quantities for Instrumentation and Control as specified hereunder are valid for
each one of the units respectively their auxiliaries, if not otherwise specified elsewhere.
Specified control systems are only basics. Detailed design may be different.
1.3
SCOPE OF WORKS
The specific scope for this Part as well as specially requested supplies and services are as
specified in this Part of the Specification but without excluding other necessary components and
services mentioned in other Parts.
Page: 3
The DCS, the communication and bus devices, servers, the CCR Man-Machine Interface and any
other component under the scope of Package P shall be designed and provided on such a way,
that the whole Plant control and monitoring shall be made available under the final responsibility of
Package P after the integration of hardware and software components provided by other
Packages as described in any part in this Specification.
1.4
FIELD INSTRUMENTATION
Field instrumentation shall be provided according to:
Individual process equipment specifications and requirements
Tender and Contract drawings, P&I diagrams and final approved documents
1.4.1 Local Measurements

The local measurements shall contain but not be limited to the following items:
Pressure gauges at HP valves
Pressure gauges at the suction and delivery side of pumps
Pressure gauges on tanks (other than atmospheric ones) and heat exchangers
Differential pressure gauges with alarm contacts for filters
Temperature gauges at heat exchanger inlets and outlets
Generally, temperature gauges on hot liquid filled tanks
Thermometers at bearing oil outlets
Test valves, connections and thermowells necessary for commissioning, testing and
maintenance.
For performance tests separate tappings, test valves, connections thermowells, etc. shall be
provided beside the existing remote measurements, which shall not be removed from the DCS
during the execution of the performance tests.
Level gauges/measurements on heat exchangers with condensate, on tanks, pits, reservoirs,

etc.
Local gauges at systems inlet/outlets
Local gauges close to tappings for remote measurements
1.4.2 Field Instrumentation for the Remote Control and Supervisory System
Field instrumentation shall be provided for all signals for remote tasks to fulfil the aims of the
Remote Control and Supervisory System as specified in any part of this Specification and to
guarantee the safe and reliable operation of the Plant.
Remote measurements for typical variables shall especially provided for
All controlled variables
Upstream and downstream of control valves and pressure reducing stations
Systems inlets and outlets
Headers
Page: 4
Values alarmed in the CCR and values important for the safety and availability of the Plant
Values important for the pant operation
Values important for the plant management functions, balances, efficiency calculations, etc.
The signals from packages shall be taken over to the DCS system for monitoring and overall
control, if the control system is not part of the DCS.
Should any signals become necessary for the above tasks or for the operation of the Plant, they
shall be provided by the Contractor without any additional costs to the Employer.
1.5
The remote control and automation concept is based on the principle that the Plant operation
(automatic start-up, generation, shut-down) shall be remotely supervised and conducted fully
automatically from the Central Operating Desk in the Central Control Room.
Full degree of remote control shall be provided from the DCS Operator Station in CCR for all plant
systems/equipment. In cases which can be accepted for local control panels such as
compressors, appropriate interface shall be made with the DCS such that the coordination/selection logic and the group control shall be carried out by the DCS.
Essential control valves such as boiler feed water control valves shall be provided redundant with
duty/standby selection facility and bumpless switchover to the standby control valve upon failure of
the duty valve. Bypass motorised valves with remote inching operation facility and control
characteristic shall be provided for non-essential control valves and subject to the
Employer/Engineer's approval. All control valves shall have motorised upstream/downstream
isolating valves.
The scope of manual preparation as release for the units automatic start-up sequence (cold startup) is to be limited and is subject to Employer/Engineers approval. For initial policy see item 1.7.2
Start-up Preparations.
1.6
DISTRIBUTED CONTROL SYSTEM (DCS)
The DCS, as a total solution, shall be the remote control and supervisory system for the plant
including GT-s, HRSG, duct firing system, STG-s, Desalination plant, Steam and Water Cycles and
for auxiliaries, Auxiliary Boilers, Water Treatment Plant, Blending Plant, Sea Water System,
Potable Water System, Fuel Gas System, Fuel Oil System and other auxiliary and common service
systems.
For the GT the MARK VI control system shall also be accepted.
The DCS shall cater for the following main functions:
Signal acquisition, conditioning and processing

Closed-loop control
Open-loop control and interlocks
Plant and Unit Co-ordinator
Plant and Unit Master Control/ Load Control
Function group controls, sub-group controls and drive controls
Plant and equipment protection
Alarm and status annunciation
Data communication
Data displaying and information presentation to the operating staff
Data storage for periodic or post-trip analysis of the plant or equipment analysis in form of
curves, tables and lists
Page: 5
Supervision and plant performance calculation

System engineering and diagnostic
The following is a minimum list of systems to be controlled and monitored by the DCS:
GT Units with their auxiliaries

HRSG including circulation systems, vent and drain systems, etc.
HRSG duct firing burner control and management system
Feedwater supply systems including auxiliaries
Steam system
Steam turbine auxiliaries (oil supply, turning device, drainage, etc.)
Steam turbine control, protection, start-up and run-down
Steam Turbine Supervisory system (monitoring only)
Evacuation systems
Condensate system
Circulating water system
Closed cooling water system
Instrument and compressed air system
Demineralisation Plant
Desalination Plant
Fuel storage and supply systems
Auxiliary Boilers
Black start Diesel (monitoring and overall control)
The DCS shall include as a minimum, but not limited to the following systems/equipment:
Redundant Fibre Optical 100 MB/s Plant (highway) Bus. The TOSMAP system provides 2
sections of redundant networks with router connection, but not one network, without limiting
the specified DCS features. The router shall be redundantly configured as instructed by the
Employer / Engineer. For important signals hardwired connections shall be provided between
the different bus sections. Selection of signals is subject to Employer / Engineers approval.
Redundant Fibre Optical Terminal(CCR LAN) Bus.
Redundant Processing Units and Server Units shall be provided to connect the Plant
Bus/highway bus to the Terminal Bus /CCR LAN.
Operator stations and large screen monitors in CCR, which are specified somewhere else in
the specification.
Local operator stations, which are specified somewhere else in the specification.
Engineering stations, which are specified somewhere else in the specification.
Diagnostic station, which is specified somewhere else in the specification.
GPS Master Clock and DCS Clock systems which shall also be used in the future to
synchronise the DCS clock of Phase II.
Plant Management System (PMS)
PMS operator stations, which are specified somewhere else in the specification.
Redundant Optical Switch Modules (OSM) to connect the DCS process control stations to the
plant highway bus redundantly and for bus-to-bus connection.
DCS Process Control Stations, which shall be provided as follows:
Each GTG shall be provided with the following DCS process control stations:
Page: 6
GTG Governor Controller.
Sequence and Auxiliaries Control.
Measurements and Supervisory System.
Failsafe Protection System.
Each HRSG shall be provided with the following DCS Process Control Stations:
Boiler Control System.
Boiler Failsafe Protection System.
Failsafe BMS for the Supplementary Firing Burners.
Each Auxiliary Boiler shall be provided with the following DCS process control stations:
Boiler Control System.
Boiler Failsafe Protection System.
Boiler Failsafe BMS.
Each BPST shall be provided with the following DCS process control stations:
BPST control, Governor control
Sequence and Auxiliaries Control.
Measurement and Supervisory System.
Failsafe Protection System.
Three (3) identical DCS process control stations shall be provided for the 3 trains of the
fuel gas supply treatment and pressure reducing stations.
DCS process control stations shall be provided for the fuel gas common system.
DCS process control stations shall be provided for the fuel oil system.
DCS Process Control Stations shall be provided for the steam systems and clean drains.
DCS Process Control Stations shall be provided for the condensate and feed water
system.
DCS process control stations shall be provided for instrument and service air
compressors, closed circuit cooling water system, chemical dosing and chemical sampling
system.
DCS process control stations shall be provided for the Demineralisation plant (Water
Treatment Plant) and make-up water system and their electrical system.
DCS process control stations shall be provided for the Plant Master Controller and Plant
Protection Co-ordination.
DCS process control stations shall be provided for the electrical system of the power
plant.
Redundant interface modules and serial data links to the PLC black box control panels, which
are subject to the Employer/Engineer's approval.
Page: 7
Redundant interface modules and serial data links to the Substation Control System (SCS) /
SCADA system.
Plant highway bus connection shall be provided and connected to the Package D DCS
cubicles distributed in the Plant.
Each unit/system shall be provided with separate marshalling cabinets, which shall be supplied
from the supplier of the DCS cabinets and shall have the same material, colour and size. MaxiTermi point connection or similar, reliable modern connection technology shall be used inside the
marshalling cabinets.
Each marshalling cabinet shall be provided with 20% spare capacity in the termination blocks to be
counted after completion of commissioning. The number of marshalling cabinets to be provided for
each unit / system shall be decided taking into consideration the quantity and size of cables in-andout. It shall be ensured that in no way the marshalling cabinets are over-crowded with cables in the
entrance opening and/or inside the cabinet. This is all subject to the Employer/Engineers approval.
Any other equipment not specified above but deemed to be necessary shall also be provided.
1.7
OPEN-LOOP CONTROLS
1.7.1 Plant and Unit Co-ordinator

The hierarchical schema of the system is shown on the Tender Drawing No. CNE/015/2002/-W-00G-D-00008.
The Plant start-up and shut-down shall be designed as to allow automatic/manual mode selection
by the Plant Co-ordinator. The Plant Co-ordinator shall monitor and control the progress of the Unit
Co-ordinators and of the function group systems of common Plant auxiliaries.
The unit co-ordinator monitors and controls the start-up controllers of the GT, ST, HRSG, Auxiliary
Boilers and the Desalination plant along with the function group systems of the unit auxiliaries and
co-ordinate all necessary interactions between them in correlation with the analogue control loops.
The start-up controllers co-ordinate the subordinated functional groups with their sub-groups and
individual drives.
The automatic mode of the start-up program shall be designed in such a way, that only a minimum
of pre-selections and commands have to be carried out by the operator.
The Plant Co-ordinator shall be designed as sequence control, which permits:
The pre-selection of different modes of operation

This selection includes a pre-selection for the different plant configurations. The operator shall
have the possibility to pre-select the desired mode (which unit will be started or not started,
which power generating units will work in simple cycle or combined cycle, which desalination
units will operate, etc) before starting of the Plant.
Automatic start up of the selected mode of operation
Automatic shut down of any of the selected mode of operation
1.7.2 Start-up Preparations

1.7.2.1 Preconditions
Prior to automatic starting the Plant, a number of relevant preconditions shall be satisfied, e.g.:
Power supplies
ready
Page: 8
Control system/DCS
ready
Make Up water system
ready
Circulating & cooling water system
ready
Instrument air system
ready
Fuel system
ready
HRSG drum levels
> min
FW tank level
> min
Steam Turbine
ready
To reach the necessary conditions the following systems are put into operation automatically:
Fuel Supply System
Circulating/Cooling Water System
Air Intake
demineralised water supply system
The circulating water line will be filled up prior to automatic start up of the main circulating water
system, i.e., when starting the circulating water system, it shall be ensured that the system is filled
respectively pressurised.
For the Desalination units see description of the operation in the Desalination Package.
1.7.2.2 Function Group Control

1.7.2.2.1 Gas Turbines
The GTs shall have automatic sequence controls for start up, synchronisation and initial loading,
further for normal and emergency shut-down, including all necessary function group controls also
for all auxiliaries and performing a complete automatic start-up or shut-down of the GT under due
consideration of the thermal stress and ranges of vibration.
1.7.2.2.2 Diverter Control

The diverter at exhaust stack/boiler inlet shall be operated automatically and for emergency
reasons manually from the central control room with continuous position indication.
For safeguarding the boiler the following process criteria shall be applied as release or protection
criteria:
Start-up gradients for steam pressure and temperature limits
Differential temperature of HP drum walls (measured)
Signals to be exchanged with the GT-control
Any other criteria which may arise during detail design and commissioning
Local panel operation by key release shall be possible.
Page: 9
1.7.2.2.3 HRSG and Water-Steam Cycle

The start-up controller controls the individual function groups of the HRSG, like vent and drains,
Re-circulation pump, etc. and the water-steam cycle, like Condensate system and Feedwater
system with the all the pumps and drives belonging to the system.
1.7.2.2.4 Steam Turbine

The ST shall have automatic sequence controls for start up, synchronisation and initial loading,
further for normal and emergency shut-down, including among others the following function group
controls:
Turning-gear operation
Oil supply
Warming up and draining system
including all auxiliaries and performing a complete automatic start-up or shut-down of the ST under
due consideration of the thermal stress and ranges of vibration.
1.7.2.2.5 Auxiliary Boilers

The start-up controller controls the individual function groups of the Auxiliary Boilers, like
combustion air and flue gas system, firing, feedwater and steam system, vent and drains, etc. The
start-up controller shall be controlled by the Plant and unit Co-ordinator.
1.7.2.2.6 Pumps
Function groups shall be provided for all main pumps, like FW Pumps, Condensate Pumps,
Circulation Pumps, Cooling Water Pumps, etc.
All the pumps shall be equipped with step logics for remote control of start-ups and shutdowns.
1.7.2.2.7 Other systems and auxiliaries

All necessary function group controls shall be provided, which are necessary for the intended
automatic start of the Plant. The function group controls with their sub-controls respectively
individual drives shall be controlled by one of the start-up controllers or by the Plant master start-up
controller, whichever case will be applicable.
1.7.2.2.8 Protection Interlocks

All the major pumps and their drives (circulating water, closed cooling water, FW, condensate,
drum circulation, make-up water, etc.) shall be provided with adequate protection which are to be
fully integrated into the DCS.
1.7.2.2.9 Desalination Plant

The operation of the Desalination Plant is described in the Specification of the Desalination Plant.
1.8
CLOSED-LOOP CONTROLS
1.8.1 General
For the main control loops electric or electro-hydraulic actuators shall be provided.
For some local control loops of minor importance, locally mounted pneumatic or electro-pneumatic
controllers/ actuators may be used. If this is the case, the instrument air shall be supplied by the
Plant Control Air System. The scope of such local control loops is subject to the Employer /
Engineers approval.
Page: 10
The design of analogue controls shall meet the VDI/VDE Standards 3501 to 3504 and 3507.
1.8.2 Plant Master Controller (PMC)

A Plant Master Controller (PMC) shall be provided. It shall control and monitor the whole plant
electrical power generation and water production. To fulfil this task, the PMC shall use the
respective demand set points, input either by the CCR operator or received from the Load
Despatch Centre and the current loading of the sub-ordinate units and accordingly generate
outputs for safe and optimised control of the sub-ordinate units, i.e. GTGs, HRSGs, BPSTs,
Auxiliary boiler and desalination units. The number of units/equipment in service along with their
current loading shall be used to determine the distribution of the overall demands on the subordinate units. If the desalination demand is fixed, the GTGs shall be used to meet the new
electrical load demand with appropriate control of the HRSGs supplementary firing rates. If the
power demand (MW) is fixed, increase or decrease in the steam demand for the desalination units
shall be achieved by varying the HRSGs supplementary firing rates and the GTGs load shall
compensate for the change in the BPSTs load due to the steam demand changes in order to
maintain a fixed electrical load. If the supplementary firing of all the HRSGs is not in service and
the desalination demand is fixed, the Auxiliary Boilers shall start and maintain the pressure on the
HP steam header. Control by diverter damper may be considered if satisfying operational
experience for the considered type and size of the damper is available.
The PMC shall have the following master controllers:
High Pressure Steam Header Master Pressure Controller (HP MPC).
Low Pressure Steam Header Master Pressure Controller (LP MPC).
Intermediate Pressure Steam Header Master Pressure Controller (IP MPC).
Electrical Load Controller (ELC).
Supplementary Firing Burners Controller (SFBC).
Diverter Damper Controller (DDC).
Auxiliary Boiler Controller (ABC).
A sophisticated software programme shall be designed in the PMC to perform the functions of
each of the above master controllers. The programme shall include set point generators, set point
adjusters and all the necessary logic and functions. The units shall be selected to PMC mode to
enable set point control externally by the PMC. The PMC software shall also perform on-line
calculation for the overall mass and heat balance of the plant in order to have a continuous
monitoring and adjustment to the set points of the electrical load, SFB load, auxiliary boiler load as
appropriate to ensure stability and smooth operation of the electrical network and steam network
under all conditions of normal operation and during disturbances such as trip of BPST, trip of
desalination unit, trip of GTG, trip of SFB, trip of HRSG and trip of the auxiliary boiler. Cascade
tripping shall be avoided.
In normal operation of the plant, the overall load is controlled by means of the GTGs, the pressure
of the HP steam header is controlled by means of the SFBs, the pressure of the LP steam header
is controlled by the BPST governor and the pressure of the IP steam header is controlled by the
BPST extraction control valves. As the pressure control of the LP steam header is very essential,
a feed-forward control function shall be provided to act on the SFBs as an anticipatory function for
steam flow changes. This is necessary to avoid severe variations of the pressure of the LP steam
header at the time of a unit trip.
Further aspects of the control of the Steam system are described in the Specifications P2.6 Steam
Turbine units and Auxiliaries and P2.7 Steam System.
Page: 11
1.8.3 Boiler Stress Evaluator and Lifetime Counter

In connection with the automatic control system of the boiler a stress evaluator shall calculate the
actual thermal stresses existing on any thick part of the boiler (drum, headers, etc.), and compare
them with maximum permissible stresses.
Similar to the turbine stress evaluator, the permissible gradient variation shall be indicated,
recorded and incorporated into automatic start-up of the combined cycle. The boiler stress
evaluator of the HRSG shall be effective during the start-up of the HRSG and shall affect the
positioning of the diverter damper. It shall not have any effect on the GTG loading gradient. When
the diverter damper is fully open and the HRSG is loaded, the boiler stress evaluator shall be
disabled.
All other functionality will be similar as those of the turbine stress evaluator.
The stress evaluator shall be combined with HRSG Lifetime Counter.
1.8.4 Steam Turbine Control

Refer to Part P2.6 Steam Turbine Units and Auxiliaries, Item 4.23 for detailed specification of the
Steam Turbine Control.
1.8.4.1 Speed Control

In automatic mode the start-up and loading is realised automatically considering the start
temperature and the thermal stress.
During synchronisation, the speed controller receives signals (H/L) from the synchronising
equipment. When connected to grid the position setpoint is automatically increased to reach a
minimum load. The load-automatic increases the position setpoint from minimum load up to the
adjusted target load.
1.8.4.2 Speed Measurement and Supervision

The speed shall be measured by six (6) probes. Three (3) probes shall be dedicated to the
hardware over speed protection system and the other 3 probes shall be used in the fail safe redundant protection system and the steam turbine controller. The speed signal to be used for
control shall be the median selection among the 3 signals. All the six speed probes and channels
shall be continuously supervised and any fault shall be alarmed and the faulty signal shall be
excluded from the protection logic/selection gate. High deviation between the signals shall also be
supervised. High deviation shall be alarmed and high high deviation shall be considered as a fault
and the faulty signal shall be excluded with alarm message.
The speed measuring system shall be able to monitor reliably the turning speed. If this is not
feasible the probes as described above, a separate system of sensors shall be provided for low
speed measurement.
1.8.4.3 Gland Steam Pressure and Temperature Control

The gland steam pressure controller shall maintain a constant pressure of few mbar above the
atmosphere in order to prevent air from entering those parts of the turbine whose pressure is below
atmosphere.
During start-up of the turbine, the steam is taken from auxiliary steam header and later on form the
turbine HP-part.
The gland steam pressure shall be measured by two transmitters.
Page: 12
The temperature controller shall keep the gland steam temperature downstream of the gland
steam cooler in an acceptable range by means of injecting condensate through the spray water
control value into the gland steam cooler.
1.8.4.4 Steam Turbine Stress Evaluator and Lifetime Counter

In connection with the automatic turbine speed/load control a stress evaluator shall calculate the
actual thermal stresses existing on any critical turbine parts and compare them with the maximum
permissible stresses.
The turbine stress evaluator shall supervise and monitor, based on the surface temperature of the
HP- and IP-rotor, the stress of the steam turbine during all operating conditions and forms signal
which limits the steam turbine controller.
Because the surface temperature of the rotor cannot be measured, a substitute metal temperature
shall be provided. This measurement includes thermocouples which will be installed at proper
places where the temperature of admission steam is identical with the temperature of the rotor.
The difference between actual and maximum permissible stress value shall determine the max.
permissible gradient of turbine speed or load changes.
Turbine speed or load permissible gradient variation shall be indicated in the central control room.
These signals shall be incorporated into automatic turbine speed and load control system. It shall
be possible to put turbine stress evaluator on advisory mode operation in which case its output
signals shall be only displayed but shall not influence turbine speed and load automatic control.
Alarms shall be provided when the difference between the actual and permissible stress value
exceeds its present minimum.
In addition to the stress evaluation a lifetime counter for each turbine shall be provided. The
counter shall calculate lifetime reduction compared with rated operation dependent upon stresses,
frequency, temperature, warm and cold starts, load changes, overspeed tests and other conditions
according to the design, data figures given by the Original Equipment Manufacturer.
The effect of the stress evaluator on the speed/load control shall comply with the requirements
specified in clause 4.23 of Part P2.6.
1.8.5 Desalination Plant

The controls of the Desalination Plant are described in the Specification of the Desalination Plant.
1.8.6 Feedwater Control for HRSG and Auxiliary Boiler:

A fully co-ordinated automatic control system shall be provided and shall give the appropriate rate
of delivery of feedwater to each HRSG and each Auxiliary Boiler to meet the prevailing steam
demand over the full operating range, whilst maintaining the drum water level to within 25 mm of
the desired setting. Under normal/ abnormal load changing conditions of changing flow demand
the transient departure from normal water level shall remain within the drum tripping limits, i.e. the
tripping limits shall not be reached.
During and subsequent to all the plant operating modes including plant trips, such as a trip of a
desalination unit from full load or a trip of BPST from full load, the drum levels shall be maintained
within the tripping limits, i.e. the tripping limits shall not be reached.
The water level in the boiler drum shall be controlled by feed water control valves capable of
maintaining the water level at a safe distance above the entry to any down coming tubes, under
any condition of design load change.
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A single element and 3 element control scheme based on drum level and steam/feedwater flow
shall be provided. Automatic changeover between single element and 3 element control in
accordance with the steam flow shall be provided in addition to a manual changeover facility.
Under start-up conditions and at loads up to approximately 30% MCR the water feed flow shall be
controlled by a single element system to maintain the drum water level at the desired setting by
controlling the position of the 30% duty feedwater regulating control valve in response to deviations
in drum water level. Above 30% load the water flow shall be under the control of 3 element system
whereby the feedwater flow is controlled to match the steam flow requirements, whilst taking into
account deviations of the drum water level from the desired setting. 3 element control shall be
performed by one of the 2x100% control regulating valves with a duty/standby selection facility.
The standby valve shall immediately and automatically take over the control duty upon a failure in
the duty control valve.
The drum level measurement shall be suitably compensated (pressure correction) so that no drift
in the zero and span calibration will occur when the boiler starts from the cold to the normal
The contractor shall carry out computational simulations taking into consideration the most severe
disturbance due to desalination/BPST trip or a trip of another boiler in order to ensure that still the
drum level will be under control and that the trip limits will not be reached. Should the results show
that improvements on the boiler and/or on the I&C equipment are necessary in order to meet the
above requirement, then all the necessary modifications shall be carried out.
1.8.7 Control Performance

The analogue control system shall be optimised in accordance to the ITAE-Criterion (Integral of
Time-multiplied Absolute-value-of-Error) in order to guarantee a stable Plant operation.
1.9
PLANT AND EQUIPMENT PROTECTION SYSTEM
The fail-safe Protection System shall assure that all trip criteria are duly processed and executed in
order to avoid any personal harm and equipment damage.
The design shall be based on the 2-out of-3 configuration, so that any given complete trip actuating channel (sensor-logic-actuator) can be tested during normal plant operation.
All binary inputs to the protection channels shall be supervised.
Plant units/equipment protection signals shall be hardwired and shall not be transferred through
the DCS plant bus.
1.9.1 Gas Turbine

Please see chapter 1.10.6 of this Specification.
The GT protections are integrated part of the DCS, however functional and constructional
separated from it.
For the MARK VI control system the GT protection will be done by the MARK VI system. All
protection/ trip signals interfaced with the DCS shall be done 3 times redundantly hard-wired.
The DCS will also handle the exchange of trip signals between the different units/equipment such
as BPST, GTG, HRSG, Auxiliary Boilers, etc. as hardwired in 3 separate circuits between the DCS
automation cabinets and not through the DCS plant bus.
1.9.2 HRSG and Steam / Water Cycle

The protection system of the HRSG and Steam/Water cycle shall be part of the DCS system.
The list of HRSG trip criteria shall include among others:
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Drum water level
Low Low/high high
HP Steam temperature
high high
Circulating water flow
Low Low
The relevant GTG
tripped
Diverter damper position
closed
Manual emergency stop
actuated
The HRSG protection system shall be provided as a fail-safe system in a dedicated DCS process
control station separate from the BMS of the supplementary firing burners which shall also be
provided in a separate dedicated fail-safe DCS process control station.
1.9.3 Back Pressure Steam Turbine (BPST)

The protection system of the BPST shall be provided in fail-safe, fault tolerant DCS process control
stations. It shall be structured in triple redundant protection channels with 2 out of 3 voting
concept. The DCS shall also handle the exchange of trip signals between BPST, GTG and HRSG
as hardwired signals between the DCS process control stations. Trip signals shall be done
hardwired in 3 separate circuits between the DCS automation cabinets and not through the DCS
plant bus.
The BPST trip signal shall immediately close the HP, IP and LP stop valves to isolate the BPST
from the HP/IP/ LP steam headers.
The BPST protection system shall be certified by TV or equivalent certification authority.
The BPST trip criteria shall include the following:
Speed
high
Lube Oil Pressure
low low
Bearing metal temperature
high high
Axial shaft displacement
high high
Shaft vibration
high high
Hydraulic oil pressure
low low
Exhaust steam back pressure
high high
Manual Emergency Stop
actuated
The protection system shall prevent any damage to the ST and its auxiliaries.
In order to avoid sudden re-admission of steam to the ST, the manual trip reset shall be interlocked
with the start-up controls.
1.9.4 Generator and Electrical System

See the electrical part in the Technical Specification.
1.9.5 Desalination Plant

See the Specification of the Desalination Plant.
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1.10 GAS TURBINE CONTROL EQUIPMENT

1.10.1 General Design Criteria
The control and protection systems of the Gas Turbine units shall be provided in the DCS process
control stations. Each GTG unit shall have its own control and protection systems. The control
system shall include all necessary control functions such as governor control, start-up/shut-down
sequence control, GTG fuel gas and fuel oil control, auxiliary equipment control, etc. The
protection system shall be provided in separate dedicated fail-safe and fault tolerant DCS process
control stations. It shall be structured in triple redundant protection channels with 2 out of 3 voting
logic concept.
For the GT the MARK VI control system shall also be accepted.
For remote supervision and control of the Gas Turbine and associated equipment, the DCS ManMachine Interface in the Central control Room shall be used. Additionally a DCS local operator
station shall be provided for each GTG at the local control room. The local operator station shall
be provided complete with 2 monitors, mouse, keyboard and printer. All the screen graphic
displays shall be the same as for the GTG graphic displays in the DCS monitors in CCR.
The GTG units shall be started, loaded and shutdown fully automatically from both the DCS
operator station in CCR and from the local operator station. The automatic start-up/shutdown
sequences of the GTG unit and its auxiliary systems shall be configured in a hierarchy system of
Functional Group Control (FGC), Sub-Group Control (SGC) and Sub-Loop Control (SLC) in a coordinated manner. Start/stop of any auxiliary system such as lube oil system, turning gear, boiler
purging etc. during the start up/shut down of the GTG shall be fully automatic. The start up
sequence shall include automatic testing programs for the equipment such as the emergency lube
oil pump. The start-up/shut down of the GTG shall be initiated by the operator from the DCS
operator stations in CCR/ LCR at the GTG screen graphic display or from the Plant Master
Sequence (PMS).
Load set point control mode selection facility shall be provided to select between local control or
external control from the Plant Master Controller (PMC).
Detailed indication of all measured values, operation conditions, signals, etc. of the GT-units and
its auxiliaries as well as all individual alarms of the GT-unit including generation, unit step-up
transformer, auxiliary supply transformer, and alarms from the LV main distribution and MCCs
shall be provided via the local control panel workstation and via the Central Control Room operator
workstations.
Loading and variation of the generators voltage level as well as power factor shall be controlled
from local, from the central control room and from the LDC. Synchronising shall be effected
according to operators selection automatically by the automatic sequence device or manually from
the central control room or from the local control panel, if applicable.
The voltage regulation of the Unit step-up transformers and the step down transformers shall be
done from the central control room.
The fuel system shall be completely controlled and supervised from the central control room.
In case of using local cab with local workstation, the very same pictures shall be displayed on the
local and on the CCR DCS workstations.
1.10.2 Sequencing System

The following basic functions shall be done:
Preparation of fuel supply
Fuel supply checking
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Start-up preparation
Start-up until full speed (Island operation)
Synchronising
Loading
Variation of inlet guide vanes
Unloading
Shut-down
Shaft-turning/cooling down phase
Purging at low speed for at least 5 minutes
Protection against overspeed, high gas turbine, exhaust temperature, high vibration,
insufficient lubrication and cooling, etc.
Start-up preparation and starting shall be fully automatic achieved included in the Plant start-up
sequence.
Full load rejection when the generator breaker opens must be possible without any GT shutdown/trip.
1.10.3 Governing System of the Gas Turbine

The governing system of the gas turbine shall incorporate:
Control for fuel supply
Control of bleed ports/IGV's for start-up and stop
Control of IGV's during full speed variable load operation
Constant speed regulation
One mechanical and two electronic overspeed trip devices with provision for testing the
operability while the gas turbine is in operation
Turbine inlet temperature limit control, based on exhaust gas temperature and pressure ratio
or compressor discharge pressure
Over temperature/vibration/oil supply trip mechanism with provision for testing the operability
while the gas turbine is in operation
Adjustable dead band setting of the governing system
A vectormeter shall also be provided for indication of the MW, MVAR and Power Factor in form of a
CRT screen based representation.
1.10.4 Speed & Load Control

The gas turbine shall be capable of operating at full speed operating conditions under speed
control on an isolated grid as well as in parallel on an interconnected grid.
Setting of the speed/load set point shall be possible from local panel, if applicable and from the
Central Control Room.
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The control from the Central Control Room shall provide all control functions, especially
Speed control (for turbine-generator operation not connected to the grid)
Load control
Load set point control internally from the control system or externally from the Plant Master
Controller (PMC)
Frequency control (Isochronous mode)
Exhaust temperature control
Output signals of the controller shall be limited by overload, overspeed, acceleration and
temperature limiting devices of the gas turbine governing system as well as by operating limits of
the generator.
1.10.4.1
Speed Control
The speed control system shall enable the turbine to be operated isolated or on the grid within the
permissible speed range. Speed adjustment related to rated speed shall preferably be possible in
a range of -5 to +5 percent. The rated speed at no load condition shall be adjustable within +/- 0.5
% for easy synchronising. The speed control characteristics shall allow a stable operation under all
conditions and the dead band of the regulation system shall not exceed 0.1 % of the rated speed.
The droop factor is adjustable between 2 and 10 %. The automatic starting sequence control shall
co-operate with the speed control. It shall increase speed up to nominal speed supervising all
relevant plant conditions to protect the unit from damages or thermal overstress. In case of load
rejection (switching over from load to speed control), the speed setpoint shall be adjusted
automatically to rated speed. Tripping of the GT by overspeed signals must be avoided in any
case, even at full load rejection. Overspeed occurring under any conditions must not have any
harmful effect on the turbine generator unit nor on its auxiliaries.
1.10.4.2
Load Control
Load control shall be activated automatically after closing of the generator circuit breaker, and the
change-over shall be bumpless. The load control system shall act either as frequency control,
constant load control or as temperature control. The load (speed) setpoint shall be adjustable from
no load to full load and peak load.
When reaching limiting temperature values of the gas turbine by increasing the load, the exhaust
temperature controller shall take over the control from the load controller and thus blocking any
further increase in the load. This condition shall be indicated on the DCS monitors and an
indication for 'Base Load' shall be shown on the monitor. If 'Peak Load' is selected, the limiting
exhaust temperature shall increase automatically to the limit value preset for peak load and the
load shall then increase automatically until the new exhaust temperature limit is reached and 'Peak
Load' shall then be indicated on the DCS monitors.
The Contractor shall state the minimum generation capacity required for stable operation when
operating under load control and operating parallel with other turbine-generators.
1.10.4.3
Auto Peaking from Base Load:
A facility shall be provided to automatically increase the load from 'Base Load' to 'Peak Load' if the
system frequency is dropped down to a preset limit.
1.10.5 Control of Other Systems

The control of all the other systems must basically be of such a nature that a fully automatic
operation is guaranteed. In the event of unavailability of individual devices or equipment, the
appropriate auxiliary devices or standby equipment, if available, shall start automatically. Thus, for
Page: 18
example, if the main lubricating oil pump fails, the AC driven auxiliary oil pump is automatically
switched on and if the latter should fail then the DC (battery) driven emergency lubricating oil pump
is automatically switched on, thus maintaining lubricating oil supply under all circumstances.
1.10.6 Gas Turbine Protection System

The protection system shall be provided fail-safe and triple redundant in DCS process control
stations. It shall be certified by TV or an equivalent certification authority. The protection signals
shall be provided triple redundant from the triple redundant field sensors in three separate circuits
up to the final actuation element. 2out of 3 voting logic shall be provided in the protection system.
Any interface signals from other systems which are used for tripping the GTG such as from the
switchgear, fire protection panel, etc. shall also be configured triple redundant from the source to
the final actuation element. The protection signals shall include, but not limited to, the following:
Overspeed protection
Over-temperature protection
Bearing Metal Temperature
Vibration detection and protection
Loss of flame protection
Fire detection and protection
Emergency stop
Lubrication oil protection
1.10.6.1
Overspeed Protection
The overspeed protection must at least possess an electronic system which is arranged to
shutdown the gas turbine unit at overspeed of 10 %. The overspeed protection device shall be
checked at shutdown and during start-up to ensure, that it is working properly. There must also be
a mechanically operated centrifugal type overspeed trip mechanism set at 12 % overspeed and it
must be possible to check its actual point of operation.
1.10.6.2
Over-Temperature Protection
Over-temperature of the turbine exhaust temperature shall produce an alarm and at a higher value
tripping of the turbine.
1.10.6.3
Combustion Monitor
The function of the combustion monitor is to reduce the likelihood of extended damage to the gas
turbine if the combustion system deteriorates. This function shall be effected by examining the
temperature control thermocouples and compressor discharge thermocouples. Should the pattern
of the exhaust thermocouples readings become abnormal, alarm shall be annunciated with a
message to be displayed on the DCS monitors.
The thermocouples shall be examined by the monitor every second after the turbine has reached
operating speed by removing each thermocouple in turn from the control for a very short time.
During this time the thermocouple reading shall be converted to a digital value and placed in the
memory of the combustion monitor.
From these readings the average exhaust temperature is determined and alarm limits above and
below this value are calculated using the exhaust temperature and the compressor discharge
temperature parameters.
Page: 19
Important signals of the combustion monitor shall be included in the event recording.
In addition, the monitor shall have a built-in "self-test" and shall alarm for all internal failures
including the loss of AC-power, and shall also detect and alarm defect thermocouples.
1.10.6.4
Vibration Detection & Protection System
The vibration detection and protection system serves to monitor the vibration occurring on the gas
turbine and the generator. The vibration detection and protection system shall be designed tripleredundant. Each vibration sensor shall be connected to a separate dedicated module. If fuses are
provided for the power supply to the modules, each module shall have its own dedicated fuse.
3 vibration sensors shall be provided at each bearing. Alarm shall be initiated if high vibration limit
is reached. Trip shall be initiated with alarm if the high high vibration limit is reached by at least 2
sensors at the same bearing as a result of 2 out of 3 voting logic. Vibration analysis algorithm and
the 2 out of 3 voting logic shall be provided in the protection system. Faulty sensor shall be
alarmed and shall be excluded from the trip voting logic.
1.10.6.5
Loss of flame protection
Loss of flame shall be detected by at least 2 flame detectors to trip the GTG. Faulty detector shall
be alarmed and shall not trip the GTG.
1.10.6.6
Fire Detection and Protection
A separate dedicated fire and gas detection and protection system shall be provided for each GTG
and shall fully comply with the specification in clause 12.4, Part P2.1 and P4.23 and any other
relevant clause. Fire protection trip to the GTG shall be a result of 2 out of 3 voting logic in the fire
protection panel and the trip signal shall then be interfaced to the GTG protection system through 3
relays and 3 separate hardwired circuits. A second 2 out of 3 voting logic shall be made in the
GTG protection system for the GTG trip.
1.10.6.7
Lubrication Oil Protection
Lube oil low pressure shall be alarmed with automatic start of the auxiliary lube oil pump. Lube oil
low low pressure shall trip the GTG as a result of 2 out of 3 voting logic. Lube oil high temperature
shall be alarmed only.
1.10.6.8
Emergency Stop
Emergency stop push buttons from any location (Local Board, Central Control Room) are to be
connected hard-wired to the GT protection system.
Each Emergency Stop Push button shall be provided with 4 contacts, 3 of them shall be NC
contacts and shall be separately hardwired to the GTG fail-safe protection system for the 2 out of 3
trip signal. The fourth contact shall be NO contact and shall be connected to the GTG control
system for status indication.
The Emergency Stop Push buttons shall be protected by shrouds against inadvertent actuation.
The above requirements are applicable to the Emergency Stop Push buttons of all the units.
1.10.6.9
Bearing Metal Temperature Protection:
Bearing metal temperature measurement and protection shall be provided and shall fully comply
with the requirements specified in cause 7.3, Part P2.1.
1.10.7 Alarm System for the GT-Units

All alarms shall appear on the display of the local Man-Machine Interface and on the CCR operator
stations.
Page: 20
1.10.8 Performance and Condition Monitoring System

In order to achieve better efficiency, higher availability and timely maintenance of the gas turbines,
monitoring and diagnostic system for each gas turbine shall be provided. This system shall be
provided as a part of the Plant Management System (PMS) which is specified in detail elsewhere
in the specification
The system shall gather the necessary information from the DCS or directly and process and
analyse them in real time mode without interacting with the functionality of the control system(s).
The current measured value sampled in pre defined periods shall be compared by the system
during the whole lifetime of the GT with a value from the baseline measurement made on the
machine under similar operational conditions when the machine was in a "healthy" state. The data
shall be stored in the system as a "fingerprint" taking all influencing variables into account. The
analysis computer monitors the changes and gives warning in case of impermissible changes.
Beside the fingerprint also the measured historical data stored in the DCS long-term archives shall
be forwarded to the system for monitoring of trend curves and for comparison of the data in different
periods .
The result may be visualised on the monitor of the workstation(s) belonging to the system as
graphic picture (profile display), as bar charts, tables, etc.
The workstation(s) shall be installed in the Computer Room beside the Central Control Room.
Detection and early warning of the followings shall be provided by the system as a minimum:
Compressor Fouling
Compressor Surge
Turbine Fouling
Exhaust-Temperature
Cooling Air failure or problem
Vibration
The scope shall contain the necessary hardware / software and all configuration and database
filling and shall also include
Interfacing to the external control systems
Interfacing to the field and any additional measurement necessary to fulfil the envisaged task
Establishing the Footprints
Any other works necessary to accomplish the specified tasks
Employers staff jobsite training shall be performed for the system hardware, software and
operation.
The Performance and Condition Monitoring System together with the GT control system shall
provide the necessary data to the Plant Computerised Maintenance Management System in order
to assist in the maintenance of equipment and control of assets on site.
1.11 HRSG SUPPLEMENTARY FIRING BURNER MANAGEMENT SYSTEM (BMS):

The BMS of the HRSG supplementary firing shall be provided in separate dedicated fail-safe, fault
tolerant and redundant DCS process control stations. Start-up/Shut-down sequence programme in
Page: 21
the structure of FGC, SGC and SLC shall be implemented in the BMS. Auto/Manual selection
facility shall be provided for the start-up/shutdown sequence. In auto mode, the overall HRSG
start-up/shutdown sequence shall automatically actuate the BMS start-up/shutdown sequence as
appropriate and the sequence shall then be performed automatically. In manual mode, the
actuation of the BMS start-up/shutdown sequence shall be done by the operator from the DCS
operator station in CCR, however, once the operator actuates the sequence by a single command,
the sequence shall then be performed automatically and without any further manual intervention.
Any necessary functions such as leak test shall be implemented in the sequence.
It shall be possible to display the HRSG/BMS sequence steps on the DCS monitors in CCR.
Indication of flame intensity shall also be provided on the monitor.
It shall be possible to isolate or shutdown one burner or one group of burners without
tripping/losing the whole number of burners. Flame loss detected by 2 flame scanners of one
single burner shall trip the relevant burner only keeping other burners in service. Flame loss in two
non-adjacent burners shall trip the relevant burners only keeping other burners in service. Flame
loss in two adjacent burners shall trip the whole group keeping the other group in service.
The BMS in addition to performing the start-up/shutdown sequence, it shall also perform the load
control of the Supplementary Firing Burners (SFB) by controlling the fuel flow control valves and
the fuel pressure control valves. Additionally, it shall also perform the SFB protection. The
following trip criteria for SFB shall be provided as a minimum:
Flame loss (to be detected by 2 flame scanners and as described above).
Fuel gas pressure high high/low low.
Control air pressure low low.
Cooling air pressure low low.
HRSG tripped.
Diverter damper position closed (closed to HRSG)
SFB Emergenc y stop push button actuated.
Trip of the SFB shall not trip the HRSG. The HRSG shall remain in service with a reduced load
when the SFB are tripped.
The SFB equipment including the flame scanners shall be robust type with the highest reliability
and shall withstand the highest GTG exhaust temperature at peak load without the cooling air.
Loss of the cooling air shall not trip the HRSG, it shall trip the SFB only.
The diverter damper shall be fully open (open to HRSG), as a permissive signal to start the SFB.
Both the HRSG protection system and SFB BMS shall be certified by TV or an equivalent
certification authority.
1.12 AUXILIARY BOILER CONTROL, BMS AND PROTECTION SYSTEM:

Fully automatic start-up/shutdown sequences shall be provided for the Auxiliary Boiler. The
sequences shall be structured in a hierarchy of FGC, SGC and SLC. The start/stop of any
auxiliary system shall be automatic by the sequence. A facility shall be provided to either start/stop
the boiler from the boiler operator station screen or from the Plant Master Sequence (PMS).
Automatic load control shall be provided. A facility shall be provided for internal load set point
control or external load set point control from the Plant Master Controller (PMC). The load
controller modules shall be dual redundant with redundant control valves.
The Protection System and the BMS shall be provided in separate failsafe and fault tolerant
redundant DCS process control stations. The protection system and the BMS shall be certified by
TV or equivalent certification authority. Two (2) flame scanners shall be provided for each burner.
Flame loss in any single burner shall be detected by the 2 flame scanners to trip the affected
burner only keeping other burners in service. It shall be possible to trip/isolate a single burner
whilst the other burners are in service without affecting their operation.
Page: 22
The design of the control, BMS and protection systems is subject to the Employer/Engineer's
approval.
1.13 BLACK BOX CONTROL:

The whole plant shall be controlled by the DCS process control stations. Black Box Control Panels
are not acceptable. Only the following equipment/systems can be accepted to be provided with
Black Box Control Panels:
1. Instrument air and service air compressors.
2. Instrument air dryers.
3. Main fuel gas compressors.
4. Storage system fuel gas compressors.
5. Emergency Diesel Generators units.
6. Diverter Damper Control System.
No other equipment/system will be accepted with black box control panel.
Acceptance of black box control panels for the above listed equipment/system is subject to
fulfilment of the following requirements:
1.
Technical justification from the supplier of the equipment/system showing the reasons that the
control of the equipment/system cannot be implemented in the DCS process control station.
2.
Each of the above equipment/systems shall be provided with its own independent dedicated
control panel.
3.
Each control panel shall be microprocessor based control system and shall be structured
entirely redundant in all aspects. Protection signals shall be provided in 2 out of 3 voting logic.
4.
Group control, co-ordination and selection logic shall be provided in the DCS. No additional
local panel will be allowed to perform this function.
H/W and serial link interface shall be provided for each control panel with the DCS. Command
signals, interlock and protection signals shall be hardwired. Status and information signals shall be
through the serial interface. The serial interface solution shall provide full integration of the black
box control panel with the DCS. Any interface modules/equipment required by the DCS
manufacturer in order to make this full integration shall be provided redundant. The serial interface
shall be dual redundant.
1.14 PLANT MANAGEMENT SYSTEM (PMS):

Plant Management System (PMS) shall be provided in server-client configuration. Dual-redundant
server and one client shall be provided. The PMS servers shall be connected on-line to the DCS
blocking the control/operation of the plant. The PMS shall have access to the real time data of the
plant.
A proven standard software package shall be provided in the PMS to the approval of the
Employer/Engineer. As a minimum but not limited to, the following tasks/functions shall be
performed by the PMS:
Optimisation of power and steam generation to an overall optimum.

Optimal load distribution.
On-line determination of the overall efficiency of the total plant.
On-line determination of the individual efficiencies of all major components such as each GTG,
HRSG, Auxiliary Boiler, BPST, Desalination Unit, etc.
Visual display of the measured efficiency deviation from the reference efficiency in meaningful
units (generated power, fuel consumption, etc.), identification of reasons and output of
diagnostics.
Clear display with financial evaluation.
Page: 23
Alarm warning when the operational configuration of the plant has to be changed to maintain
adequate control margins.
Guidance giving the most appropriate configuration of running plant to meet the predicted and
current power and water demands with the given available plant.
Mass and energy balances for the whole plant.
Off-line function to permit the operator to explore the influence on plant output, efficiency and
control margins of different plant operating configurations.
Printing of monthly and daily management reports including all important parameters of the
plant.
Long term archiving of all analogue trends, all binary signals required for reports, maintenance
logs, trip logs, etc.
Any other functions deemed necessary shall be provided.
PMS stations shall be provided at the following locations:
Computer Room (Master station / Engineering station)
CCR Shift supervisor desk
Shift supervisors room close to the CCR
1.15 CONTROL OF ELECTRICAL MOTORS IN CASE OF POWER FAILURE

The purpose of the system logic is to manage the opening/closing of motors contactors in case of
transient power failure with power supply resuming and in case of total black-out.
This actions have to be co-ordinated between electrical system and Distributed Control System to
manage correctly all the conditions.
In order to detect the power failure the Undervoltage (UV) signal relevant to the each bus-bar shall
be acquired by DCS. Alarm for each undervoltage signal shall be available for the operator in CCR.
When a power failure occurs, first a transfer operation with fast or slow transfer shall automatically
be performed as specified in the electrical part of the Specification. In case of a total blackout
without power resuming the Plant shall be brought in a safe position.
Contractor shall analyse the process and the electrical system for each individual drive with duly
consideration of the Plant availability and safety aspects and establish the control logic
accordingly.
1.15.1 Resuming of Power

If transfer is achieved, the power supply is resumed and the motors can be re-accelerated or restarted. On the contrary if power supply is not resumed the motor is tripped.
Electrical system and re-acceleration logic in the DCS manages the re-start and the trip actions
depending on type, size and process relevant function of the motors connected to the related busbar.
The re-acceleration shall be a completely automatic logic. Therefore no manual intervention shall
required.
Depending on their size, motors will be fed by different types of starters. Depending on their size
and their process function relevance the various plant motors shall be divided in groups, like
MV Motors Powered by Power Centre
LV Motors Powered by Power Centre
LV Motors Powered by MCC
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Motors Powered by MCC with Stand-by
Not critical motors Powered by MCC (without stand-by)
Motors powered by MCC without stand-by to be re-started
For each of the groups the proper action shall be taken by the DCS control logic.
1.15.2 Emergency Shut Down

In case of total black out emergency diesel generator unit(s) will supply the most critical consumers
to guarantee the safe shut-down of the Plant.
In order to initialise the safe shutdown, a signal Start Safe Shutdown shall issued by a dedicated
logic activating a step sequence program.
Only those consumers, which are needed for the safe shut down of the Plant shall get an ON
command from the DCS, not to overload the emergency diesel generator unit(s).
The procedure shall be accomplished fully automatically by the DCS logic. Therefore no manual
intervention shall be required.
1.16 CENTRAL CONTROL ROOM

1.16.1 CCR Layout and Design
The tentative layout of the Central Control Room is shown on the Tender Drawing No.
CNE/015/2002/-R-03-G-D-00001.
The design, engineering and layout of the whole Central Control Room, including the portion
delivered by Package D with operator workstations, printers and large screen device shall be
carried out in the Package P scope by a specialised company, subject to the Employer /
Engineer's approval. The documentation is subject to separate approval. The specialised
company shall make a detailed study of the CCR design and layout including the lighting, colours,
material, interior architecture, etc. and shall consider carefully the ergonomic standards and up-todate control room design principles. It shall also be considered in the design that the general
overall process information to be displayed on the large screen monitors shall be visible to all
persons. The design study shall include the specification, type and colour of the CCR furniture.
The interior design and execution of the CCR is fully in the Package P Contractor.
1.16.2 Central Control Room Equipment

The following equipment shall be provided in the Central Control Room (CCR):
One (1) Power Control Desk (PCD) comprising of:
Three (3) DCS operator stations, each with dual channels and two (2) monitors
One (1) event/alarm laser printer
One (1) colour hard copy printer
One (1) large screen monitor
Hardwired emergency shutdown push buttons for each of the GTGs, HRSGs, BPSTG's
and Auxiliary Boilers and for each fuel gas inlet emergency shut down valve
Hardwired depressurising push button for each gas depressurising valve for the gas
stations
Page: 25
Hardwired synchronising facility with synchronoscope for each of the GTGs and
BPSTG's.
One (1) Common Service and Electrical Control Desk (CSECD) comprising of:
Two (2) DCS operator stations, each with dual channels and two (2) monitors
One (1) large screen monitor
One (1) Water Control Desk (WCD)

(The printers and operator stations and large screen for the WCD will be provided by Package
D)
One (1) Shift Supervisor's Control Desk (SSCD) comprising of:
One (1) DCS operator station with dual channels and two (2) monitors.
Two (2) PMS workstations, each with single screen
One (1) laser printer for DCS
one (1) laser printer for PMS
One (1) colour hard copy printer shared for PMS and DCS for A3/A4 size
Two (2) periodic/on-request log report laser printers for the PMS
All DCS operator stations and large screens in CCR shall have global access to the entire plant
database, including also all systems in Package D scope. Functions, features and graphic
displays of the entire plant shall be accessible from any operator station at any location and it shall
be possible to operate and control each component of the entire plant from any DCS monitor at
any location in CCR. Each of the DCS operator stations and large screen monitors shall be
individually controlled by the pertaining mouse. The two monitors of each DCS operator stations
shall be controlled by only one mouse which can move the cursor all through the two monitors.
Any other equipment not specified above but deemed to be necessary shall be provided.
Indication of the fuel gas supply pressure at the inlet to the fuel gas stations shall be displayed on
a large LCD display unit to be provided in CCR.
Indication of the total station output MW and MVAR shall be displayed on a large LCD display unit
to be provided in CCR.
Indication of the system frequency in Hz shall be displayed on a large LCD display unit to be
provided in CCR.
Summated MW and MVAR of Stations D, E, G, H, K including L Station to be displayed on 4
inch display units/large screen displays in CCR. Necessary signals from respective Power Stations
DCS can be obtained through DEWA communication network Backbone Data Highway (BDH) /
FOX-U to L Station. All the interfaces at the remote Power Station and BDH / FOX-U for
transmitting and receiving these signals shall be included in the scope of supply. All interfaces shall
be compatible to existing communication system. Complete details shall be submitted for approval
of Employer / Engineer.
1.16.3 Software, Tasks and Functions

The scope includes all necessary configuration and programming works, special software
packages, etc., for all specified tasks. As far as standard, graphic and other displays are
concerned, the Contractor shall provide them in a sufficient number to control and supervise the
Plant to the Employer/Engineer's satisfaction.
Page: 26
The scope shall also include the integration of all tasks for the portion delivered by Package D
1.16.3.1
Short-Term Archive
For the short-term archive the data shall be stored in main memory (RAM), for at least 24 hours.
After this period the data shall be transferred automatically in the Long-term archive.
Storage of the following data shall be considered as a minimum:
All alarms and events
Post trip protocols
Pre-selected curves with high resolution
Pre-configured protocols, on request and periodic protocols
1.16.3.2
Long Term archive
Long term archive data shall be stored on hard disk for a duration of at least 1 month. It shall be
possible to export the contents of the long term archive automatically or on-request to external data
carrier like magneto-optical disks.
Storage of the following data shall be considered as a minimum:
All alarms and events
Post trip protocols
Pre-selected curves with reduced resolution
Pre-configured protocols, on request and periodic protocols
1.16.3.3
Post-Trip Protocol
The following structure shall be followed for the post trip protocols (analogue values):
Time axis in minutes before and after the trip Sampling time of the analogue
signals
-10
to
-3
1 minute
-3
to
-1
10 sec
-1
to
0 (trip time)
1 sec
to
+1
1 sec
+1
to
+3
10 sec
+3
to
+10
1 min
The binary events shall be buffered in a memory and printed out along with the analogue scanned
values (in a separate log), independently from the regular event/alarm protocol. 200 binary
events/alarms before and further 200 after the trip or 2 minutes before and 2 minutes after the trip
shall be considered, whichever case is giving the higher amount of information.
The trip protocols shall be stored in a non-volatile overflow memory having enough capacity for the
last 10 trips and allowing the on-request printing any time.
Any given trip event shall automatically release a post-trip protocol combined with trip-relevant
alarms and the main process status data. The following measurements are some typical examples:
HRSG
HP/LP steam temperature at outlet
HP steam flow at outlet
HP/LP steam pressure at outlet
FW flow at inlet
HP/LP drum level
Steam Turbine
Load
HP/LP steam pressure at inlet
HP/LP temperature at inlet
Speed
Back pressure
Differential expansion
Rotor eccentricity
Vibrations
Generator
AC voltages/currents
DC voltage/current
Stator winding temperatures
Rotor winding temperatures
Oil temperature
Bearing temperatures
Bearing vibrations
Main Transformer
AC voltages/currents
Primary winding temperatures
Secondary winding temperatures
Oil temperature/level
Desalination Plant
As specified by the Desalination Plant supplier
Page: 27
Page: 28
1.16.3.4
Plant Management Functions
Plant Management Functions have been specified in detail under the title Plant Management
System in this specification.
1.16.3.5
Monitoring and Control Tasks for Other Systems
Beside the full control and monitoring of the power and potable water generation including station
and unit electrical auxiliaries, the DCS workstations shall take over the task of remote monitoring
and remote control for other systems / equipment in the Plant. The extent of monitoring and control
shall be done as specified at the pertaining system specifications and/or shall be performed as far
as the monitoring / control of the system or equipment has an interest for the central control room
operator and shift supervisor in favour of the plant availability and safety and proper conducting.
The monitoring and remote operator control shall involve all specified means and features at the
workstations, as applicable, like screen mimics, curves, bar charts, alarm lists; printing of logs and
protocols; archiving retrieving of data, etc.
Such systems and packages are, e.g.
Package D Desalination (full integration)
Package S 400 kV Switchgear (monitoring only)
GTs performance monitoring system
Computerised Maintenance Management System, if applicable (Supervisors workstation)
Black box systems and local controllers, if applicable
HVAC system for process/control areas, electrical rooms (Supervisors workstation)
Fire Alarm/Detection system (Supervisors workstation)
Weather Station
etc.
1.16.4 Furniture
The CCR furniture shall be delivered from well known European manufacturer and shall be
designed especially for computerised control centres. The manufacturer and type of equipment
shall be approved by the Employer / Engineer. For the approval material and colour samples shall
be submitted along with the CCR architectural design
The following furniture shall be provided:
Operators desks for each workstation, including supervisors workplace
1 set each
Printer tables and racks for all printers specified, complete with feeder and paper 1 set
holder
Operator chairs for each workstation, including supervisors workplace
1 pc each
Filing cabinets, total length 4,5 m
1 set
Wall whiteboard (min. 1000 x 1500 mm) with 2 sets of colour pens
1 set
The delivery shall also include the furniture for workstations included in the Package D scope.
Page: 29
1.17 COMPUTER ROOM

1.17.1 Central Programming and Configuration Station
Central Engineering Stations shall be provided for the DCS in the computer room as fully
integrated part of the DCS and allow communication with the entire DCS hardware including the
portion provided by the Package D in order to have a powerful engineering tool for carrying out all
necessary work on the entire user-software package.
The minimum requirements of the station functions shall be according to the General Technical
Specifications. However, any function offered by the manufacturers system and is applicable for
the Plant, shall also be provided.
For remote diagnostic/analysis a gateway with Modem (hotline) to the DCS Manufacturers place
shall be provided.
1.17.2 Central Diagnostic Station

Central Diagnostic Station shall be provided for the DCS in the computer room as fully integrated
part of the DCS and allow communication with the entire DCS hardware, including the portion
provided by the Package D, down up to the I/O level in order to have a powerful tool for system
diagnostic, troubleshooting and maintenance.
The software shall allow easy and user friendly way to identify failed equipment in any part of the
digital system and peripheries.
The minimum requirements of the station functions shall be according to the General Technical
Specifications. However, any function offered by the manufacturers system and is applicable for
the Plant, shall also be provided.
1.17.3 Scope
The following shall be provided:
Two (2) Engineering and Documentation Stations (EDS). Each EDS shall be provided
complete with a dedicated CPU, graphic display controller, monitor, keyboard and mouse.
One (1) hard copy printer and one (1) A4/A3 format laser jet printer shall be provided.
Since the TOSMAP system cannot provide redundant Engineering and Documentation
Stations, one workstation shall be provided extra as spare.
One diagnostic station complete with monitor, keyboard, mouse and laser jet printer.
Any additional equipment not specified but deemed to be necessary for engineering and diagnostic
shall also be provided. All necessary software packages and licence shall be provided. The scope
of supply is subject to the Employer/ Engineer's approval. A list of equipment shall be submitted
for approval.
For any other digital system provided in the frame of the present Contract similar functions shall be
available, as described above for the DCS system. Should the tasks not be fulfilled by the DCS
Engineering & Diagnostic Station or where system specific workstations have been specified or
rendered necessary in any other part of the Specification, like workstations for the HVAC, Fire
Detection, performance monitoring, Emission Monitoring, etc., the necessary hardware,
engineering workstation and software, further operator desks and chairs shall be provided by the
Contractor and shall be installed in the Computer Room.
1.17.4 Furniture
The computer room furniture shall be delivered from well known European manufacturer and shall
be designed especially for computer centres. The manufacturer and type of equipment shall be
Page: 30
approved by the Employer / Engineer. For the approval material and colour samples shall be
submitted.
The following furniture shall be provided:
Operators desks for each workstation
Operators chairs for each workstation,
Operators desk and chair for a Maintenance Management station
3 nos. of spare operators desks
3 nos. of spare operators chairs
Printer desk (at least 1600 x 800 mm) and/or special rack for all printers
specified, complete with feeder, paper holder
Working desk (ca 3000 x 1000 mm)
6 nos. of chairs for the working desk
2 nos. of lockers (cupboard-size) for spares and consumables
Wall whiteboard (min. 1000 x 1500 mm) with 2 sets of colour pens
3 nos. of cupboards for documents and manuals
Fire proof cabinet for software and data holder storage
Different accessories like disk archive boxes, streamer tape containers, etc.
in the necessary quantity
1.18 LOCAL CONTROL ROOM

The following equipment shall be provided:
Gas Turbine Units:
One (1) DCS Local Operator Station (LOS) with dual channels and two monitors shall be
provided for each GTG at the GTG LER. The LOS shall be complete with key board, mouse
and one (1) event/alarm printer.
One (1) set of furniture consisting, as a minimum of two (2) operator chairs, one (1) writing
desk with adequate space, one (1) filing cabinet for storing drawings and documents and one
(1) side board.
1.19 CENTRAL AND LOCAL ELECTRONIC ROOMS

Central and Local Electronic Rooms shall be provided to accommodate the DCS process stations
and equipment. Local Electronic Rooms (LER) shall be provided for the plant units which are
relatively far from the CCR such as water treatment plant, GTG, Fuel supply, etc. The
arrangement and equipment location in the Central Electronic Room (CER) and in the Local
Electronic Rooms (LER) is subject to the Employer/Engineer's approval.
The DCS cubicles of Package D will be installed in the electronic rooms of the pertaining
system/plant switchgear building in the scope of Package D.
Page: 31
1.20 DEMINERALISED WATER PLANT CONTROL AND MONITORING

The Demineralised Water Plant shall be fully controlled by the DCS process control stations with
fully automatic start-up/shutdown and regeneration sequences. The DCS process control stations
shall be located in the local electronic room in the Demineralised Water Plant building.
Start/stop, control and full supervision shall be provided from the DCS operator stations at CCR.
Black box control system(s) shall not be accepted.
1.21 OPERATOR STATIONS MONITORS

All DCS operator stations in CCR, Computer Room and in Local control Room(s) shall have
monitors of the following specification:
18 inch LCD TFT display.

High resolution 1280 x 1024 pixels.
16.7 million colours.
IPS (in plane switching) technology extremely wide viewing angle typical 170 horizontal and
vertical.
Optimum ergonomics ISO 13406-2.
Distortion-free image.
Excellent focus and high contrast.
Low power consumption.
Multi-level power management EPA, VESA DPMS.
Plug and play VESA DDC2B device.
Inventory data readable VESA EDID V3.0.
Low radiation and environmental friendly according to TCO 99.
Immune to external electromagnetic fields.
Automatic auto-adjust.
Tilt-and-swivel base with height-adjust and rotation (portrait function).
Mechanical interface standardised to VESA FPMPMI (100 mm).
Other monitors of systems not realised in the DCS such as fire detection and alarm system, BMS
of HVAC, etc. shall also be provided with the same monitors as specified above.
1.22 LARGE SCREEN MONITORS

The Large Screen Monitors to be provided in CCR shall have the following specification:
Three-panel poly-silicon LCD technology.

Four (4) cubes of screens for each of the three large screen monitors, each screen shall have
width of 1000 mm (39.37") and a height of 750 mm (29.53") and 50" diagonal.
Resolution per cube shall be 1024x768 colour pixels.
Colours: 16.7 millions.
Colour Management: Digital 30 bit/pixel.
Power supply 230V AC, 50 Hz.
Luminance: typical 800 cd/m 2
Efficiency: 6 lm/w
Brightness uniformity > 95%
Contrast: 250:1
Each large screen monitor shall be provided complete with its own control unit and frame. High
standard wall cladding shall be provided for all Large Screen Monitors (including the third one
provided by Package D) as recommended by the supplier and subject to the Employer/Engineer's
approval.
Page: 32
1.23 PROGRAMMING AND DIAGNOSTIC DEVICES FOR THE PLANT

At least two (2) sets of programming and diagnostic devices/tools (e.g. Laptop) with appropriate
software shall be provided for each digital or numeric system supplied in the frame of the present
Contract, independently from the fact, whether the system was specified under the I&C
Specifications or not. The Employers staff job-site training shall include the use of such devices.
1.24 SIGNAL EXCHANGE WITH THE LDC

The Load Dispatch Centre shall be informed about the general plant status. Therefore, the
following scope of process signals, as a minimum, shall be made available to the package S
SCADA / telecommunication equipment in the HV switchyard area (see table).
Equipment
Description
Steam Turbines, Stand-by

each
Outage
Gas Turbines,
each
Binary
Analogue
x
x
Operating
Generator connect/disconnect
Maximum possible output
Minimum possible output
Generator actual active power
Generator actual reactive power
Generator actual voltage
Net generation and total aux. power

MW/MVar
Load actual set point
Ready to start
Outage
Operating
Generator connect/disconnect
Maximum possible output
Minimum possible output
Generator actual active power
Generator actual reactive power
Generator actual voltage
Net generation and total aux. power

MW/MVar
Load actual set point
Gas flow
Oil flow
HRSGs, each
Status ON/OFF
Page: 33
Steam outlet flow
x
x
Duct firing ON/OFF
Aux. Boilers,
each
Operating ON/OFF
Desalination
Plant and
Potable water
Unit operation status signals
Plant
System / generation limitations
Plant
Total auxiliary load per generation

units
Steam outlet flow
X
x
Water production
x
x
x
x
Further, all signals shall be received from and made available for the Employers Automatic
Generation Control (AGC), including other EMS applications through the package S interface, i.e.
Optimal Power Flow (OPF), Reactive Power Scheduling (RPS), etc. on continuous closed loop
function having the option to control any or all of the following:
1.
Generator under AGC control (request for control for each generator).
2.
Generator Megawatts setpoint of each generator.
3.
Generator Megavars setpoint of each generator.
4.
Generator AVRs setpoint of each generator.
5.
Generator transformer tap position of each generator.
During disturbance, base loaded units should provide primary governor response to initially
stabilise the frequency. However during AGC frequency restoration, an option for AGC action to
restore the base loaded units to their scheduled load is required.
The power station DCS shall also be responsible for verifying the setpoint values it receives from
the SCADA system whether they are within the operating limits before acting upon them (e.g. with
alarm/acknowledgement sent to operator before execution).
For the Employers Energy Management System the following controls shall be made available by
Package P through the Package S interface:
Electric active power (MW)
Reactive power (MVARs)
Voltage
Transformers Tap Changer Position
On the DCS workstations a separate screen picture shall be allocated to the LDC/SCADA
communication. The screen shall allow countercheck of the signals, respectively operator inputs for
parametric / constant values.
Page: 34
The signals from/to the HV Switchyard are handled in Package S of the specification. In any
case, the signals shall also be forwarded to the DCS system and appear on the CCR DCS
operator workstations. The kind of interfacing and the protocol used shall be commonly agreed
between the packages P and S.
1.25 WEATHER STATION

Weather station shall be provided for the following measurements:
ambient air temperature
ambient air pressure
ambient air humidity
wind velocity
All measurements of the weather station shall have local indication and all signals shall be
connected to the DCS for monitoring by the CCR operator workstations.
1.26 I&C POWER SUPPLY

The I&C power supply is specified in the Electrical part of this Specification and shall fulfil the
requirements as stated in the Specification General Technical Requirements for Instrumentation
and Control Systems.
1.27 TESTS AND INSPECTIONS

The general rules and details of Tests and Inspections are specified elsewhere in this
Specification.
1.27.1 Factory Acceptance Test (FAT)

Before delivery to the site and after the approval of all function and logic diagrams, hardware as
well as functional Factory Acceptance Test (FAT) shall be conducted on the DCS and other control
systems. Test simulator shall be used to simulate the field input/output signals and shall be
hooked up to the system to be tested. The test plan and test procedure shall be submitted for the
Employer/ Engineer approval. Permission to deliver the DCS/other control systems depends on
the result of the FAT and subject to the Employer/Engineer's approval.
1.27.2 Site Test

All instrumentation and control items shall be tested on the Site after erection, during precommissioning and commissioning.
After start-up, first synchronisation and loading the control system shall be adjusted and optimised
for Plant operation. The final results shall be demonstrated during initial operation tests.
1.28 EMPLOYERS STAFF I&C TRAINING

1.28.1 General
The stipulations of the general specification about the Employers Staff Training shall be obeyed.
Moreover the following shall be also considered for the I&C staff.
Classroom training
On-the-job training
involving the whole I&C staff, like all DCS system engineers and maintenance staff.
Page: 35
During the commissioning stage the Contractor shall assign 1 (one) instructor for I&C to
accomplish the On-the-job training, additionally to the classroom training. The On-the-job training
will normally be presented to smaller groups to best utilise the instructor's capabilities without
significantly altering job performance.
The training shall include training on all I&C control systems and all computerised systems in the
Plant. The necessary training documentation shall be provided by the Contractor.
All costs of the training shall borne by the Contractor.
1.28.2 Content
The I&C training shall include but not limited to the following items:
System principles initiation.
Basic design and functions of the I&C control system(s) and any controllers delivered in the
frame of the Contract.
System operation and operating parameters.
System engineering, configuring, programming and diagnostic
Application software.
The theory of maintenance, including preventive and corrective maintenance, calibration

procedures, use of specific diagnostic and programming tools, etc.
Routine and major inspection, including procedures on all functional tests, assessment and
analysis of inspections results
Hardware maintenance, troubleshooting and repair.
Testing and application of spares, handling and storage requirements.
1.28.3 Instructor Qualification

The Contractor shall supply qualified personnel as instructors. Personnel designated as classroom
instructors should have previous experience in a classroom environment or equivalent
qualifications and instructional training. Personnel designated as on-the-job training instructors
should have previous jobsite training experience. The On-the-job instructor should have theoretical
knowledge of his equipment or a suitable support organisation that can provide that information in
a timely manner.
1.29 INSTRUMENTATION AND CONTROL WORKSHOP

The I&C workshop is specified elsewhere in this Specification.
1.30 CONTINUOUS EMISSION MONITORING SYSTEM (CEMS)

The Continuous Emission Monitoring System (CEMS) is specified in a separate Part of this
Specification.
Page: 36
2
2.1
Part P2.27 Instrumentation and Control Working Doc
COMMUNICATION AND CLOCK SYSTEM

TELEPHONE SYSTEM
2.1.1 General
The requirements specified under Part "General Technical Requirements" are to apply and where
applicable, further regulations from the other Parts of this specification.
Equipment and system shall be provided with easy access for maintenance and calibration. All
equipment shall be designed for at least 50 C continuous operation temperature
In areas with high noise levels (e.g. turbine hall, burner gallery) etc. and in the open, suitable
telephone booths shall be provided. Call lights shall be mounted on the roofs of the booths. In
addition, an auxiliary bell signalling for each incoming call shall be installed in the vicinity of each
booth and operating simultaneously with the call lights.
The Telephone System shall be interfaced to the specified Public Address Systems.
The system shall be provided with specified minimum of tie-line interface cards for future
interconnection to external telephone systems of Jebel Ali complex.
2.1.1.1 PABX
The PABX shall be state of art fully digital non-blocking switch. It shall be modularly expandable to
the specified maximum capacity. It shall facilitate both full duplex voice and data communication.
Concerning the type of the PABX, Contractor shall arrange for the approval of his equipment by the
national telecommunication company ETISALAT.
The PABX shall as a minimum be provided with the following functions/facilities:
call transfer
abbreviated dialling
call me (lamp indication)
automatic recall
break in
multi-party conference (minimum: 3)
follow me
emergency call
group call (minimum: 8 groups)
operator attended operation
unattended operation
voice guidance
system maintenance hardware and software including PC and printer
interface to Public Address System
busy call repeat,
last number memory,
call switch over,
code dialling with 30 numbers memorised,
call forward to another extension,
self policy unit with print out,
facility for DID (Direct Inward Dialling) from any extension in L station. Facility shall be
provided to call any number in existing D, E, G and K stations. The reverse shall also be
possible. The Contractor shall check the existing facility and prepare the system accordingly.
Page: 37
The system shall facilitate on-line maintenance with no disturbance to unaffected subscribers. On
total PABX failure the specified CO lines shall be automatically switched to dedicated (preprogrammed) subscribers in a fail-safe manner.
2.1.1.2 Telephone sets

Depending on their location of installation, the specified telephone sets for the system shall be
provided in dust-proof, water-tight or explosion-proof versions and connected by corresponding
control cables.
The specified telephone sets shall be provided as desk or wall telephone sets according to place of
installation.
The specified telephone sets shall be, as a minimum, of the following types:
2.1.1.2.1 Control telephone sets

Control telephone sets shall be aesthetically built into the specified Control Desks in the CCR.
These shall be dust-tight and shall facilitate hands-free conversation.
2.1.1.2.2 Desk telephone sets

Desk telephone sets shall be used only in air-conditioned rooms and offices, and shall be impact
resistant and dust-tight.
2.1.1.2.3 Wall telephone sets

Wall telephone sets for use in rooms that are not air-conditioned shall have water-and dust-tight
(degree of protection at least IP 54) temperature resistant plastic cases.
2.1.1.2.4 Wall telephone sets, explosion-proof type

In hazardous classified areas such as gas reduction station, oil tank farm, etc. wall telephone sets
with explosion-proof and corrosion resistant metal cases shall be provided. The following functions
as a minimum shall be provided:
calling dial
hand set complete with fixed dynamic receiver insert, fixed carbon transmitter insert and cable
2.1.1.3 Alarm bells

For use as an auxiliary bell connected to the relevant telephone sets to meet the following
minimum requirements:
type of enclosure IP 54
housing, light metal, weatherproof
sound pressure level 110 dB (max.) distance 1 m.
In hazardous areas the alarm bells used shall be of the explosion-proof type.
2.1.1.4 Telephone Booths

The telephone booths for wall-mounting shall consist of high impact and corrosion-proof steel or
aluminium material (resistant to radiation) and shall be equipped with the following:
one 230 V AC internal roof light, type IP 54 enclosure, fully wired with switch
one 230 V AC external call light, type IP 54 enclosure, marked on three sides (mounted on
roof of telephone booth)
distribution box for lighting, type IP 54 enclosure, for 230 V AC cable infeed
Page: 38
distribution box, type IP 54 enclosure, for telephone connection cable and cable connection of
auxiliary alarm bell
telephone relay for auxiliary bell
For installing telephone booths in hazardous areas all equipment used shall be exclusively of the
explosion-proof type
The Contractor shall provide the 230 V AC power supply for the internal light and call light with
PVC cable 3 x 2.5 mm from the lighting distribution units.
2.1.1.5 Main Distribution Frame (MDF)

The MDF shall be accommodated in a steel enclosure with IP 32 type for wall-mounted /freestanding installation.
On the front of the panel doors with safety locks shall be provided.
All internal and external control cables shall be brought out to terminal strips using a solderless
connection technique (Krone type or equivalent).
The terminal strips shall be provided with overvoltage protection to divert overvoltages on the field
cables.
In addition, the terminal strips shall be furnished with isolating contacts to enable cable test to be
made subsequently in both directions.
The MDF shall be provided with minimum of 20% spare terminal strips for future modification.
All incoming and outgoing cables shall be attached to a cable anchorage structure
All terminal strips shall be properly labelled
2.1.1.6 Power Supply Equipment

The telephone system shall be provided with an independent UPS complete with battery and
charger, which shall automatically switch in, on mains failure, and supply for at least 5 hours. The
main supply for the UPS shall be taken from the station essential supply.
2.1.2 Particular Requirements

The power plant shall be equipped with a telephone system. This system shall take over the
internal and external telephone traffic of the whole power plant, including all packages.
The telephone system shall provide a modern, digital storage program exchange which is fully
modular, therefore easily expandable.
The system shall enable the telephone communication for
min. 250 internal subscribers indoor and outdoor
10 Nos. of incoming lines
10 Nos. of outgoing lines
10 Nos. of two way trunks
The external lines shall be picked up at the plant boundary and shall be transferred via cable trays
and partly via underground line to the PABX main marshalling rack in the Administration Building.
The system shall be interconnected to the PABX exchanges at D, E, G & K station with 20 tie lines
each.
The exchange shall be provided with DID facility and the required software and hardware.
Page: 39
The exchange shall have interactive voice device to guide the party to be connected to operator or
desired extension.
The PABX shall be delivered and installed according to the prescriptions and codes of ETISALAT,
Dubai and shall get ETISALATs approval.
Facility shall be provided to talk between subscribers, to other substations of the system and with
Post & Telegraph subscribers of the city. Conference facility shall be also provided.
The telephone system shall be easy expandable taking into consideration the same capacity for
the requirements of Jebel Ali Power and Desalination Station L - Phase II as specified hereunder
for Phase I. The requirement of expandability shall be applicable to the modularity of the PABX
without providing, however the necessary extension hardware or the telephone sets.
For common parts of an established future system (e.g., external power distribution and supply,
internal battery, internal common power supply module(s), and for the space of installation
including common cable trays, duct, channels, etc. already the requirements of Phase I and Phase
II shall be considered.
The specific scope for this Part covering the Communication and Clock system for the Jebel Ali
Power and Desalination Station L Phase I, is as outlined below as well as specially requested
supplies and services hereunder but without excluding other necessary components and services
mentioned in other Parts.
2.1.2.1 Telephone Exchange (PABX)

The PABX shall have a 100 % automatic exchange system provided in compact cabinets with
slide-in technique. It shall be of modern design operating with electronic components in the
telephone channel network and in the control system.
The PABX shall be compatible to an ISDN (Integrated Services Network, if used). The PABX shall
correspond with the public telephone grid via the external lines.
The interface on both ends and the cable interface shall be co-ordinated by the Contractor with the
local communication authorities.
The PABX shall contain at least the software functions as specified in item 2.1.1.1 above:
The PABX shall have an internal interface for the paging system of the plant, which gives the
opportunity to locate persons by loudspeaker and telephone connection via the PABX.
2.1.2.2 Telephone Cable Network

The telephone network shall be in a star-shaped network with a main marshalling board and subdistribution boxes. The terminals of the junctions shall be of the clip-on type. The cabling shall be
executed with multicore cables. For the cabling communication cables shall be installed according
to the equivalent standards only. The necessary tray system shall be included in the scope of cable
network.
In the offices at least one telephone outlet for each 10 m2 shall be cabled/wired and installed
independently from the number of telephone extensions included in the scope of supply of the
telephone system.
2.1.2.3 Extensions
A complete telephone system with individual components of approved type and constructed of best
quality materials shall be supplied, installed and commissioned in the plant.
Each extension shall be equipped with a push-button block with at least 16 buttons for dialling and
function dialling.
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Each extension shall have a key switch for disconnecting the extension to avoid an unauthorised
use. The individual types of extensions shall be as follows:
Desk type for offices,
wall type for inside areas,
heavy duty wall type for external areas,
desk built-in types for Central Control Room, etc.,
Executive sets
chief secretary type for secretary offices
special telephones of robust design and mainly for installation in hazardous areas, if
applicable.
2.1.2.4 Switchboard and Operator Console

The plant shall be equipped with one (1) telephone switchboard located in the administration
building. This switchboard shall handle the complete external telephone traffic. Every call from
outside to an extension and vice versa shall be transferred via the switchboard.
The switchboard shall contain, but not be limited to:
Extension to switch into lines.
Call indicators.
Internal call indicators.
Meters for long distance calls.
Switching facilities.
Conference call establishing facilities.
The operator console serves to route external calls to the desired extensions and to connect
internal call requests.
The operator console shall represent a sophisticated digital telephone, which is also used as a
service and maintenance tool to program and modify individual connections.
The operators set shall, amongst others, provide the following features:
Optical and acoustical indication of incoming calls,
40 characters alpha-numeric display,
LED indications of operational conditions,
dialling pad, answering keyboard, change-over buttons, function keys, headgear connection
for hand-free operation, light circuits etc.
2.1.2.5 Battery
A battery with charger shall be provided for the telephone exchange. The battery shall take over
the system supply in case of power failure for at least five hours. Then the battery shall be
switched off from the supply to the exchange if the power is not restored.
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After restoration of normal power, the supply system shall be switched to normal. The battery shall
be of maintenance free type and compatible to the telephone system. The charger shall comply
with the relevant electrical specifications.
2.1.2.6 Accessories
Sound hoods shall be installed for the wall mounted telephone extensions in the Turbine Hall,
Workshop and other noisy and outdoor areas, further for all outdoor areas.
The hoods shall be of plastic material, front side open, with a height of approximately 1 m. The
style and type shall be approved by the Employer / Engineer.
In the vicinity of telephone sets on noisy areas and outside bell and signalling light shall call the
attention to incoming calls.
2.1.2.7 Chief-Secretary Extensions

The chief-secretary extensions shall have a two line capacity, one line connected to the extension
and one direct line connected directly to the public network with separate meters at the main
switchboard.
The chief-secretary extension shall have two receivers for chief and secretary with calling sound,
internal speech and announcement at both extensions.
In the chief office a free-speaker equipment shall be installed operational from the chief extension.
2.1.2.8 Scope of Supply of the Telephone System

The scope of Supply for the telephone system shall comprise a complete functioning digital type
system with all accessories not limited to the following items
1 telephone exchange (PABX) for min. 250 subscribers, incoming, outgoing and tie-in lines
and tie-in interface with cabling and connection to Station D, E, G and K telephone
switchboards
1 fault diagnosis printer printing all faults and outside calls with time, duration and date
Laptop computer for maintenance including the necessary software and interface connections
to the PABX and to any other part of the telephone system, subject to configuration/diagnostic.
1 telephone marshalling rack for the incoming trunk lines and the subscriber lines from and to
the extensions and exchange
1 cabling distribution system with junction boxes, outlet sockets and trays including power
communication channels
1 switchboard with desk and chair for the external telephone on traffic operation
1 desk switchboard for night operation
5 tele-picture transmitter (telefax)
1 internal battery set.
5 chief-secretary extensions
One telephone set for each of the units in the CCR
Two telephone sets for the supervisor in the CCR. Beside this, Package S will provide
telephone set(s) connected to the SCADA system in the CCR and other locations as specified
at Package S Specifications.
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One telephone set for the supervisor in the CCR for direct LDC communication
Following number of telephone sets in the 400 kV substation
GIS Room
4 sets
GIS Workshop
1 set
Substation Control Room
2 sets
Relay Room
1 set
Telecommunication Room
1 set
LVAC Room
1 set
Office
1 set
One telephone set for each of any local control room, local operator board, local GT cabinet, if
applicable
Two telephone sets in each of the offices
Executive sets for the station manager, senior discipline engineers and shift supervisors
offices
At least one telephone set in each of the electric and electronic equipment rooms unit-wise
At least one telephone set in each of the occupied (manned) rooms, like workshops, etc.
At least one telephone set in each of the common rooms (meeting rooms, canteen, training
room, archive, etc.)
At least one telephone set for each major process, seawater, desalination plant, etc., system
indoor and outdoor
The further telephone extensions with location shall be proposed by the Contractor based on the
final building layouts of and subject to Employers/ Engineers approval. Altogether 250 telephone
sets shall be supplied and allocated. Out of the 250 sets at least 50 sets shall be for outdoor
installation.
2.1.2.9 Inspections and Tests on the Telephone System

For inspections and tests the stipulations in the general technical requirements shall be applicable.
Further the following tests shall be considered at site.
The complete telephone system shall undergo tests at Site prior to the acceptance. The tests shall
be divided into steps, but shall not be limited to the following:
Each equipment shall be tested at Site in the workshop for functioning and range limits.
These tests shall be documented and signed.
After system installation a complete installation test shall be carried out, checking the system
installation according to the specified requirements.
This test shall be documented by marked up as-built drawings and photographs.
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A cable distribution system measurement test shall be carried out for each wire. Including all
junctions with this measurement the figures for resistance and voltage drop shall be measured
and documented.
After carrying out the tests mentioned, the system shall undergo a complete commissioning
test, checking all system functions from/to each extension. The test shall be carried out and
documented according to a step program.
2.2
MAINTENANCE TELEPHONE SYSTEM
2.2.1 General
Jack plug sockets shall be provided at each junction box, marshalling cabinet, electronic cabinet,
control desk, transmitter rack and local control panel. These jacks plugs shall be wired in such a
way that it shall be possible to communicate verbally by means of suitable plug in telephone head
sets, from any socket to any other socket position associated with the same island, as defined
below.
The system shall, as a minimum, consist of the following independent communication loops:
Power Generation Island
Water Production Island (in Package D scope)
Common Services Island
Electrical System Island
Each telephone head set shall be intrinsically safe and shall be complete with earphone and
mouth-piece and jack pluggable to the communication loops.

Maintenance telephone system shall be provided for all electrical and electronic cubicles, panels,
boards, major distribution boxes, etc., in the whole Plant including all packages.
The system consists basically of the following components
a passive interconnected network of wiring
outlet telephone sockets for telephone jacks in the cubicles, panels, boards, boxes, etc.
headphone sets with built-in battery, which can be connected to the a.m. network
Four independent networks shall be established for the plant as specified under the above item
2.2.1, offering also the possibility to interconnect the systems in one central place (equipment
room)
For the passive networking system cores from existing multicore cables can be used, reserving,
however the number/percentage of spare cores specified elsewhere in this Specification.
25 (twenty five) headsets shall be delivered with the system.
The communication network shall be tested during the normal commissioning of the plant. Before
handing over the system to the Employer, random communication checks shall be done as
instructed by the Employer / Engineer.
2.3
LOUDSPEAKER SYSTEM / PUBLIC ADDRESS SYSTEM
2.3.1 General
A public address system (loud speaker system) shall be provided to cover the cover the Plant
Station L Phase I requirements, as specified. The complete loudspeaker system shall conform to
the latest state of the art, in the field of loudspeaker system engineering. The system shall be
Page: 44
complete including central amplifier station, master call station, remote call stations, loud speakers,
interfaces, cables, etc. as specified. The system shall be interfaced to the specified Telephone
System. It shall be possible to make public announcements from any of the extensions of the
specified telephone system. However, specified alarms as under shall be given priority over such
announcements. To facilitate public address the Station shall be divided into zones.
The requirements specified under Part "General Technical Requirements" are to apply and where
applicable, further regulations from the other Parts of this specification.
A central amplifier station must be set up for transmitting alarm signals and broadcast instruction
and information in the event of catastrophic failure or the occurrence of various operational faults
and breakdowns.
The system shall be provided with specified number of indoor and outdoor call stations. The indoor
call stations shall facilitate half duplex intercommunication between respective outdoor call
stations.
The loudspeaker system shall be designed for the following operating modes:
It must be possible to switch on the following different tone and frequency signals with the
appropriate alarm buttons
fire alarm
major, large scale breakdown
fuel alarm
all clear signal (for resetting of alarm)
Provision of fire alarm with two different tones one for actual fire and the other for mock fire drill
are to be included.
Priority control shall be given in accordance with the above tone arrangement.
The following call types shall be provided and shall be signalised by a tone.
selective call (for example only the loudspeakers in the turbine area or boiler area will be
switched in)
group call from several loudspeaker lines
collective call from all loudspeaker lines
The loudspeaker announcement following the alarm signal must be recorded and stored in a
cassette recorder with facility for the recorded tape to be played back.
The alarm signal, instructions and broadcasted announcement will be initiated from a master call
station in CCR. Alarm signals shall take priority over broadcast announcements.
In addition, each master call station shall facilitate intercommunication (Press to talk, release to
listen) in half-duplex mode with the following call stations :
outdoor call stations
indoor call stations in Local Electronic Room(s)
Safety protection must be provided to ensure against accidental operation of the respective alarm
buttons.
The number and installation of the specified loudspeakers shall be suited to the conditions of
operation and to that of the environment in such a way that alarm signals and broadcast
announcements can be clearly understood by the operating personnel.
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As regards the acoustic irradiation of the individual rooms, which differ very widely, and of external
facilities, care must be taken only to install the specified loudspeakers with a loudness level 6 dB
above the prevailing plant noise level.
Furthermore, care must be taken that "hearing double" does not occur. The loudspeakers must
radiate all pitches uniformly and free from distortion and at a sufficiently constant volume.
The specified loudspeakers of each area to be irradiated shall be grouped to form loudspeaker
lines and connected to the amplifier station. Each specified loudspeaker shall be numbered and
labelled with the loudspeaker line to which it is connected.
The specified external loudspeakers must be suitable for continuous broadcasting duty in an
operable temperature range in accordance with the specified Site conditions.
The specified outdoor loudspeakers shall be mounted on hot-dip galvanised tubular poles,
including foundations. The conductor cross-section of the individual loudspeaker lines shall be so
chosen that the voltage drop on the respective lines shall not exceed 10% of the amplifier output
voltage.
All required amplifiers, relays, switching and control elements, equalisers, tape cassette recorders
etc. shall be mounted in the same steel sheet cubicle (central amplifier station) clearly arranged on
the modular construction principle and using plug-in module technique. Suitable steps shall be
taken for cooling and ventilation.
All cable connections within the central amplifier station shall be designed on the plug-in principle.
When in operation the whole loudspeaker system shall be supplied by the required number of
amplifiers. Six 250 W power amplifiers with one 250 W power amplifier in reserve shall be
provided, as a minimum.
In the event of a breakdown or output reduction affecting the performance of a power amplifier,
there shall be an automatic change over to the reserve power amplifier, to ensure that the
loudspeaker system continues to function. The power amplifiers shall be monitored by pilot tone
monitoring equipment which shall send a group alarm to the master call station in the event of a
malfunction. This reporting of a malfunction shall be indicated at the master call station both
visually and by audible means. It shall be possible to reset the audible alarm manually.
The central amplifier station as well as the associated loudspeakers shall be designed for
maximum continuous loading capability.
Equipment and system shall be provided with easy access for maintenance and calibration. All
equipment shall be designed for continuous operation at 50 C ambient temperature.
The panel/cabinet for the central amplifier station shall be in accordance with the I&C cubicles with
regard to main dimensions and design in order to achieve uniformity of appearance.
2.3.1.1 Central Amplifier Station

The central amplifier station shall consist of a metal clad cabinet with type IP 32 enclosure or better
for free standing installation with frame to take the following plug-in units :
2.3.1.2 Power Amplifier

The power amplifiers shall be fully solid state and equipped with plug-in modules in a compact
steel case for rack-mounting and shall fulfil the following minimum requirements in accordance with
IEC-268.
input symmetrical with level controller

power output : 250 W (sinusoidal wave)
rated output voltage at rated power output :100 V
Page: 46
frequency range: 300 - 12500 Hz l dB

distortion factor at 1000 Hz : 2% or better
signal - to - noise ratio : 80 dB or better
Electronic protection against overload and short circuit as well as overheating, mains switch cutout, status indication, overload indicator, level controller, measuring instrument for modulation in
percentage and in volume units (VU).
2.3.1.3 Pre-amplifier
The pre-amplifier shall be fully solid state and equipped with plug-in modules housed in a compact
steel case for rack-mounting.
The appropriate adjustable inputs for microphone, alarm tone generator, pilot supervisory unit,
announcement tone, cassette recorder, etc. which shall fulfil the following minimum requirements
in accordance with IEC 268.
inputs protected against being over driven by electronic limiters
distortion factor : 1.5% (IEC 268) or better
frequency range : 300 -12500 Hz l dB
outputs with short circuit protection
mains switch, status indication, level control, level pre-setting control by screw driver, separate
treble and bass adjusters, measuring instrument for modulation in percentage and in volume
units (VU), as applicable.
2.3.1.3.1 Intercom Amplifier

The intercom amplifiers shall be fully solid state and equipped with plug-in modules suitable for
rack mounting, and shall be used for the specified intercommunication (half duplex) between call
stations. Each intercom amplifier shall fulfil the following minimum requirements:
audio frequency power : 5W (continuous sine wave)

microphone input (-70) dBm nominal level
gain adjustable between 0 and 40 dB
loudspeaker output : 5 W, 100 V into 2 K Ohms
short circuit proof: transformer, ungrounded
high level output : +19 dBm
2.3.1.3.2 Automatic Recording /Playback Equipment

The recording equipment shall switch on automatically after an alarm signal has sounded so that
the subsequent broadcast announcement can be recorded. If no announcement takes place, the
recorder shall switch off automatically after 5 - 10 seconds.
The playback equipment shall be capable of being switched on and off automatically so that the
recorded speech can be played back by master call station.
The recording system shall be fully solid state and housed in a compact steel case. The automatic
recording/playback equipment must fulfil the following requirements:
frequency range : 300 - 12500 Hz 1 dB

distortion factor : 2% or better
recording and playback in mono
automatic start /stop and recording
manual control buttons for ON/OFF, start/stop, recording and playback, etc.
status indication lights.
Page: 47
2.3.1.3.3 Pilot Tone Generator

It shall be fully solid state and equipped with plug-in modules for connecting to pre-amplifiers and
power amplifiers. Automatic two-way switch over from power amplifier to reserve power amplifier
shall be provided.
The pilot tone generator shall be provided for an output signal of 20-40 kHz.
Main switch and status indication shall be provided.
2.3.1.3.4 Electronic Filters

Electronic filters shall be provided in accordance with the requirements and shall fulfil the following:
frequency range : 300 - 12500 Hz 1 dB

distortion factor : 1% or better
adjustable frequency levels.
2.3.1.3.5 Alarm Tone Generator

Electronic four-tone alarm generator, initiation of the three different alarm signals and also the all clear signal under remote control shall be provided.
Tone-frequency range 200 - 1000 Hz, tone and sequence of notes must be variable, clock
frequency steps are to be 1 to 4 Hz. The selected alarm tone will run for about 30 seconds and
then switch off automatically.
The period of the alarm signal shall be adjustable. Premature switch-off of the alarm tone (false
alarm) to be effected by repeated pressing of the start/stop button.
The different alarm signals shall be electronically interlocked relative to one another.
The output of the alarm tone generator must be ungrounded in accordance with the requirements.
The noise level control shall be possible.
2.3.1.3.6 Announcement-Tone Generator

It shall be provided with
electronic two-tone signal for signalling a broadcast announcement
initiation of the tone signal by remote control. Adjustable range for clock frequency to be 400 600 Hz.
The output of the announcement-tone generator must be ungrounded in accordance with the
requirements, The noise level control and priority control of announcement tone shall be possible.
2.3.1.3.7 Control Panel

Control panel shall be provided with loudspeaker and volume control, selector switch for
supervising and announcement and program signals of the individual power amplifiers, and test
jacks for impedance measurements on the outgoing loudspeaker lines for each power amplifier.
The appropriate measuring instruments for measuring the power amplifier input and output levels
as well as for balancing of the power amplifiers shall be included.
The control panel shall fulfil the following requirements:
inputs: 100 V, symmetrical, ungrounded

main switch
status indication
Page: 48
2.3.1.3.8 Relay Panel

Relay panel shall provide for broadcasting announcements and initiation of alarms from the central
control unit and also for the pilot tone monitoring unit. The appropriate enclosed relays with change
over contacts and with plug in base shall be mounted on a printed circuit board with the following
priority circuits:
1
alarm tone signals
tone signals
broadcasting announcements
The relay panel shall be provided with the following requirements:
relay panel output: 100 V, ungrounded

main switch
status indicator
2.3.1.3.9 Power Supply Panel

Power supply panel shall provide for the switching on and off of the central amplifier station with
automatic main cut-out and main pilot lamp. The lamp must be proof against sustained short circuit
and shall be automatically ready for operation again after a short circuit clearance.
The loudspeaker system shall be provided with an independent UPS complete with battery and
charger, which shall automatically switch in, on mains failure, and supply for at least 5 hours. The
main supply for the UPS shall be taken from the station essential supply.
Contractor shall be responsible to supply and install all necessary cabling and protection for the
feeder.
2.3.1.3.10
Cable Connection Panel
Cable connection panel shall provide for the connection of outgoing loudspeaker lines, control unit,
cable infeeds, control cable for control of the cassette recorder. The necessary terminal boards,
cable inlets, access panels, etc. shall be provided. The terminal boards as well as all cables shall
be labelled.
To take the specified plug-in units standardised steel cabinets shall be used with the appropriate
contact strips for mounting in hinged frames.
2.3.1.4 Master Call Stations

The control unit with steel case IP 32 enclosure shall be built-in the Supervisors Control Desk
(CCR) with the following requirements:
with microphone control station
pre-amplifier
switchboard
built-in monitoring loudspeaker with level controller
screw in dynamic microphone with flexible support with connecting plug. Not sensitive to
interference by structure borne sound
cardiod characteristic
frequency range: 300 - 12500 Hz
intercom facility with specified locations
Page: 49
the non latching alarm buttons for fire alarm, major alarm, fuel alarm, all clear signal shall be
protected against unintentional mal-operation (appropriate circuit logic).
The selector panel shall be provided with keys for collection, group or selective calls with built-in
pilot lamps, a red pilot lamp showing engaged if the system is engaged by the alarm generator.
Microphone button shall be operative upon pushing in all buttons. Main switch, main pilot lamp and
cable connection box shall be provided.
2.3.1.5 Indoor and Outdoor Call Stations

Each indoor call station shall be complete with
dynamic microphone on flexible neck
loudspeaker
matching transformer
call button with busy indication lamp
Each outdoor call station shall be complete with
microphone with cardioid characteristic etc.
microphone amplifier
loudspeaker with matching transformer
call button with call and busy lamps
The outdoor call stations shall be protected as a minimum to IP 54.
2.3.1.6 Loudspeakers
The following types of loudspeakers shall be provided as a minimum:
pressure-chamber loudspeakers with plastic or metals horns and with swivelling mounting
flange for wall mounting. Type IP 54 enclosure (resistant to UV radiation) shall be provided for
indoor and outdoor mounting, The loudspeakers must fulfil the following minimum
requirements in accordance with IEC 268
frequency range 300 to 12500 Hz
power handling capacity in accordance with DIN : 5, 10, 20 or 30 W
built-in transformer for 100 V operation for output matching in stages (1:1, 1:2, 1:4)
main sound pressure level 110 dB
cable connection box
the pressure chamber loudspeakers shall be selected according to the local operational
noise level
Hot dip galvanised tubular poles, 4.50 m long with flange and necessary foundations for mounting
outdoor loudspeakers shall be provided.
wall mounted loudspeakers with type IP 54 enclosure and impact resistant casings of either
plastic or sheet steel for internal mounting.
ceiling mounted loudspeakers for mounting in false ceilings.
The loudspeakers shall fulfil the following requirements:
frequency range 300 - 12500 Hz
power handling capacity in accordance with DIN: 6W
Page: 50
main sound pressure level in accordance with DIN: 100 dB
built-in transformer for 100 V operation for output matching in stages (1:1, 1:2, 1:4)

2.3.2.1 General
Loudspeaker system shall be installed for the whole plant, including all packages.
The loudspeakers shall be operated by a microphone and a tape recorder/DC player. For
emergency warning and clearance 5 different tone/frequency/burst audible signal shall be
provided, which can be called by allocated alarm pushbuttons installed in the supervisory desk in
the central control room.
The system shall allow selective, group and collective addressing by the loudspeakers. The master
station shall be on the central control room and a slave station shall be installed in the
Administration building reception desk.
The system shall be easy expandable taking into consideration the same capacity for the
requirements of Jebel Ali Power and Desalination Station L - Phase II as specified hereunder for
Phase I. The requirement of expandability shall be applicable to the modularity of the central
system/amplifiers without providing, however the necessary extension hardware or the
loudspeakers.
For common parts of an established future system (e.g., external power distribution and supply,
internal common power supply module(s), and for the space of installation including common cable
trays, duct, channels, etc. already the requirements of Phase I and Phase II shall be considered.
2.3.2.2 Loudspeakers
The pressure-chamber type weather-proof loudspeakers shall be surface mounted on universal
swivel brackets. The exact location shall be adjusted at Site according to the best understanding.
2.3.2.3 Loudspeaker Centre

The loudspeaker centre shall be constructed as a 19 rack containing amplifier and tape recorder.
The rack shall be installed in a cabinet. The microphone shall be of the free speaking type
constructed as desk type.
2.3.2.4 Cable Network

The cabling system shall be part of the telephone network. This network shall be increased
accordingly.
2.3.2.5 Scope of Works

The scope of supply for the loudspeaker system shall comprise a complete functional system and
not be limited to the following items.
1 loudspeaker central located in the entrance of the administration building with tape
recorder/CD player, amplifier and connection box installed in a 19 inch rack enclosed with a
furniture cabinet, suitable to supply Phase II in the future.
2 microphone desk type located at the porter/reception desk and in the CCR.
alarm call pushbuttons in the CCR.
1 set of cabling network as part of the telephone network.
Page: 51
60 loudspeakers locations of which have to be proposed by the Contractor for the Employers/
Engineers approval.
2.3.2.6 Tests on the Loudspeaker System

Each equipment shall undergo a Site workshop test after arrival for function and range.
After system installation a complete installation check shall be executed according to the
Specification requirements. This check shall be documented by photographs and marked up
as-built drawings.
A complete commissioning test shall be executed. The test shall prove all functions and shall
include a sound level measurement at all offices and areas.
2.4
CLOCK SYSTEM
2.4.1 General
The clock system shall be designed and installed as a redundant master-slave system with
independent timing and adjustment possibilities from International general clock signal via
antennas and with synchronisation of slave clocks and plant control systems.

2.4.2.1 Master Clock
The master clock shall be mounted in the Electronic Room or in the CCR in a free standing cabinet
with windows in front to observe the instruments built in.
The master clock shall consist of two independent units operating in a redundant stand-by principle
with automatic change-over. A change-over shall be announced locally and as unit common
auxiliaries alarm. The master clocks shall be controlled by a temperature stabilised quartz oscillator
with an accuracy of 0.01 sec./ day producing all reference data necessary to control and supervise
electronic and electromechanical time controlled equipment. A synchronisation of the time shall be
executed automatically by a GPS signal via antenna(s).
A digital frequency differential indicator shall be installed in the control panel showing the network
frequency, the quartz frequency and the difference in seconds.
The system shall work on seconds, minutes and hourly impulses. Date facility shall also be
available. For the date (day, month and year) a memory shall be installed. A date facility shall also
be available in the master clock system.
A battery back-up for at least 12 hours shall be provided. Charger and battery shall be installed in
the master-block cubicle.
The cabinet shall contain, but not be limited to the following equipment:
Master clock (2),
quartz generator,
frequency dividers for hours, minutes, seconds,
battery back-up for 12 hours with charger,
Page: 52
signal channels for 10 lines of secondary clocks, each line capable of serving at least 5 slave
clocks,
signal input channel for International clock signal,
automatic re-adjustment for the slave clocks,
change over and trouble alarms with additional dry contacts and terminals for remote alarming,
signal lines for adjusting impulse of computer clocks (every 24 hours, one impulse for
approximately 2 sec.) for each digital control system in the plant.
5 spare signal lines
The same amount of signal lines for the requirements of Jebel Ali Power and Desalination
Station L - Phase II as specified for Phase I.
terminal strips with connection of all incoming and outgoing signals.
2.4.2.2 Slave Clocks

The slave clocks shall be designed to operate as secondary clocks commanded by the master
clock and shall have good architectural design.
Every type of clocks foreseen for installation shall be subject to the approval by the
Employer/Engineer for type and architectural design.
The types of secondary clocks are as follows:
Analogue type,
digital type,
date type.
2.4.2.3 Wiring
The cabling and wiring shall be executed as independent system using the junction boxes and
cable trays of the communication system. The cable prices shall be included in the equipment
prices.
2.4.3 Scope of Works

Master clock system with slave clocks and synchronising signal lines shall be provided for the
whole Plant including all packages.
The scope comprises a complete functional clock system in all respects and not be limited to the
following:
Master clock mounted in a free-standing cubicle.
Cable distribution system with junction terminals using the communication tray and junction
system.
Differential frequency/ time indicator with automatic and manual adjuster in the control panel.
Antenna for International time signal and automatic adjustment of master clock.
Synchronisation with the DCS and with all other digital control systems in the Plant
slave clocks
Page: 53
Altogether minimum 50 nos. of slave clocks shall be provided. The final location of the clocks is
subject to Employers/ Engineers approval. However, the design shall foresee the following
clocks/locations
Administration building outside front:
Big size analogue type
Administration building, each floor
Analogue type
Reception area
Digital, date type
Central Control Room
Digital, date type
Any auxiliary control room
Digital, date type
Entrance, Guard House(s)
Analogue type
Director and superintendent offices
Digital, date type
Department heads offices
Digital, date type
Each of the electric and electronic equipment rooms unit-wise Analogue type
Each of the occupied (manned) rooms, like workshops, etc. Analogue type
except individual offices not specified explicitly above
Each of the common rooms (meeting rooms, canteen, Analogue type

training room, archive, etc.)
SF6 switchgear building
Analogue type
2.4.3.1 Tests on the Clock System

Each equipment shall undergo a Site workshop test controlling the function and the range
limits of the equipment.
After installation an installation check shall be executed to check the method of installation
according to the Specification and the relevant standards.
A complete system function check shall be executed showing all functions for each equipment
in the system as specified including the adjustments and the power failure.
Synchron tests for all digital systems installed in the Plant.
2.5
LOCAL AREA NETWORK (OFFICE LAN) AND COMPUTERISED MAINTENANCE

MANAGEMENT SYSTEM (CMMS)
2.5.1 Local Area Network / Office LAN

Local area network between all offices and secretary offices, conference rooms, training rooms,
computer rooms, storekeeper offices, workshops and other locations with comparable functions
shall be provided in the Plant. The scope contains the cabling, distribution/marshalling and
connectors only without computer equipment like servers, workstations and PC-s for the complete
Office LAN itself. However all components necessary for the network operation itself, like
repeaters, switches, etc., shall be provided together with the system;
Page: 54
The system shall be connected to the existing network of other Stations in the Jebel Ali complex
and shall also fulfil the needs of the future Phase II of Station L. The LAN of the L station shall
be connected to the DEWA existing backbone at the G station.
The laying of star shaped cabling system shall be combined with the cables of the telephone
system with combined telephone/data outlets in the offices. The cabling shall ensure protection
against electromagnetic disturbances, which can occur in the Plant. Between buildings fibre optic
cable shall be installed.
For each office at least 1 outlet and further outlets one for each 10 m2 shall be provided (2 outlets
for 10 m 2, 3 outlets for 20 m 2, etc.).
The network system shall be according to the Category 5 or better of the Standard ISI/IEC IS
11801 (EN50173) with RJ 45 Western type connectors.
The star shape cabling shall go to common marshalling places, one in the Administration building
and another one in the Control Building, containing among others the following equipment:
Marshalling racks for star shaped telephone system and data network with the connected star
shaped cables
Marshalling racks for multicore telephone cables, included in the scope of the Telephone
system
Spare place and racks for the future servers, data switches, etc. of the intended Office LAN
system
Power supply in the Computer room of the Administration Building for the future installation of
computer room equipment like servers, hubs, switches, workstations, PC-s and peripheral
equipment provided by others.
An Uninterruptible Power Supply (UPS) shall be provided and shall be located at the
Administration building at the L station to support all essential computing and networking
equipment.
2.5.2 Computerised Maintenance Management System (CMMS)

The Computerised Maintenance Management System (CMMS) hardware and system program will
be provided by others.
The system shall support among others the following interactive tasks:
Assist in the maintenance of equipment and control of assets on site. This includes scheduling,
planning, execution, controlling and recording various types of maintenance, like preventive and
corrective maintenance, further handling and printing of work instructions, issuing work permits,
single and multiple work orders, cost records and various reports, including printing of list of
isolations, safety labels, etc. Internal and external human resources and materials shall be
planned and monitored for each work order.
Schedule regular activities on equipment like lubrication, testing and calibration of
instrumentation.
Keep records of spare parts, manage stock inventory along with procurement of spares, goods
and services. This includes issuing of purchase orders, supervising of minimum limits, keeping
database with vendor and manufacturer data, equipment types and substitutions.
Manage As built drawings and O&M Manuals through compliant links
Perform cost and budget analysis by the accounting structure
Page: 55
Link from the Plant remote control and supervisory system to acquire the necessary input data.
In case of any on-line connection the system must not interact with the functionality of the
connected control systems.
Contractor shall provide the following for the above tasks:
filled in database, data, procedures and all necessary information including drawings, technical
details and manuals for an operational CMMS system as far as Station L is concerned, in
electronic format compatible with the Master Station software.
The necessary support to the Employer up to the end of the Defect Liability Period to apply the
Contractors data on his system.
COMPUTER SYSTEM
(SECTIONS Q, R AND U OF THE ATTACHMENT TO P2.27)

Computer System (Maintenance Management System Document Management System IT
Facilities) shall be provided as specified in the Attachment to this Specification.
1.
Some aspects of the Office LAN / Computerised Maintenance Management System

have been specified above in Clause 2.5..
2.
The Document Management System is additional to the DMS specified in the basic
scope in Part G4 of the Contract Specification.
CNE/015/2002
P2.28
Civil Works
WORKING DOCUMENT
Part P2.28 Civil Works Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
PAGE
GENERAL ..................................................................................................................................... 1
LAYOUT ........................................................................................................................................ 1
SCOPE OF WORKS..................................................................................................................... 2
3.1
GENERAL ......................................................................................................................... 2
3.2
SCOPE OF WORKS FOR PACKAGE P-POWER PLANT ......................................... 2
DESCRIPTION OF STRUCTURES, BUILDINGS, ROADS AND OTHER CIVIL WORKS........ 4

4.1
COMMON ARCHITECTURAL AND STRUCTURAL FEAT URES.................................. 4

4.1.1
Main Architectural Features........................................................................ 4
4.1.2
Other Common Features............................................................................. 6
4.2
GAS TURBINE FOUNDATIONS AND HOUSE............................................................... 7
4.3
BACK PRESSURE STEAM TURBINE FOUNDATIONS AND HOUSE......................... 8
4.4
HEAT RECOVERY STEAM GENERATOR FOUNDATIONS, BYPASS AND STACK

FOUNDATIONS................................................................................................................ 9
4.5
AUXILIARY BOILERS FOUNDATIONS.......................................................................... 9
4.6
TRANSFORMER FOUNDATIONS AND FIRE WALLS .................................................. 9
4.7
CONTROL BUILDING...................................................................................................... 9
4.8
DEMINERALISATION PLANT, LABORATORY AND DEMINERALISED WATER

TANKS ............................................................................................................................ 11
4.9
FUEL OIL TANK YARD.................................................................................................. 12
4.10
FUEL OIL PUMP FOUNDATIONS................................................................................. 12
4.11
FIRE PUMP HOUSE....................................................................................................... 12
4.12
OTHER TECHNICAL STRUCTURES/BUILDINGS....................................................... 12

4.12.1
Emergency and Black Start Facility......................................................... 12
4.12.2
Diesel Fuel Pump and Day Tank for Black Start and Emergency
Generator..................................................................................................... 13
4.12.3
Gas Receiving Station ............................................................................... 13
4.12.4
Gas Compressor Building......................................................................... 13
4.12.5
Fuel Oil Unloading Station and Pipe Line from Jebel Ali Port.............. 13
4.12.6
Air Compressor Building........................................................................... 13
4.13
MECHANICAL AND ELECTRICAL STORES / OPEN AIR STORAGE....................... 13
4.14
PIPERACKS FOUNDATIONS........................................................................................ 17
4.15
PIPE /CABLE TRENCHES............................................................................................. 17

4.15.1
General ........................................................................................................ 17
4.15.2
Requirements for Cable and Pipe Ducts ................................................. 17
4.15.3
Requirements for Shafts, Manholes and their Covers........................... 18
4.15.4
General Requirements............................................................................... 18
P2_28Civil_Works_Working_Doc.doc
Page: ii
4.16
ADMINISTRATION BUILDING.......................................................................................19
4.17
COVERED CAR PARK...................................................................................................23
4.18
MECHANICAL WORKSHOP..........................................................................................23
4.19
SAND BLASTING AND HEAT TREATMENT BUILDINGS ..........................................24
4.20
SEWAGE TREATMENT PLANT ....................................................................................24
4.21
WASTE WATER TREATMENT PLANT AND BASIN ...................................................24
4.22
OIL SEPARATORS.........................................................................................................24
4.23
ROADS, PAVEMENTS AND SIDEWALKS ...................................................................24
4.24
DRAINAGE AND SEWAGE SYSTEM ...........................................................................25
4.25
ENTRANCE GATE..........................................................................................................26
4.26
LANDSCAPING AN D IRRIGATION SYSTEM ...............................................................26
4.27
RETAINING WALL..........................................................................................................27
4.28
CIVIL WORKS FOR ELECTRICAL INSTALLATIONS..................................................27
4.29
PASSIVE FIRE PROTECT ION.......................................................................................28
4.30
OTHERS..........................................................................................................................28
AUXILIARY SITE WORKS .........................................................................................................28

5.1
SITE SURVEY AND TOPOGRAPHICAL CONTOUR MAP ..........................................28
5.2
SOIL INVESTIGATION ...................................................................................................28
5.3
LEVELLING AND FILLING.............................................................................................28
5.4
SITE FACILITIES............................................................................................................28
Page: 1
GENERAL
Particular Technical Specification for Civil Works for Package P - Power Plant covers all
construction works required for erection and other civil works required for the functionality of the
Station within the scope of works for Package P.
This Specification describes generally the works to be provided and specifies the components of
structures, buildings, roads, underground services and other civil works. The quality of the
materials to be used in those components and workmanship for their execution has been specified
generally in the General Technical Requirements. Whether any quality requirements mentioned in
this Particular Technical Specification or not, they are deemed to have been specified if included in
General Technical Requirements or in the relevant standards and codes.
All work is to be constructed to the lines and levels shown on the drawings prepared by the
Contractor and approved by the Engineer unless varied by instruction of the Engineer.
All work shall be handed over to the Employer new and unused unless approved by the Engineer.
The tolerances for the works shall be within the limits given in this Specification and in the relevant
codes and standards applicable to those works. Where nothing is specified, the Engineer will
decide to accept the work or not considering the influence of the deviation on the function and
appearance of the work.
The dimensions and specifications stated for the buildings and structures and tender drawing
referred to below are indicating the minimum requirements only. It is Contractors responsibility to
check, to complete, to revise (if required and approved) and increase and to detail the buildings
and structures in order to have a complete and functional building. Reference is made to G2Conditions of Contract, Clause 6.55
2
LAYOUT
Refer to Tender Drawing General Plant Layout, No.CNE/015/2002-X-00G-D-00025.

Site ground level shall be at +6.00m DMD (Dubai Municipality Datum) and +3.0m DMD separated
by the retaining wall as shown in the Layout.
The structures, buildings, roads and other civil works have been shown in the Layout are at the
approximate locations only. Responsible Contractor shall design and prepare the layout drawing
with the fixed positions of structures, buildings, roads etc. within the boundaries given by the east
and west property limits (existing fences) (but including the area outside of the fence for Intake
Channels and Outfall) and by the existing roads and installations for the Station G to the north
and north/east as well as by the site co-ordinate approximately S 2370 to the south. There are
existing underground service pipelines to the east and south which are indicated in the Layout.
Development of the site should begin in a safety distance generally not less than 5m from these
pipes.
Administration Building is placed within the existing Station G area at the northern boundary of the
Site area and the Stores between two Stations.
The Layout is not showing all required civil works, neither showing complete and comprehensive
where it shows. The Layout is not meant to define the complete scope of work. All required civil
works, whether shown/partially shown or not in the Layout or whether or not mentioned in the
Specifications, such as foundations for smaller plants and equipment and any other civil work
required for the erection of electro/mechanical equipment and for the proper functioning of plant or
parts of plant deemed to be included in the scope of works of the Contractor.
Page: 2
SCOPE OF WORKS
3.1
GENERAL
in to four packages, the civil works required by each package will be divided accordingly.
The scope of work and supply for each package shall include all the necessary design, planning,
delivery and execution of the civil works required for the completion of the concerned Package.
Interfaces of the scope of works have been specified under Part P1, Clause 4.4-Interfaces of Civil
Works.
3.2
SCOPE OF WORKS FOR PACKAG E P-POWER PLANT
The scope of work and supply shall include all the necessary design, planning, delivery and
execution of the civil works required for the completion of the Jebel Ali Power and Desalination
Station L Phase I Package P- Power Plant and the access roads connection to Sheikh Zayed
Road as specified in this Part below.
The civil works shall be complete in all respects and to include but not limited to the following:
Site preparation work including clearance of all Site, removal of existing facilities and
obstacles in complete Site - except Package D area west of co-ordinate E 220 -, grading,
levelling, grubbing and filling and compacting the complete Site - except Package D area
west of co-ordinate E 220 - from the existing grade level to the specified levels
Demolishing, removal of temporary works, labour camps etc. at the Site within package Parea and in lay-down areas of Package P-Contractors and grading of the areas after
completion of works, as requested by the Employer
Water and power connections from tapping and interface points at Site to lay-down areas
outside of Site area shall be made by Contractor for Package P
Dewatering works required to the civil works for Package P- Power Plant
General survey work onshore and particular survey required for the civil works for Package
P- Power Plant
Additional soil investigations onshore with soil report and recommendations, if required in
Contractors opinion or directed by the Engineer for the civil works for Package P- Power
(Factual soil report is enclosed to the Contract Documents)
All necessary basins, tanks, buildings, structures, pipe supports, sleepers, thrust blocks for
the Package P- Power Plant
All necessary foundations for electro/mechanical equipment and bus ducts for the Package
P- Power Plant
Piling, soil improvement for the Package P- Power Plant
All excavation, backfill, compaction for cable and pipe trenches for the Package P- Power
Plant
Temporary works such as temporary roads, and chain-link fence, gates within Package P
and at the perimeters of the Station
Page: 3
Potable water, sanitary installation for buildings and structures for the Package P- Power
Civil works for required plant grounding system of foundations, buildings and structures for
the Package P- Power
Room and building indication nameplates for the Package P- Power Plant
Searching, excavating of underground facilities (if required, by hand) in the area of the
Package P and their relocation, if required
Removal or relocation of existing facilities such as fence and lighting posts at the south
boundary of existing Station G as and if required by the Employer
Master key system arrangement for complete Station, hard ware shall be supplied by each
Package contractor for the doors in his scope
Furniture for the Package P- Power Plant
Plant Buildings, Structures and Foundations, such as:
Gas Turbine Foundations and House
Back Pressure Steam Turbine Foundations and House
Heat Recovery Steam Generator Foundations, Bypass and Stack Foundations
Auxiliary Boilers Foundations
Transformer Foundations and Fire Walls
Control Building including Lift
Demineralisation Plant, Laboratory and Demineralised Water Tanks and Acid Basin
Fuel Oil Tank Yard
Fuel Oil Pump Foundations
Emergency and Black Start Facility
Gas Receiving Station
Gas Storage
Diesel Fuel Pump and Day Tank
Mechanical and Electrical Stores / Open Air Storage
Mechanical Workshop
Heat Treatment and Sand Blasting Buildings
Piperacks / Busduct foundations for the Package P- Power Plant
Administration Building including Lift
Covered Car Park
Page: 4
Roads, Pavements and Walkways within the area of package P- Power, including
continuation of external asphalt road from Station G-entrance to the road from Dubal at
Sheikh Zayed Highway-interchange (For road lighting system for this road and other roads
refer to Part P2.26) and access roads in the area of Package S
Storm Water Drainage and Sewage System for buildings, structures roads and paved areas
for the Package P- Power including drainage line from boiler blow down tank to waste water
treatment basin
Landscaping and Irrigation System within the area of package P- Power
All Retaining Walls
Waste Water Treatment Plant and Basin
Oil Separators
Civil Works for Electrical Installations for the Package P- Power Plant
Any other foundations, buildings and structures as required for the Package P- Power Plant
Site Facilities as specified under Particular Technical Specifications, including Site Offices for
Employer/Engineer
First Aid Station for all Packages
Field Laboratory for testing of building materials and soil for all Packages
Any other work, service and auxiliary work specified for package P in the General Technical
Requirements and Particular Technical Specifications or in the Package G - General of the
Contract Documents or shown in the relevant Tender Drawings, even if not mentioned in words
elsewhere shall be deemed included in the Scope of Work.
4
DESCRIPTION OF STRUCTURES, BUILDINGS, ROADS AND OTHER CIVIL WORKS
4.1
COMMON ARCHITECTURAL AND STRUCTURAL FEAT URES
The requirements under this Clause are common features for normal finishing and other materials
applicable in general, unless otherwise specified in individual locations/sections. Quality and
property of the materials have been in general specified in the relevant chapters of General
Technical Requirements. If not so, they have still to comply with the standards and codes whether
referred to them directly in the Contract Documents or not.
4.1.1
Main Architectural Features
The minimum standard of architectural finishing of rooms will be- unless otherwise specified in
relevant locations- as follows:
Floors
Electrical & Control
Rooms
PVC
UCF
ACF
CF
X
Offices
Page: 5
Chemical Handling
Toilets and Kitchens
PVC
= PVC Floor Tiles or Mats
UCF
= Unglazed Ceramic Tiles
ACF
= Acid Proof Ceramic Floor Tiles
CF = Computer Floor
Walls
CPP
Electrical & Control

Rooms
Offices
Battery & Chemical

Handling Rooms
APT/P
GCW
Toilets and Kitchen
CPP = Cement (or Gypsum) Plaster with putty as required and Painted
APT/P= Acid Proof Tiles 2.0m, above Acid Proof Paint/Coating
GCW = Glazed Ceramic Tiles
Ceilings
SMC
Control Rooms
SMB
CAP
Offices
Battery & Chemical

Handling Rooms
Toilets
X
X
SMC = Suspended Mineral Board or Metal Cassette or special design

SMB = Suspended Mineral Board
CAP = Concrete Acid Proof Paint
External Walls for Buildings/Rooms: Double skin with insulating core as specified
Windows:
Powder coated aluminium frames, toughened double glazing
Page: 6

All windows in the occupied areas, where no out-side louvers are foreseen
unless otherwise specified- shall be provided with coated aluminium Venetian
blinds.
All windows in the technical rooms or halls such as turbine halls, switchgear
rooms, stores etc. shall be provided with louvers as specified. Louvers related to
HVAC will be supplied by HVAC- Contractor under Part P2.24, Clause 23.
External Doors: Aluminium or fire rated steel doors (as required)

Internal Doors: Except Administration Building, occupied areas of Control Building top floor, fire
doors and office doors are steel. External doors are generally aluminium doors
unless otherwise directed by the Engineer.
Sanitary Equipment: All toilets shall be provided with toilet paper holder, anal spray, mirror and
porcelain shelve, fluid soap spender, hot air-hand drier and hand drying paper
spender
All showers shall be provided with curtain, soap holder
All water taps in toilets and showers shall be mixer type as specified in relevant
chapter of General Technical Requirements
Built-in Cupboards for Wardrobes and Files: All office rooms in Administration Building
(including meeting rooms), Control Building, Demineralisation Plant (laboratory
and office) and (Main-)Store shall be provided with built-in cupboard. The sizing
shall be adequate for the numbers of people work in the offices.
4.1.2
Other Common Features
Room height will be minimum 2.7m (Clear height up to the suspended ceiling, where
applicable. Corridor may be less, subject to the approval of Engineer)
All accessible roofs will be provided with galvanised and painted steel ladder with protective
cage
All elevated platforms, stairways, accessible permanent opening will be provided with
galvanised and painted hand railing at both side and all around respectively
Landing shall be provided after maximum 14 risers
All outdoor above ground outdoor concrete surfaces will be fair face and epoxy coated as
specified
Top surfaces of open air concrete slabs and foundations will have a slope to enable the flow of
water
All edges of concrete members will be chamfered
Concrete covers to trenches, manholes etc, shall be provided with galvanised steel angles at
the supporting edges
All step irons and expansion bolts for their anchorage in to the concrete shall be stainless steel
of approved quality
All basement, trenches etc. below ground level shall be provided with pump sump as
necessary and connected to drainage by gravity run, where possible
Cable and Pipe Trenches shall be above ground water table, unless unavoidable.
4.2
Page: 7
Out door steel columns, lighting posts, sign posts or similar components, if they are galvanised
but not to be painted as per specification, shall receive from the bottom up coal tar epoxy
coating (400m DFT) for a height of 20cm together with base plate and grout surfaces.
GAS TURBINE FOUNDATIONS AND HOUSE
Function: The building will provide weatherproof shelter for the gas turbines and auxiliaries.
Finished floor level shall be at +6.20m DMD (Dubai Municipality Datum), which shall be also
reference +0.00m level of the Station.
Size (approximately): L x W x H =
generator area).
142m x (23m x 22m for turbine area plus 17mx14m for
Clear distance for maintenance between gas turbines shall be minimum 16m. At both end of the
building sufficient space for loading and overhauling shall be provided. Free space of about 3m
width shall be provided along the eastern wall for the un-hindered passage of forklifts.
Gas Turbine Foundations: Reinforced concrete foundations on piles or on compacted soil shall
be provided. The foundations will be free standing and isolated from the building with joints.
Dynamic vibration analysis will be required for each foundation. DIN 4150 shall be followed in
transmission of vibration to the adjacent building. Design of the foundation, including specification
of the grout is to be supplied by the Gas Turbine manufacturer.
Superstructure: Structural steel will be provided for all columns, cladding and roof supports,
corrosion protected by painting as specified. The joint to Control Building shall be minimum 10cm
to allow sufficient space for coating etc. of columns built or erected after the wall of one building
completed.
Ground Floor: Reinforced concrete slabs with separate floor finish. Elevated floors with gratings
will be supported on steel beams and columns. Channels will be covered with chequered plate or
precast concrete covers depending on the span and approval by the Engineer. They shall be
separated from foundations by sealed joints. Supporting edges of channels and precast concrete
covers shall be protected by galvanised steel angels.
Stairs, platforms and walkways: will be supported by steel beams and columns and shall be
covered with galvanised gratings as specified.
Floor finishes: Non-metallic floor hardener and epoxy paint, epoxy screed, chlorinated rubber
paints, acid proof ceramic floor tiles etc. as required.
Walls: Up to 2.20m.height masonry, plastered and painted. Walls to the transformer bay will be
concrete fire and blast walls. Wall to Control Building shall be masonry in whole height, supported
adequately by horizontal and vertical steel beams.
Roof and Wall Cladding: Galvanised and coated profiled steel sheet with thermal insulation as
specified under the Chapter G5.4.16-Metal Works. Joint to Control Building shall be closed
watertight but allowing thermal expansion of both buildings without transferring the horizontal loads
from one to the other building.
Windows: A band of windows along both long sides of building will be provided. Windows will be
powder coated aluminium frame with double glazing. Windows will be shaded by a band of
horizontal coated aluminium louvers of about 1.50m. The windows shall be accessible form crane
walkway for repair and cleaning. Their height at the transformer side shall be established
considering blast and fire protection requirements in relation to the height of concrete fire wall.
Doors: Two electrically driven (one rolling shutter, one (eastern) folding) main access doors for
both sides of loading bay and three aluminium escape doors between gas turbines at the side to
HRSG shall be provided. In the eastern main door another personal door is to be integrated.
Further properties will be as specified under the Chapter G5.4.16-Metal Works.
Page: 8
Crane: For bridge crane at elevation about 17.5m crane rails will be provided.
Crane Walk Way: 1.5m wide walkway with grating and handrails shall be provided along the
western wall at elevation about 14m.
Access Ladders and Stairs: ladder to crane girders and stair to crane walkway have to be
foreseen. Outside access to the roof where air inlet filter are located, shall be arranged by
galvanised and painted steel stairs.
4.3
BACK PRESSURE STEAM TURBINE FOUNDATIONS AND HOUSE
Function: The building will provide weatherproof shelter for the steam turbines and two LVswitchgear rooms of size about 10x5x5m.
Size (approximately): L x B x H =
60 x 25 x 22 m
Free space of about 3m width shall be provided all around for the unhindered passage of forklifts.
Turbine Foundations: Reinforced concrete foundations on piles or on compacted soil shall be
provided. The foundations will be free standing and isolated from the building with joints. Dynamic
vibration analysis will be required for each foundation. DIN 4150 shall be followed in transmission
of vibration to the adjacent building. Design of the foundation, including specification of the grout is
to be supplied by the Turbine manufacturer.
Superstructure: Structural steel will be provided for all columns, cladding and roof supports,
corrosion protected by painting as specified.
Ground Floor: Reinforced concrete slabs with separate floor finish. Elevated floors with gratings
will be supported on steel beams and columns. Channels will be covered with chequered plate or
precast concrete covers depending on the span and approval by the Engineer. They shall be
separated from foundations by sealed joints. Supporting edges of channels and precast concrete
covers shall be protected by galvanised steel angels.
Stairs, platforms and walkways: will be supported by steel beams and columns and shall be
covered with galvanised gratings as specified. .
Floor finishes: Non-metallic floor hardener and epoxy coating; epoxy screed, chlorinated rubber
paints, acid proof ceramic floor tiles etc. as required.
Walls: Up to 2.20m.height masonry, plastered and painted. Walls to the transformer bay will be
concrete fire walls.
Roof and Wall Cladding: Galvanised and coated profiled steel sheet with thermal insulation as
specified under the Chapter G5.4.16-Metal Works.
Windows: A band of windows along both long sides of building will be provided. Windows will be
coated aluminium frame with double glazing. Windows will be shaded by a band of horizontal
coated aluminium louvers of about 1.50m. The windows shall accessible form crane walkway for
repair and cleaning. Their height at the transformer side shall be established considering blast and
fire protection requirements in relation to the height of concrete fire wall.
Doors: electrically driven main access door (steel folding) to loading bay and one escape
aluminium door shall be provided. In the main door another personal door is to be integrated.
Further properties will be as specified under the Chapter G5.4.16-Metal Works.
Crane: For bridge crane at elevation about 16.5m to 17.5m crane rails will be provided.
Crane Walk Way: 1.5m wide walkway with grating and handrails shall be provided along the
western wall at elevation about 14m.
Access Ladders and Stair: ladder to crane girder and stair to walkway have to be foreseen.

4.4
Page: 9
HEAT RECOVERY STEAM GENERATOR FOUNDATIONS, BYPASS AND STACK

FOUNDATIONS
Reinforced concrete foundation on piles or on compacted soil to support the HRSGs will be
provided. The size and design of the foundations shall be in accordance with the requirement of
the soil investigations and loads from HRSG manufacturer.
Top surfaces of the foundations shall be protected as specified under Chapter G5.5- Corrosion
Protection and Painting.
4.5
AUXILIARY BOILERS FOUNDATIONS
Reinforced concrete foundation on piles or on compacted soil with approximate dimensions

55x35 m will be provided. Exact dimensions have to be determined in accordance with the
requirement of the soil investigations and loads from the manufacturer.
Top surfaces of the foundations shall be protected as specified under Chapter G5.5- Corrosion
Protection and Painting
4.6
TRANSFORMER FOUNDATIONS AND FIRE WALLS
Foundations shall be provided for each main and auxiliary gas turbine transformer, for each steam
turbine transformer.
All transformer foundations shall be raft foundation on compacted soil or piles as required. The
transformers will be separated by concrete fire walls. The integrated oil collection basins with
perimeter walls will have at the top a grating covered with gravel. Bottom of basin shall be sloped
down in direction of sump pit and from there connected to oily waste water catch basin. The
coating of internal concrete walls has to be oil resistant.
Capacity of the oil collection area - has to be designed according to the oil capacity of the
transformer as well as the maximum expected fire fighting water.
Transformers shall have in the front galvanised and painted steel mesh type fencing as required.
Ventilated metal roof and bird protection net shall be provided.
Galvanised transformer rails are included in scope of supply. They shall be extended up to the
road as required.
Other Transformer Foundations: Foundations required for various small transformers shall be
under the same considerations as above
4.7
CONTROL BUILDING
Refer to the Tender Drawing No. CNE/015/2002-R-03-G-D-00002 (Sheet Nos 1 to 3) - Central

Control Building. (The tender drawing is for reference only, indicating minimum requirements. It is
Contractors responsibility to check, complete, revise (if required and approved) and detail the
drawings in order to have a complete and functional building. Reference is made to G2-Conditions
of Contract, Clause 6.55.)
Function: This building with cable basement will provide for both Phases space for transformers,
switchgears, electrical workshops, battery rooms, the installation of electrical and control
equipment, control room, instrument store and workshop, training room, conference room, offices,
prayer room, tea-kitchen and toilets. Special architectural features for the facades shall be
provided; since this building - not only in function but also from architectural point of view, would be
the central point in the layout of the complete Station L
Size (approximately): L x B x H = 55 x 48 x 23 m
4 stories
Page: 10
This building will be constructed atop of the main access road. Clear height for traffic shall be
6.0m.
Foundations: Pad or piled foundations. The foundation design shall be in accordance with the
requirement of the soil investigations. A minimum 2.0m high basement for the cables will be
provided except the area of transformers.
Superstructure: Reinforced concrete will be provided for all columns, floors and roof.
Walls: External walls double skin masonry, plaster and paint if and as required by the architectural
facade design. Wall to future Turbine Building Phase II shall be plastered and painted.
Windows: Powder coated aluminium frame with insulated and tinted double glazing.
Doors: Wooden and fire proof steel doors as required. Main entrance doors (Corridors outlets) are
to be palisade type double wings steel bars door with architectural appearance. Door shall be
integrated in the palisade type closing fence of the same design for the corridor.
Roof: Built up roofing.
Ground Floor:
Each wing four transformer boxes: with oil catchments basin connected to oily drainage,
floor, walls (as reinforced concrete blast wall) and ceiling with oil resistant epoxy coating as
specified, front side galvanised and painted steel mesh fence with integrated door.
Corridor for bus ducts, hardened surface with top epoxy coating
Three electrical rooms and two workshops, 5mm epoxy screed and epoxy top coating
Corridor for second entrance to electrical room and to staircase hardened surface with top
epoxy coating
First Floor:
Electrical equipment: for Phase I only, 1.30m and 0.80m high raised floors as required shall
be provided as per approval by the Engineer. Floor finishing will be epoxy coating adequate
for indoor concrete protection. Windows shall be provided as required but with louvers if any.
3 (three) Battery Rooms with integrated Charger Rooms: floor and walls up to 2.0m with acid
proof tiling, remaining walls and ceiling with acid proof paint. Shower with eye-washer to be
foreseen. Drain shall be provided and connected to chemical waste system.
Second Floor:
I&C equipment and spare room: 0.80m high raised floor
Battery room: one room, specification as first floor battery rooms.
Top Floor:
Reserved for control block including control room, computer rooms and shift engineer office,
I&C-workshop and store, training room, conference room, offices, record rooms, prayer
room, tea-kitchen and toilets for the requirements of Phase I and II.
Floor finishing will be epoxy screed with top coating for workshop and store, ceramic floor
tiles for tea-kitchen and toilets, computer floor (raised floor) for control room (higher quality),
PVC flooring for training room, conference room, offices, carpet for prayer room.
Toilets shall have one western and one eastern type WC, two urinal bowls, one wash basin
counter sunk in granite and one hot air drier as specified under Chapter G5.4.19- Plumbing
Page: 11
and Sanitary Installation. Floor is to be constructed as water tight structure. Ceramic tiles
also for the walls
Tea-kitchen as specified under Chapter G5.4.19- Plumbing and Sanitary Installation. Floor is
to be constructed as water tight structure. Ceramic tiles also for the walls
Tinted, double glazed aluminium windows shall be provided as required.
Control room shall be designed as a high quality complete package by a specialised company. All
features of interior like suspended ceiling, lighting fixtures, control panels, walls, floor etc. shall
match and harmony with each others.
Main staircases: Main stair case fire proof reinforced concrete construction. Stairs, landing and
corridors shall be covered with granite; type is subject to approval by the Engineer. Hand railing
shall be stainless steel.
Escape stair case: ground floor, steel structure with grating; upper floor, reinforced concrete with
PVC or marble surface and galvanised and painted hand railing.
Lift: One lift shall be provided for people and equipment as specified under G5.4.20.
Independently from the specified lift, Contractor shall be responsible for the suitable lift for
electrical equipment in the building and may adjust the requirements accordingly.
Office Space: 8 offices shall be provided for 16 people.
4.8
DEMINERALISATION PLANT, LABORATORY AND DEMINERALISED WATER TANKS
Function: To house the demineralisation equipment, LV-switchgear room in the ground floor;
laboratory, office and toilet in the upper floor as well as foundations for tanks outdoor. Wash basin
and eye-washer shall be foreseen in ground floor. The Contractor shall adequately dimension the
building to permit the installation one additional demineralisation train with the necessary control
room and switchgear areas to be installed in Phase II.
Size (approximately): L x B x H = 30 x 12 x 8 m
2-storey
Foundations: The foundation design shall be in accordance with the requirement of the soil
investigations.
Superstructure: Reinforced concrete shall be provided for all columns and roof.
Floor: Reinforced concrete slabs with separate floor finish.
Floor finishes: Acid proof ceramic floor tiles for water treatment and laboratory, ceramic tiles for
toilet, PVC flooring for office and 5mm epoxy screed with epoxy top coating for local electronic
rooms and switchgear room.
Walls: Interior masonry with acid proof tiles up to minimum 2m and acid proof paint above for
water treatment and laboratory, ceramic tiles for the toilet. Exterior masonry plastered and painted.
Windows: Powder coated aluminium frame with insulated double glazing.
Doors: External steel door (main door) and aluminium doors (personnel doors) at ground floor and
aluminium doors for local electronic rooms and in upper floor
Toilet: Toilet shall have one western and one eastern type WC, one urinal bowl, one wash basin
and one hot air drier as specified under Chapter G5.4.19- Plumbing and Sanitary Installation
Laboratory: Walls up to 2.0m and floor will be acid proof tiling. Size for Phase I+II as required.
Office: 20m 2 of size shall be provided.
Page: 12
Crane: Monorail for maintenance.

Demineralised Water Tank Foundations: Reinforced concrete foundation as required shall be
provided to support the Demineralised Water Tank, integrated in a walled basin, which shall collect
leakages. Exposed concrete surfaces inside shall be epoxy coated accordingly.
Acid Clearing Basin for demister pads from desalination shall be provided as required. Concrete
surfaces shall be protected as specified.
4.9
FUEL OIL TANK YARD
Four (4) tanks of each 9000 m 3 capacity shall be provided. The yard will have overall dimension of
approx. 100x120 m and shall be subdivided between each tank. The height of the perimeter wall
shall be designed including fire extinguishing requirements.
Function: To store oil for emergency operation.
The oil tanks shall be supported on a reinforced concrete ring beam on compacted soil or on piles.
All drainage shall pass into oil separation chambers, from which the oil may be removed and led
finally through interceptors. Perimeter and separation walls with about 3.5 m high Tank
foundations shall be elevated about 1m above the ground slab and separated from the foundations
by sealed joints resistant to oil. Inside of yard shall be coated by oil proof paint.
4.10
FUEL OIL PUMP FOUNDATIONS
Raft foundation about 48x18 m with metal deck shading as specified under Part G5.4, Clause 16.8
for Phases I and II shall be foreseen. 2m high chainlink fence with gate shall be provided.
4.11
FIRE PUMP HOUSE
Function: To house the fire water pumps.

Size (approximately): L x B x H = 25 x 18 x 5m
Foundations: Raft foundation design shall be in accordance with the requirement of the soil
investigations.
Superstructure: Reinforced concrete columns and roof.
Roof: Built up roofing
Floor finishes: Hardened surface with epoxy coating.
Walls: Masonry plastered and painted
Windows: Powder coated aluminium frame with insulated glazing.
Doors: Aluminium doors as required
Monorail: shall be provide along the axis of the pumps
4.12
OTHER TECHNICAL STRUCTURES/BUILDINGS
4.12.1
Emergency and Black Start Facility
Raft foundation 47 x 19 m for the container type of generator will be foreseen or a concrete
building of same size with LV-switchgear room. Top of foundation epoxy coated as specified.
Generators shall be separated by fire walls from each other.

4.12.2
Page: 13
Diesel Fuel Pump and Day Tank for Black Start and Emergency Generator
The pump and tank will be placed on a 25 x 20 m concrete slab. The tanks will be surrounded with
2m high concrete wall. Internal concrete surfaces shall have oil resistant epoxy coating as
specified. Sunshade for the pumps shall be provided as specified
4.12.3
Gas Receiving Station
Base slab with approx. dimensions of 65 x 45 m with fencing around shall be foreseen. Top of
foundation epoxy coated as specified. Fencing will be as specified but without barbed wire top.
Sunshade shall be provided as specified.
4.12.4
Gas Compressor Building
One story reinforced concrete building with dimensions 50 x 20 x 5 m shall be provided, which
shall include a LV-switchgear room and local electronic room. Top of foundation slab shall be
epoxy coated as specified.
4.12.5
Fuel Oil Unloading Station and Pipe Line from Jebel Ali Port
All required civil works, including foundations for unloading facilities and survey, excavation and
backfilling works, special support at road crossing or similar for fuel oil pipe line shall be provided.
4.12.6
Air Compressor Building
One storey reinforced concrete building with dimensions 15x8x5 m shall be provided. The building
shall house service air compressor and related equipment. Compressor foundations shall be
isolated from the base slab. Architectural features are as Fire Pump House above. Monorail shall
be provided. Location of the building shall be in the vicinity of Turbine Buildings, e.g. west of Oil
Separator.
4.13
MECHANICAL AND ELECTRICAL STORES / OPEN AIR STORAGE
Function: To store spare parts, chemicals etc.

Size (approximately): L x B x H=
90 x 30 x 9m for Store; 90 x 12 x 6m for Open-air Store. Main
store area with the width about 12m will be served by an overhead crane and shall be designed so
that it can be extended towards east.
Requirements and scope:
Air-conditioned areas
An area of approximately 500 m2 of the store shall be partitioned off and fully equipped as an air
conditioned store. The temperature in this area shall be maintained at a maximum of 25 C. (dry
bulb) in summer and 20 C. (dry bulb) in winter.
The level of illumination shall be 350 400 lux and arranged to illuminate stack/rack faces.
This area shall be provided with heavy duty racking and shelving for palletised stores as well as
shelving for smaller items. The pallet racking shall be arranged in aisles wide enough to permit
stacking and retrieval using a front loading fork lift truck. The pallet racks shall be of steel structure
fixed to the floor by anchors.
A ladder shall be provided with the shelving to facilitate storage and retrieval of the small items by
hand.
Partitioned areas with suitable racking shall be provided for:
Storage for electronics
Heavy material storage
Page: 14
Cleaning Chemicals
Rubber products
Paints and varnishes
Air conditioning plant room.
Access to the air conditioned part of the store shall be through steel faced personnel door adjacent
to a roller shutter electrically operated door 4m x 4m high, from the main store.
Air conditioned store shall also have electrically operated roller shutter door.
Main Store Area
The remaining area shall be provided for the main store. This area shall be equipped throughout
with very heavy duty racking and shelving for palletised stores but shall also have a section for the
storage of long items. Sheet steel shall be stored in a purpose built rack. Dedicated chemical store
is to be provided within the main store for 3 month storage of chemicals.
A 10T electric gantry crane with a clear height to the hook of 7 meters minimum shall be installed
to serve the entire non air conditioned store area to facilitate handling and unloading of stores.
Ancillary spreaders, spiders, chains etc. shall also be provided.
The required number and sizing of the racks with heavy duty steel plates, cabinets and shelves
shall be adequate and suitable for the storage of spares recommended by the Contractor and shall
be to the approval of the Engineer/Employer. Racks of all types shall have back and side panels
individually except for ones meant for the storage of long components and no mesh panels are
acceptable. All the racks shall be braced for better rigidity and column guards/ protective plates
shall be provided to avoid damage by fork lift movement. Arrangement of racks, cabinets and
shelves shall be suitable for fork lift movement and to be approved by the Engineer / Employer. All
the cabinets supplied under the Contract shall be dust proof. Adequate number of assorted size
bins (minimum of 3000 nos.) cabinets/ shelves and drawers of varying sizes together with standard
size bin card holders shall be provided.
For further details reference is made to Part P2.22, Clause 3.
Bin racks shall be considered for accommodating standard bins and drawers of different sizes. 2
nos. cantilever arms type pipe racks shall be provided.
Chemical and lubricant stores should be provided with suitable racks to accommodate drums and
jerry cans. Chemical store room shall be provided with floor clearing pits, jump showers, wash
basin and gas preventive masks.
Rubber products, paints and chemical storage area shall be maintained slightly under negative
pressure. Load capacity and location code shall be painted and no stickers are acceptable. Load
capacity and location code shall be painted and no stickers are acceptable. The pallets for racking
shall be fire resistant.
All stores and bin locations should be properly labelled and decorated with safety and quality
slogans sign boards.
Gangway lanes to be provided on the flooring throughout the store.
Equipment to be supplied
Store handling equipment must be consisting of following:
two wheeled ladders for chemical stores
tool box with hand tools
Page: 15
for further equipment reference is made to Part P2.22, Clause 3.
Two electronic weighing scales shall be provided, one for precision measurement up to 100 kg and
one up to 2 tons capacity with provision of label printing. Basic tools, e.g. hammers, saws,
crowbars, strapping machine etc. shall also be provided.
Requirements for the two (2) weighing scales:
one (1) electronic high accuracy balance
weighing range 0 50 kg
desk top type
platform size 600 x 600 mm
accuracy class 0,1 %
one (1) electronic platform scale
weighing range 0 2,000 kg
floor mounted platform
platform size 2,000 x 1,500 mm
accuracy class 0.5 %
The following requirements shall be regarded for both weighing scales:
platform material: stainless steel
high accuracy digital weighing indicator
automatic zero tracking
net weight display
tare weight display
gross weight display
serial interface
Low-voltage switchgear room shall also be provided in the main store.

Two transformer foundations shall be provided outside and adjacent to the switchgear room as
specified. The requirements of the transformer specified above shall apply also for these
transformers.
Offices
Two air conditioned offices of 6 m x 4 m and one 6 m x 6 m and an inward receipt and inspection
bay for delivery lorry shall be provided in the main store adjacent to the entrance. Toilets shall be
arranged in the same block. Offices shall be provided with suspended ceilings.
At least one of the offices should be having independent entrance and provision to be isolated from
the main store building. Office furniture is to be provided for all offices. Communication terminal
points to be provided in the store offices with connection to existing fibre optic network at Jebel Ali
Station. Chilled drinking water fountain shall be flush mounted in the walls.
Page: 16
Toilet room shall be included and this shall be fitted with 1 eastern style W.C, 1 western style
W.C, 2 urinals and 1 wash basin, 1 hot air drier and anal sprays
Mezzanine Floor
The roof of the offices is to be used as additional storage area. The mezzanine floor shall also be
built in the A/C store with proper racking. Permanent notice written in both Arabic and English
shall be prominently displayed showing the permissible loading limit of minimum 500 kg/m2 and
permanent access and safety railing shall be installed.
Description of Building
Foundations: The foundation design shall be in accordance with the requirement and
recommendations of the results of the soil investigations.
Superstructure: Structural steel will be provided for all columns, floors, cladding and roof
supports.
Walls: External walls up to 2.0 m height masonry, plastered and painted. Walls to the transformer
bay will be concrete fire walls. In chemical storage areas the inside of the exterior walls from
ground floor up to +2.00 m to be coated with epoxy
Roof and Wall Cladding: Galvanised and coated profiled steel sheet with thermal insulation
Floor: Reinforced concrete slabs with separate floor finish. The floor shall be designed to support
the stored material and racking without overstress.
Floor finishes: The floor shall be of hardened concrete treated with epoxy paint to render it dustfree and oil resistant. In chemical storage areas the floors and the raised borders thereto must be
protected with an epoxy coating for areas without traffic and with acid resistant tiles for areas with
traffic. Offices with PVC flooring, toilets tiled as specified.
Windows and ventilation apertures: The windows are to be powder coated aluminium-framed
and double-glazed. Manually operated window vents are to be provided. Fans are to be provided
in accordance with the supply and extraction of air as described in the HVAC section.
Doors: Access to the store shall be through two 4 m x 5 m electrically operated, rolling shutter
door with a personnel door integrated at the east entrance and one the same at the west entrance.
Emergency exit doors, fitted with panic escape bars on the inside and not to open from outside
shall be installed in all air conditioned store rooms, the air conditioning plant room, and the main
stores. All the external doors should be with dust proof rubber linings in the bottom. Steel doors
shall be provided for all internal doors of store rooms too. Internal doors of offices and toilets shall
be aluminium door as specified.
Open-air Storage
Externally and adjacent to the building an area of approximately 1,100 m2 shall be covered and
paved as an outdoor storage area. After preparation of the sub-base the area shall be paved using
interlocking concrete blocks. The paving shall be laid to falls to drainage gullies leading surface
water to soakaways.
The edges of the paved area shall be supported by kerbs set in concrete. The area shall be
surrounded by a plastic coated chain-link fence 2.4 m high surmounted by three strands of barbed
wire 100 mm apart. One pair of substantial gates totalling 6m wide shall be provided in the fence
close to the building.
Covering shall consist of a painted steel space frame roof system with no internal columns and
trapezoidal metal sheets. The headroom shall be a minimum of 6 metres. Downstand vertical
cladding shall be provided for 2 meters height to provide shade.
Page: 17
A similar covered, paved and fenced area of 70 m2 shall be provided for storage of oil and
lubricants.
4.14
PIPERACKS FOUNDATIONS
Pipe and cable racks shall be provided as indicated in the Layout Tender Drawing
No.CNE/015/2002-X-00G-D-00025.
For the steel super structure see relevant mechanical Parts of the Specification.
Foundations shall be constructed 1.0m above ground water table where possible. Top of
foundations shall be minimum 30 cm above ground level and protected as specified. Top surface
shall be inclined to prevent standing water.
4.15
PIPE /CABLE TRENCHES
4.15.1
General
Cable and Pipe Trenches shall be above ground water table, unless unavoidable and connected to
drainage by gravity run, where possible.
Reinforced concrete pipe and cable trenches will be provided with drainage sumps, precast
removable covers, galvanized steel anchor rails and lifting hooks.
The necessity of providing cable and pipe ducts as well as the approximate routes of these ducts
are specified in the relevant sections of specifications for electrical works, for feedwater treatment,
waste water systems, etc.
All cable trenches/cable ducts required for interconnection of the electrical equipment provided in
Phase I for Package P -Power Plant are included in the scope of supply:
4.15.2
Requirements for Cable and Pipe Ducts
For large numbers of cables and pipes the Contractor shall provide ducts in such areas where
installation above ground is not possible or advisable. Cables and pipes shall be laid in separate
ducts.
The ducts are to be constructed of reinforced concrete according to the requirements of Part
General Technical Requirements G5.4.9-Concrete and Reinforced Concrete, and must be
watertight and non buoyant under the prevailing groundwater conditions, if applicable. Particular
attention must be paid to satisfactory expansion and settling joints. The walls and roofs of the ducts
must be designed and reinforced to withstand the relevant traffic loads. The ducts are to be
provided internally with hot dip galvanised anchor rails every 1.5m for the easy attachment of clips
and cable racks.
Plugging and shooting of fixing devices are permissible only in isolated cases and are subject to
the Engineers agreement. All ducts covered by removable concrete covers will have to be
provided with metal protection angles protecting on one hand the edges of removable covers and
on the other hand the edges of the duct walls beside the removable covers.
Every attempt shall be made to locate the ducts away from roads in order not to disrupt or
endanger traffic during subsequent necessary work such as overhauls and repairs. The corners of
the duct walls in the vicinity of junctions, inlets and bends must be rounded-off so that no damage
is suffered by the cables when they are being drawn in allowing for their minimum bending
radius.
For drainage purposes the cable and pipe ducts shall be provided with slopes (min. slope 0.3%)
towards accessible pump sumps. The pump sumps in which will be frequently water (e.g. in the
area of desalination units) will have to be provided with permanently installed automatic pumps. In
this case the level control system must comply with the requirements of the electrical section of this
Page: 18
specification. All the other pump sumps will be pumped out, if necessary, by portable pumps to be
delivered by the Contractor in five (5) numbers of the required capacity, which shall be subject to
the approval by the Engineer.
For construction of cable and pipe ducts the requirements of DIN 1045, DIN 1054, BS 8110 and
BS 6031 shall be complied with.
For small pipe and cable ducts removable covers are permitted (such as chequered plates,
gratings, iron sheets, etc . for indoor ducts and reinforced concrete covers for outdoor ducts), but
only if these covers are situated above ground water level.
The dimension of ducts is to be appropriate to the width of the cable and pipe racks and to the
maintenance operations which will be effected. If the upper level of duct covers coincides with the
finished ground than no access manholes are needed, because the necessary covers can be
lifted.
4.15.3
Requirements for Shafts, Manholes and their Covers
Shafts and manholes shall be provided at each inlet to the drainage system, at each change in
gradient or direction, and at maximum intervals of 50 m. The diameter of manhole shall be chosen
as a function of the pipe cross section.
Either prefabricated or cast-in-situ concrete manholes may be used. The construction of
prefabricated shafts or manholes shall meet the requirements set out in BS 5911, Part 2.
Cast-in-situ concrete shafts shall meet the requirements set out in Part General Technical
Requirements G5.4.9-Concrete and Reinforced Concrete.
At the end of each main run of foul water sewer, flushing shafts equipped with automatic drain
flushers of 50 l/s rating (total flushing quantity 4,000 litres) shall be provided.
Shaft and manhole covers shall be made from cast iron and reinforced concrete, of watertight
construction, with and without dirt traps, to suit local requirements. Shaft and pit covers shall have
a test load suited to the traffic conditions.
GRP/GRC covers shall be provided in non-traffic areas as and where directed or approved by the
Engineer.
The dimensions of trash gratings shall be those determined by proper structural design. Trash
gratings shall be of cast steel.
The type and choice of climbing irons shall meet the requirements of BS1247. Only stainless
steel or GRP shall be used. Where shafts are constructed of reinforced concrete, the step spacing
shall be 33.3 cm. Climbing irons shall be staggered, maintaining a horizontal axial spacing of 30
cm. Access shafts to cable tunnels shall be provided with handrails for the ease of climbing down
and up. The hand rails shall be sinkable in the shaft if not used and arrestable after pulling out for
holding during climbing.
4.15.4
General Requirements
Beside the civil works shown above, the following works are deemed to be included in this Clause:
All civil works (earthworks, manholes, etc.) necessary for buried cables and pipes. It is to be
noted that all buried pipes and cables shall be protected under the roads by protection pipes
and protection slabs of reinforced concrete.
All demolition and relocation works of the existing underground services due to the new
cable and pipe ducts and buried pipes and cables.

4.16
Page: 19
ADMINISTRATION BUILDING
Refer to the Tender Drawing No. CNE/015/2002-R-01-A-D-00001 to 00004 - Administration

Building. (The tender drawing is for reference only, indicating minimum requirements. It is
Contractors responsibility to check, complete, revise (if required and approved) and detail the
drawings in order to have a complete and functional building. Reference is made to G2-Conditions
of Contract, Clause 6.55. The office room sizes and numbers may be also varied in the final design
stage)
Location of the building is in the area of the existing Station G east of the existing road of Station
G at S 1650 and at about E 340.
Main access will be from east. Front access road is to be provided. From the existing road to the
east opposite to the main entrance, an entrance in to free parking area to be foreseen by lowering
the walkway for the car access.
Function: This air-conditioned building will provide computer floor at the top floor; offices and
meeting room for management in the second floor; offices, meeting and record rooms for senior
engineers in the first floor and offices for administration, result engineers and safety engineers,
maintenance department; main record room, library, kitchen and mess room/coffee shop (for 20
people), room for telephone equipment and operator and lobby/reception as well as specious
amphitheatre type auditorium for 250 people in the ground floor. Toilets shall be provided at each
floor men and at the first floor for ladies (separately) and one in each manager office. HVAC
equipment, switchgears and transformer may be placed in suitable location e.g. under the
auditorium. For further rooms etc. see the drawing.
Passenger lift shall be provided as specified under G5.4.20.
Building shall have sun shade canopy ranging over the access road.
Area under auditorium bottom slab will be utilised, where head clearance is sufficient for locating
one men toilet, one janitor room, electrical rooms.
Contractor shall prepare a finished typical office room as sample prior to commencement of interior
finishing works under utilisation of approved materials.
Size (approximately): L x B x H = 48x 32 x 15m 4 storey building. (See layout)
Foundations: The foundation design shall be in accordance with the requirement of the soil
investigations.
Superstructure: Reinforced concrete will be provided for all columns, floors and roof.
Floors: Reinforced concrete slabs with separate floor finish.
Floor finishes:
Granite for lobby/reception area (of higher quality), staircase and all corridors as well as
ground floor level of amphitheatre, which means for floors: open floors and corridors of
ground floor including floor and corridors leading to amphitheatre and for upper floors, the
floors of all corridors (including corridors leading to offices) and stairs as specified.
Wall to wall carpet for management offices including their secretarial rooms and auditorium
(quality of carpets is subject to the approval of the Engineer)
Telephone equipment and operator rooms, library, records rooms, meeting rooms, janitors
room as the offices
Coffee shop: ceramic tiles
Page: 20
Top floor: two blocks with computer floor
DCS-rooms: with computer floor
Other floors as specified under General Architectural Features above (Clause 4.1.1)
Main Staircases: Fire proof reinforced concrete construction.
Handrails stainless steel with vertical supports and glass panels.
Escape Staircase: reinforced concrete construction with finishing as main staircase

Walls: External walls double skin masonry plastered and painted in general.
Outside special architectural features to be foreseen with e.g. aluminium sheet panel or GRC
cladding.
Lobby/reception granite or marble of selected quality and colour, means all walls belonging
to open floors and corridors of ground floor including floor and corridors leading to
amphitheatre.
Auditorium, up to 2 (two) m marble or wood subject to approval
General manager office, wood panelling as may be required by the Engineer
Variable partition walls (dry wall or de-mountable partition (combination of glazing and wood
gypsum panels)) for internal walls within the fire zones
Others wall as specified under General Architectural Features above
Windows: Powder coated aluminium frame with insulated and tinted double glazing.
Doors:
Main entrance: Air lock-double door system, both automatic sliding and side wing doors
type and quality subject to approval by the Engineer
Fire proof or rated doors where required
Office doors of management floor and doors of auditorium: Wooden doors of higher quality,
double or single wing as required, type and quality subject to approval by the Engineer
Other office doors: wooden veneered doors as specified
Kitchen and external toilets: synthetic resin plastic veneer doors as specified
Toilets internal doors and partitions: as specified under Part G5.4, Clause 15.3.11
Ceiling:
Auditorium: special design for architectural appearance and sound absorption/echo

prevention
Lobby/Reception: open up to the roof, roof of this portion with architectural features as glass
pyramid etc.
Managerial offices: suspended ceiling of higher quality, with integrated lighting and airconditioning features
Toilets: metallic suspended ceiling. Sanitary piping of the toilets for Senior Engineers offices
is to be hidden well.
Page: 21
Other areas incl. DCS-rooms: mineral board suspended ceiling, if required from lighting and
air-conditioning point of view or as directed by the Engineer.
Kitchen: Materials specification as Part G5.4, Clause 19.5.22, sizing and equipment for need of
coffee shop for 20 people
Toilets: as shown in the drawing, materials of top market quality for managerial toilets and higher
market quality for others. Wash basins counter sunk in granite plate.
Auditorium- Furniture, Sound, Video and Light System:
The following is the minimum specification for the auditoriums equipment not necessarily complete
in every respect. Contractor shall supply functional and comprehensive system for a satisfactory
functional auditorium. One room shall be required for the equipment in a suitable location.
Furniture
The chairs fixed in row shall be cushioned and the seats foldable type. Quality shall be higher
market quality for such buildings, subject to approval of Engineer. All furniture required at the
stage for various purposes shall be supplied.
Sound System Overview
The sound system will be required to provide a high quality vocal reinforcement and music
playback. The system will be required to perform in all manners required as a multi functional
system.
Speaker System
The speakers should be configured as: Left / Centre / Right
The Main Left /Right Speaker Cabinets should have the following Specifications:
Two 60 Degree dispersion Pattern Speakers arrayed on the left / right side of the stage, each
speaker shall have the following specifications:
1 x 12 low frequency driver and 1 HF Compression Driver
Minimum 600W RMS ( IEC ) Rating with a 60 x 40 Dispersion Pattern
95DB @ 1w-1mtr , frequency response : 60Hz 18Khz @ 3db
Two 60 Degree dispersion Pattern Speakers arrayed in the centre position of the stage. Each
speaker shall have the following specifications:
1 x 12 low frequency driver and 1 HF Compression Driver
Minimum 600W RMS ( IEC ) Rating with a 60 x 40 Dispersion Pattern
95DB @ 1w-1mtr , frequency response : 60Hz 18Khz @ 3db
Custom Array Brackets to be fitted with System

Two Dual 15 Bass Speakers left / right. Each speaker shall have the following specifications :
2 x 15 low frequency driver with 4 edgewound ribbon voice coil
Minimum 1200W RMS ( IEC ) Rating with 100DB @ 1w-1mtr , frequency response :
40Hz 900Hz @ 3db
Amplification:
Page: 22
Left / Right amplifier shall have a power rating of 1700W per channel at 4 Ohms
Centre Cluster amplifier shall have a power rating of 950W per channel at 4 Ohms.
Bass amplifier shall have a power rating of 1700W Per channel at 4 Ohms
Processing:
Four Input Eight Output Digital Management System

( Must be able to Run Different Setting for different Inputs )
Dual Channel Graphic Equaliser
Dual Channel Compressor Limiter
Mixing Console: Minimum 24 Mono Channel with 2 Stereo Inputs, minimum four
bus groups and master left, centre and right outputs
Sources :
5Cd Carousel CD Player

Twin Cassette Deck
Accessories:
Four UHF Radio Microphones (2 Lapel Type / 2 Hand Held)

Dynamic Podium Microphones (Two)
Dynamic Vocal Microphones (Four)
Video System Overview

The video system shall have the capability to project all formats and be mounted on a scissor
type lift with a three meter drop positioned in the front areas of the stage.
The specifications shall be as follows:
Minimum 3000 Ansi XGA Rated LCD Projector
3m drop scissor lift for projector
150 Diagonal Motorized Projection Screen
Audio visual matrix 6 Inputs two outputs
14 Monitor for preview purposes
Sources : Hi Fi VCR Machine

DVD Player
Control System Overview
The projection system and sources shall be controlled by a wireless touch screen system, this
shall have two way communication capability and shall include:
Touch Screen
Gateway receivers
Volume control modules
Infra Red Probes
Main Control Processor
Page: 23
Lighting System Overview

The lighting shall consist of the following:
Six Units 1200W Pebble Convex Lighting Fixtures with accessories
Six Units 1200W Fresnel Lighting Fixtures with accessories
Six Units 1000W Optic Profile Spot Lights with Accessories
Six Units Stage Lighting 1000W Par 64 Lighting Fixtures with Accessories
Two Units Pre Wired Six Way Bars for Front Stage
Two Units Pre Wired Side Lighting Bars For Side Stage
One Unit 24 Channel DMX Lighting Controller Wall Mount Type
Lot Dimmers to Suit
Engineering Systems Overvie w

All equipment shall be housed in a professional equipment rack, all sources must be provided
with rack accessories. Looming, security fans, covers and power distribution system are to be
in place. Mains Power Sequencer must also be included.
Two Input floor boxes on the stage must be fitted to plug-in microphones, computer audio
systems.
Contractor shall employ a specialised interior design company for the interior design of the
building, who shall be approved as sub-contractor for this work. Interior design shall be a package
elements of which (such as colour of equipment, walls, ceiling, doors, windows etc.) shall match
and harmony with each others. Draft of complete interior design shall be submitted for approval.
4.17
COVERED CAR PARK
The paved and covered car park for 80 cars will be constructed in corrosion protected structural
steel with steel columns, roof beams, girds and bracings. Galvanised coated metal or coated
aluminium cladding (un-insulated) will be provided for the roof and the facade with rain gutters and
down pipes.
The covered car park clear height will be 2.3 m.
Paved roads for pedestrians are to be foreseen to the Administration Building.
The location will be north of the Administration Building or as directed by the Engineer.
4.18
MECHANICAL WORKSHOP
Reinforced concrete building with dimensions 20x20x5m will be provided. The buildings shall be
constructed adjacent to heat treatment building as one building separated by a partition wall in
masonry and connected by internal door.
Foundations, superstructure, walls, roof and windows as the other reinforced concrete building
described above for similar buildings.
Door shall be vertical lift steel door as specified, with integrated personnel door, the size suitable
for access of fork lifts.
Page: 24
Floor finishing 5mm epoxy screed epoxy with top coat as specified
Monorail shall be provided.
4.19
SAND BLASTING AND HEAT TREATMENT BUILDINGS
Ventilated reinforced concrete building with dimensions 20x15x5m and 20x15x5m respectively will
be provided. The buildings shall be constructed as one building separated by a partition wall in
masonry.
Foundations, superstructure, walls, roof and windows as the other reinforced concrete building
described above.
Door shall be double wing vertical lift steel door as specified, with integrated personnel door, the
size suitable for access of fork lifts.
Floor finishing epoxy coated as specified
4.20
SEWAGE TREATMENT PLANT
Sewage treatment plant for biological treatment will be provided at discharge area. Civil works for it
are to be provided as required. Treated water may be connected to discharge system if approval is
given by concerned authorities and by the Engineer.
4.21
WASTE WATER TREATMENT PLANT AND BASIN
Civil works for Waste Water Treatment Plant shall be provided as required. Watertight concrete
and concrete protection shall be provided as required for acid in contact in the basins. Waste
Water Basin shall be designed and protection provided for water temperature 100oC and for
cooling by sea water. Adequate protection is to be provided for concrete for the variation of
temperatures, if necessary steel shell is to be provided. If closer than 1.0m to the ground water
level it shall be considered in capillary zone for the concrete specification.
2x100% pumps with automatic level control shall be provided for pumping out water to the existing
drainage channel or into the discharge system of the Station.
4.22
OIL SEPARATORS
Civil works for Oil Separators shall to be provided as required. Watertight concrete and concrete
protection shall be provided as required for oil contact in the basins. If closer than 1.0m to the
ground water level it shall be considered in capillary zone for the concrete specification.
Soakaways (if feasible) or connection to drainage system shall be provided for the treated water.
4.23
ROADS, PAVEMENTS AND SIDEWALKS
Asphalt roads shall be provided as shown in the Layout Tender Drawing No.CNE/015/2002-X00G-D-00025.
Scope of works for the asphalt roads for Package P is as follows:
External Road: Existing service road along the eastern Station fence outside will be
constructed as a permanent asphalt road about from Station G-gate up to the interchange
on the Sheikh Zayed Road for the length of about 1600m with the same width as the existing
asphalt road (about 8m). This road shall be completed within four months from the end of
mobilization period except wearing course, which shall be constructed at the end with other
Station roads.
Main road width 7.5m shall be provided at centrelines E 367 from existing road of Station G
at S 1657 to S 2070
Page: 25
Road width 5.0m shall be provided for road at centrelines E 226 from road at about S 1707
to S 2015 and all other asphalt roads east of about E 222 (for limits refer to Part P1Interfaces).
Road width 5.0m shall be provided from the road at E 660 to External Road at the centreline
S 2006 (about 30m long). Protection of under-crossing gas pipeline is to be provided, if and
as required.
The widths above shall be considered as minimum requirements. Contractor has to verify them
and widen as it may be necessary for the functionality of traffic. Centrelines and limits of the roads
given here and in the Layout are approximate only. The exact locations will be fixed in the design
layout to be prepared by the Contractor.
Whether or not specified or shown in the layout, Contractor shall provide roads to all buildings,
structures, areas and equipments, to where vehicle access is required for fire fighting, service and
maintenance purposes. Sufficient asphalted areas have to be foreseen in front of main gates to
buildings and structures for manoeuvring, turning, loading and unloading etc. of vehicles and
trucks.
The roads shall be designed as specified, however Contractor has to consider particular traffic in a
power station where the specified DIN 1072-SLW 60 class may not be sufficient.
The same applies also to the bending radius and ramps. Contractor shall verify specified bending
radius and ramp inclinations with regard to particular traffic in a power station. Ramps more than
5% and bending radius less than 8m shall be avoided.
Walkways with 1.5m meter width on both sides of all asphalt roads within the Station shall be
constructed with concrete paving slabs as specified. Walkway shall further be provided at the
routes of frequent pedestrian traffic away from the roads such as from the buildings to parking
places, to the equipments and buildings in the vicinity where walking along the roads would be time
consuming. For the necessity of providing, the decision of Engineer shall be final in case of
dispute.
Areas between plants, in and around equipment foundations and slabs close to each other shall be
paved by interlocking concrete blocks. For the necessity of providing, the decision of Engineer
shall be final in case of dispute.
Paths around the buildings shall be provided with minimum width of 1.0m.
Traffic signs, carriage markings, guard rails shall be provided as specified.
Height Limit Indicators shall be provided as structural steel frames of 6.0m height (or as
required) before each passage to the height limited overhead installations such as pipe racks, bus
ducts, Control Building western side. Type and colour shall be as approved.
4.24
DRAINAGE AND SEWAGE SYSTEM
An independent drainage system from existing Stations shall be designed for the Station Phase I
area. Each system shall have separate drainage. Oily water passing through oil separator will be
lead to storm drainage system or soakaway pits/trenches.
Contractor shall consider in his design the different site levels.
Surface water shall be collected into main drains which are then to discharge into storm water
drains, alternatively the surface water is to discharge into approved soakaway pits or other properly
designed disposal systems as approved by the Engineer. Contractor shall prepare drawings
showing the drainage of all roads, roofs, basins, parking and other paved areas and unpaved
areas. The Contractor will be responsible for obtaining all necessary consents and approvals from
the appropriate authorities for the discharge of water into sea.
Page: 26
Underground drainage system with flow by gravity shall be provided. Design shall avoid the lift
pumps as far as possible. If required, submerged pumps and one stand-by pumps shall be
provided. All pumps shall be fitted with automatically operating level switches. The drainage
system shall include all necessary gutters and down pipes from buildings, gullies, traps, manholes,
lifting stations, retention basins and is to be laid to gradients sufficient to ensure self-cleansing
velocities in the pipes.
Storm drainage shall be designed for a 75 mm/hr rain with the duration of one hour. Minimum flow
shall be 0.4 m/s and maximum 3.0m, with an average flow velocity of 0.8 m/s.
Manholes shall be foreseen at all intersections of lines, changes of directions and every 40m in
straight sections. Each manhole will have a sand trap. Road gullies shall be provided every 25 to
30m.
All down pipes from the roofs shall be connected to storm drainage system.
Drainage pipes shall always be laid under potable water lines. At road crossing adequate
protection by sleeves or concrete slabs shall be foreseen.
Material for piping shall be fibre cement or un-plasticized polyvinyl chloride (UPVC) pipes as
specified.
Sewage drainage shall discharge into the biological sewage treatment plant which will be provided
to process sanitary waste close to the outfall area. Sewage system has been specified as
pressured system as per Part P2.19. Interface sewer pipes shall be 1.0m away from the buildings.
Internal concrete surfaces of the sewage manholes shall be protected by suitable coating.
Manholes shall be sized adequately to enable the roding.
Contractor shall provide the drainage system within his area and other areas east of co-ordinates E
considering also future connections from Phase II in his area and connect it to the lines of Package
D (or Soakaways) respectively. The Contractor of Package S will design drainage and sewage of
his areas, and assist and supply necessary data to the Contractor for Package P to enable him to
design the mains and plants in his scope of works.
Blow Down Water Drainage in to the Waste Water Treatment Plant:
Waste water from blow down tanks shall be brought in to Basin by adequate piping system for
water with temperature 100oC.
4.25
ENTRANCE GATE
A double wing, permanent gate, 7m wide, chainlink in the eastern fence at the location of
temporary site entrance (centreline at S 2006) shall be provided.
4.26
LANDSCAPING AND IRRIGATION SYSTEM
The area of and around the Station shall be landscaped as follows:
Palm trees 8 x 8 (8 m distance between trees and 8 m height of trees)
Shrubs 2 x 2 (2 m distance between shrubs and 2 m height of shrubs)
Ground cover of grass and gravel.
Plantations and gravel shall be provided for the following areas:
The northern perimeter road of L and western perimeter road of G-Stations from E 450 to E
220 shall be planted with two rows of shrubs; areas in between laid with lawn. The road
along the eastern fence of the power plant at E 670 shall be planted with two rows of shrubs.
Page: 27
Around the Administration Building ground cover with lawn. Two rows of shrubs along the
roads and one row around the parking area.
The island between Station L-road at S 1705 and existing Station G-road (south of
Administration Building only) shall be planted both side with shrubs and in between with
grass. Planting shall be minimum 3.0m away from the foundations. Areas in between shall be
paved instead of grass or shrubs, even if landscaping is foreseen in order to avoid wetting of
soil at the foundations
The 7.5m main roads of the Station L Phase I - Package P (except at S226) shall be
planted with 1 row of shrubs along each side of road and in addition 1 row of palms along the
one side of road.
All other open areas of the Package P-area west of retaining wall enclosed by Phase Iroads, which are not covered by buildings, structures, roads, paved lay-down areas, etc.
shall be covered by gravel specified under G5.4, Clause 25 (except Package S areas).
The trees, shrubs and grasses chosen must be varieties which can thrive well under the prevailing
climatic conditions and in view of the salt content in the sandy soil. All plants and grasses must be
replaced during a period of three years if this is necessary due to bad growth of the plants.
The soil is to be prepared appropriately for the plants. All landscaped areas are to be provided with
a suitable irrigation system consisting of, but not limited to: PVC-pipes, isolation valves, control
valves, quick coupler valves, pop-up sprinkler, etc.
The irrigation system shall be connected at suitable points to the drinking water system of the
plant.
Trees to be removed in the Station area shall be either re-planted or handed over to concerned
authority as instructed by the Engineer.
4.27
RETAINING WALL
At the drop of Site level from +6m to +3m a retaining wall will be provided in order to support the
constructions on the higher elevation as indicated in Layout Tender Drawing No.CNE/015/2002-X00G-D-00025. Top of wall shall be at + 6.50m. Concrete surfaces shall be fair face and corrosion
protected as specified. Backfilled surfaces need to be protected by bituminous felt system as
specified. Retaining wall shall be constructed and the backfilling completed at least at the area of
the Package S and L so that the commencement schedule of the Package S and L-contractors
for their construction activities can be met.
Another retaining wall of about 0.50m height shall be constructed around existing Gas Storage BottleArea at co-ordinates about E 500 and S 1800 to S1900 as well as south of existing Gas Pipe Line at
the co-ordinate S 1810, where existing ground level is +2.60m DMD.
4.28
CIVIL WORKS FOR ELECTRICAL INSTALLATIONS
Following civil works will be included for the electrical installations as a minimum :
-
Excavation and backfilling of trenches and pits for all buildings to be surrounded by a subgrade earthing electrode to be placed at a depth of about 1m and a distance from walls/slabs
of about 1.5m.
Similar trenches required as grid in switchgear buildings and substation
Similar trenches required along the Station fence
Soil excavation and backfilling for road lighting and foundations
Soil excavation and backfilling required for duct banks
Page: 28
4.29
Connection of re-bars to form interconnected grid for earthing purposes

PASSIVE FIRE PROTECT ION
Areas of high fire risk, hazardous areas and areas of high smoke generation shall be designed in
accordance with the requirements of NFPA, National Fire Codes and as indicated.
-
Two hour fire barriers for the transformers where minimum separation of 15m cannot be
obtained
Two hours minimum barriers and doors shall be installed for enclosed corridors in finished
buildings.
Floor drains shall be provided in areas containing fixed sprinkler or water spray systems.
4.30
OTHERS
All other foundations for smaller plants and equipment and any other civil work required for the
erection of electro/mechanical equipment and for the proper functioning of plant or parts of plant
deemed to be included in the scope of works of the Contractor, whether or not mentioned in the
Specifications
Crane rails and transformer rails will be supplied and installed by the Contractor
5
AUXILIARY SITE WORKS
5.1
SITE SURVEY AND TOPOGRAPHICAL CONTOUR MAP
The topographical map of existing site level is attached in Part G6.5-Attachments of the
Specifications. Contractor shall consider contour maps for information only. The completeness and
correctness of the contours are Contractors risk. Survey stations along Station G boundary are
available and can be given to the Contractor upon request.
5.2
SOIL INVESTIGATION
The Report on Soil Investigation (Factual) is attached in to the Specifications Part G6.4Attachment. Based on the data of the Report the necessity and requirement for soil improvement
and compaction or piling as well as allowable soil bearing capacity may be determined by the
Contractor. The completeness and correctness of the data in the Report are Contractors risk.
Ground water level given in the Report may be subject seasonal variations.
5.3
LEVELLING AND FILLING
Site area is to be levelled, filled and compacted to the design elevations of +6.0 m DMD and
+3.0 m DMD as indicated in Layout Tender Drawing No.CNE/015/2002-X-00G-D-00025 for Phase
I and II areas up to the existing piping at about S 2305. The safety distance from the piping is to be
agreed up on with the Engineer prior to the execution of the work.
Contractor shall execute the levelling and filling works within his Package area defined in Part P1Interfaces, Clause 4.4 Civil Interfaces of the Specifications and others east of co-ordinates E
222.
5.4
SITE FACILITIES
Refer to Drawing No. CNE/015/2002-R-60-G-D-00001-A Construction Fence and Contractors Lay

Down Areas
Fencing: Temporary boundary fence will be provided during the construction of Phase I at the
boundaries to the Station G, including around Administration Building area (which is placed in the
Page: 29
area of G) and to the future Phase II area or close to the locations of southern fence at the coordinate S 2300 and S 2370 as directed by the Engineer.
Accesses, Gates and Site Roads: A temporary gate 8.0 m wide during the construction shall be
provided. The route of site roads shall be as much as possible on the Station roads.
Temporary access to laydown areas (Station M-area) above the gas pipeline shall be constructed
so that undercrossing pipeline would not be damaged. The Contractor shall obtain NOC from the
concerned authority and follow their requirements if any.
Electricity and Potable Water: Refer to Part G2-Conditions of Contract, Clause 6.25.
The potable water supply tapping points from the potable water grid and power supply interface
details will be given to the Contractor, if provided by the Employer. Contractor shall make then his
own connections and distributions within the Site area. Connection to lay-down areas outside of
Site area will also be made by Contractor for Package P. Distribution within the lay-down areas
should be made then by individual Contractors. All these works are subject to approval by the
Engineer. The routes of underground service line shall be marked on the ground by the suitable
marker to be approved by the Engineer. Contractor shall provide water and electricity also for
Employers/Engineers Site Office.
Construction Site Lay-Out Drawing: Contractor shall prepare as-built drawings of the service
lines, which may be included in the Construction Site Layout of the Contractor showing all
temporary facilities of site and submit to the Engineer within two months of construction
commencement. He will be assisted by the Contractors of other areas for the facilities in their
areas.
Site Laboratory: Site Laboratory as specified under G5.4, Clauses 5.4, 7.5 and 9.10 shall be
supplied by Package P.
First-Aid Station: First-Aid Station as specified under G5.4, Clause 4 shall be supplied by
Package P.
Site Offices for Employer/Engineer: Complete operational Site office with air-conditioning, fully
furnished and equipped for Owner/Engineer will be arranged as a compound with the Site Offices
of Contractors, if possible from space point of view. The offices will be located either north of GTBuilding or south of Control Building/400kV Substation, depending on the final Layout.
Office space shall be provided as follows:
Meeting room 8x4m
Site Manager office with secretary office 8x4m
Photocopy and Record room 5x4m
nine (9) offices for two people each 5x4m
one toilet for ladies complete with toilet paper holder, soap spender, mirror etc,
one toilet with two cabins and two urinals with toilet paper holder, soap spender, mirror etc
one shower fully equipped
one fully equipped kitchen with table and chairs for 6 people to eat
one office for three people 7x4m
one managerial office 5x4m
one material sample room
Page: 30
Offices shall be built of solid temporary construction, type of which shall be approved by the
Employer/Engineer).
Contractor shall arrange the cabling for required numbers of telephone lines up to the sockets and
the sockets. Garbage disposal and septic tank disposal have to be undertaken by the Contractor.
Contractor is responsible for the demolishing and clearance of the site office if requested so by the
Employer.
Car park for Owner/Engineer: A paved and covered car park for 20 cars shall be provided
CNE/015/2002
P4
Technical Schedules
and
Data Sheets
WORKING DOCUMENT
Part P4 Technical Schedules and Data Sheets Working Doc.
Page: i
TABLE OF CONTENTS
TITLE
PAGE
PERFORMANCE AND GUAR ANTEE DATA.............................................................................. 1
GAS TURBINE UNITS AN D AUXILIARIES INCLUDING BYPASS STACK ............................. 9
HRSGS AND AUXILIARIES....................................................................................................... 27
AUXILIARY BOILERS................................................................................................................ 37
FUEL OIL STORAGE AND SUPPLY SYSTEM FOR GTS AND BOILERS............................. 47
GAS SYSTEMS FOR GAS TURBINES AND BOILERS........................................................... 57
STEAM TURBINE UNITS AND AUXILIARIES ......................................................................... 73
STEAM SYSTEMS..................................................................................................................... 87
CONDENSATE AND FEEDWATER SYSTEM .......................................................................... 89
CLOSED COOLING WATER SYSTEM ..................................................................................... 95
10 BLACK START / EMERGENCY POWER SUPPLY.................................................................. 97

11 INSTRUMENT AND SERVICE AIR SYSTEM ........................................................................... 99
12 NOT USED................................................................................................................................ 109
13 STEAM / WATER SAMPLING SYSTEM ................................................................................. 111
14 STEAM/WATER CIRCUIT CHEMISTRY/DOSING.................................................................. 113
15 DEMINERALISED WATER PLANT......................................................................................... 115
16 NOT USED................................................................................................................................ 123
17 CHEMICAL LABORATORY..................................................................................................... 125
18 WASTE WATER TREATMENT PLANT .................................................................................. 127
19 SEWAGE TREATMENT PLANT.............................................................................................. 131
20 SUMP PUMPS.......................................................................................................................... 133
21 CRANES AND HOISTS............................................................................................................ 135
22 WORKSHOP AND STORE EQUIPMENT ............................................................................... 159
23 STATION FIRE FIGHTING AND FIRE DETECTION SYSTEMS............................................ 161
24 HEATING, VENTILATION AND AIR CONDITIONING ........................................................... 165
25 EMISSION MONITORING SYSTEM........................................................................................ 195
26 ELECTRICAL EQUIPMENT ..................................................................................................... 201
27 I&C SYSTEMS.......................................................................................................................... 217
28 CIVIL WORKS .......................................................................................................................... 227
P4_Techn_Sched_Datasheets_Working_Doc.doc
Page: 1
PERFORMANCE AND GUARANTEE DATA
In general the Performance and Guarantee Data are specified in the Particular Technical
Specifications (Part P2) and the General Part G3.3.
The following Performance / Data Sheets shall be duly filled in by the Contractor.
Performance and Design Data
Item
0.1
0.2
DESIGN LIFETIME OF THE PLANT
Minimum
Requirements
Unit
Value/Description
30 years respectively
250,000 operation hours
GAS TURBINE GENERATOR UNITS

3
0.2.1
Number of gas turbine generator units
0.2.2
Type
Heavy Duty
0.2.3
Design
Package Units indoor

installation
0.2.4
Special features
-
Modulated inlet guide

vanes; dry low NO X
combustion, dual fuel
service
Base load, as well as

intermittent, as per
DEWA el. load profile
10,000
0.2.5
Operation mode
0.2.6
Minimum uninterrupted operation capability
0.2.7
Expected operation hours per year
h/a
8,000
0.2.8
Expected number of cold starts per year
-/a
100
0.2.9
Minimum of consecutive starts without cool

down of starting equipment
0.2.10 Critical speed outside the range
85 - 125 of nominal
speed
0.2.11 Number of cold starts GT / HRSG set
100
0.2.12 NOX - emission as NO 2 (at 15% O2 Vol. dry)

with natural gas firing and supplementary
firing in service
ppmvd
less than 25
0.2.13 NOX - emission as NO 2 (at 15% O2 Vol. dry)

with dry diesel oil firing
ppmvd
max. 200
0.2.14 CO content @ 15% O2
ppmvd
15
Bacharach
1-2
0.2.15 Smoke spot number (colourless)
Page: 2

Item
0.2.16 Mixed fuel operation at any proportion
0.3
Minimum
Requirements
Unit
Value/Description
h/a
Part G4
bar
Part G4
FUEL SPECIFICATION AT TERMINAL

POINT
0.3.1.1
Natural gas:
composition and heating value
pressure
0.3.1.2
Diesel oil
Part G4
specification
0.3.2
Maximum allowable sound pressure level
Part G4
0.3.3
Ambient conditions
Part G4
0.3.4
Ambient air quality
0.3.5
Air inlet filter
Part G4 and P2.1
Standard Coarse AC test dust
99.94
Standard Fine AC test dust
99.6
Filter medium face velocity
m/s
max. 1.5
0.3.6
Minimum lifetime for filter elements
years
0.3.7
Material of filter house without inlet air

cooling
painted carbon steel

with 5 years corrosion
resistance guarantee
0.3.8
Minimum wall thickness of ducts
mm
0.3.9
Material of frame for individual filter elements
0.3.5.1
Filtration efficiency (minimum):
0.3.5.2
stainless steel
0.3.10 Bypass stack

0.3.10.1
0.4
Minimum height
60 above ground level
GENERATORS
0.4.1.1
Guarantee and tolerance values of

generator
0.4.1.2
Rated voltage at generator terminals
in accordance with
IEC/VDE regulations
kV
as per generator rated

voltage level

Item
Page: 3
Minimum
Requirements
Unit
Value/Description
Hz
50
cos phi
0.8
0.4.1.3
Rated frequency
0.4.1.4
Rated power factor
0.4.1.5
Short-circuit ratio
0.4.1.6
Saturated subtransient reactance x"d

(without minus tolerance and at rated
generator output)
28 (including generator
transformer impedance)
0.4.1.7
Insulation class for generator and exciter
0.4.1.8
Permissible operation according to

insulation class
base load
peak load (if applicable)
B + 15K
0.4.1.9
Protection class of generator
IC8A1W7
0.4.1.10
Current transformer secondary rate
0.4.1.11
Voltage transformer secondary rate
110:3
ppmvd
max. 75
minimum 0.55
Definitions:
Rated generator output
defined to be at GT base-load design rating with fuel
gas at 50 C ambient air temperature, operation
within insulation class B limits and at rated power
factor (lagging) measured at generator terminals
0.5
AUXILIARY BOILERS
0.5.1
NOX - emission as NO 2 (at 3% O2 Vol. dry)

with natural gas firing
0.5.2
CO content (at 3% O2 Vol. dry)
mg / Nm 3
100
0.5.3
Smoke spot number (colourless)
Bacharach
0.5.4
Total Particulate Matter
mg / Nm 3
0.5.5
Number of cold starts for load operation

a
100
(not including starts for keeping the boilers

warm respectively under pressure)
0.6
NATURAL GAS CONDITIONS AT

TERMINAL
Page: 4

Item
Minimum
Requirements
Unit
Value/Description
0.6.1
Minimum gas pressure
bar(a)
21
0.6.2
Maximum gas pressure
bar(a)
50
0.6.3
Normal gas pressure
bar(a)
23
0.6.4
Minimum gas temperature
18
0.6.5
Maximum gas temperature
50
0.6.6
Normal gas temperature
18 - 32
bar(g)
50
0.7
DESIGN CRITERIA FOR NATURAL GAS

PIPING AND EQUIPMENT
0.7.1
Design Pressure
0.7.2
Design Temperature
80
0.7.3
Maximum velocity
m/s
20
0.7.4
Material according to
MR-00175-90
0.7.5
Corrosion allowance in carbon steel
mm
0.8
The impurities content

shall be in accordance
with the GTmanufacturer
requirements
NATURAL GAS QUALITY (IMPURITIES,

LIQUIDS, DROPLETS, ETC.) WITH THE
MINIMUM CONDITIONS
0.8.1
Particle size
0.8.2
Temperature
<2
>10 gas mixture dew

point and 15 above dew
point of water with more
than 10 ppm H2S
0.8.3
Pressure Tolerances by 10-100% of max

fuel flow rate
0.8.4
Pressure Tolerances by 0-10% of max fuel

flow rate
0.8.5
Pressure and Temperature requirements
0.9
NOISE LEVEL AT 1 M (MAX)
Gas Turbine
Manufacturer
dB(A)
85

Item
0.9.1
Noise limits at site boundary according to

environmental regulations
Page: 5
Minimum
Requirements
Unit
Value/Description
dB(A)
55 day / 45 night
0.10 STEAM TURBINE

Back pressure steam
turbine
0.10.1 Turbine type

0.10.2 Operation mode
Constant pressure
0.10.3 Turbine design
According to GT/HRSG
and desalination plant
requirements at any
ambient conditions;
0.10.4 Permissible deviations of live steam

pressure and live steam temperature
According to IEC
recommendations, latest
edition
0.10.5 Absorption /swallowing capacity at 100%

nominal live steam pressure, throughput ref.
MCR (Maximum Continuous Rating, i.e.
max. load demand of plant system plus all
MSF units at fouled conditions)
107
0.10.6 Permissible tolerance of absorption capacity
-0
0.10.7 Frequency
Hz
50
0.10.8 Permissible frequency deviations at MCR

0.10.8.1
without limitations
-5 to +3
0.10.8.2
maximum 20 minutes duration but not

exceeding 2 hours per year
-4
0.10.8.3

exceeding 1 hour per year
-5
0.10.9 The coupled critical speeds of the turbine

and generator rotors must lie outside the
range of the nominal speed
- 20 / + 25%
years
30
0.10.10
Following operating cases are to be
considered as minimum:
0.10.11
Operation time
0.10.12
Cold starts (ambient temperature)
per year
100
0.10.13
Cold starts (50 h standstill period)
lifetime
600
Page: 6

Item
Minimum
Requirements
Unit
Value/Description
0.10.14
Warm starts (8 h standstill period)
lifetime
5,000
0.10.15
Hot starts (2 h standstill period)
lifetime
2,000
bar (a)
2.3 0.2
- / C
dry / 132
t/h
for fouled conditions of

desalination plant
kVA
In accordance with the

consumer load, but min.
envisaged 1250 kVA
0.10.16
Max. overspeed in case of full load
rejection
0.10.17
Exhaust pressure at inlet MSF units
0.10.18
Exhaust steam conditions and
heating steam temperature at MSF units
0.10.19
Steam flow rate at MSF units
0.11 EMERGENCY DIESEL GENERATOR

0.11.1 Generator
0.11.2 Apparent power at guarantee site conditions
at generator terminals
0.11.3 Power factor
0.8
0.11.4 Generator cooling system
air
0.11.5 Frequency
Hz
50 (+ / - 5%)
6 terminals
0.11.6 Terminals
0.11.7 Voltage
400/230
0.11.8 Neutral
Neutral direct earthed
0.11.9 Voltage regulator variation
Automatic 10%
0.11.10
0.5
0.11.11
Transient/dynamic voltage variation
at 100% load rejection
+15
0.11.12
-10
0.11.13
Insulation class of generator and
exciter
0.11.14
insulation class
Static voltage variation
0.12 BLACK START DIESEL GENERATOR
Page: 7
Minimum
Requirements
Item
Unit
Value/Description

kVA
In accordance with the

consumer load
0.12.3 Power factor
0.8
Air, totally enclosed
Hz
50 (+ / - 5%)
0.12.1 Generator
0.12.5 Frequency
6 terminals
0.12.6 Terminals
0.12.7 Voltage
kV
11
0.12.8 Neutral
Automatic 10%
0.12.10
0.5
0.12.11
+15
0.12.12
-10
0.12.13
exciter
0.12.14
insulation class
0.13 VIBRATIONS
0.13.1 Vibrations after commissioning shall not
exceed the ISO 10816 respectively ISO
7919 Standards
Zone A
Page: 9
GAS TURBINE UNITS AND AUXILIARIES INCLUDING BYPASS STACK

GAS TURBINE GENERATOR UNITS (GTG)
1.1
Unit
Value/Description
----------

GENERAL
1.1.1
Number of gas turbine generator units
1.1.2
Type
Heavy duty
1.1.3
Design
Package units indoor

installation
1.1.4
Special features
Modulated inlet guide

vanes; dry low NOx
combustion, dual fuel
service
1.1.5
Operation mode
Base load, as well as

intermittent, as per
DEWA el. load profile
1.1.6
Minimum uninterrupted operation capability
Later
1.1.7
Expected operation hours per year
h/a
8,000
1.1.8
Expected number of starts per year
-/a
100
1.1.9
Minimum of consecutive starts without cool

down
Later
%
Later
1.1.11 NOx - emission as NO 2 (at 15 % O2 Vol. dry)

with fuel gas (with and without
supplementary firing)
mg/Nm
52
1.1.12 NOx - emission as NO 2 (at 15 % O2 Vol. dry)

with diesel oil firing (without supplementary
firing)
mg/Nm
1.1.10 Critical speed outside the range
1.1.13 Smoke spot number
@50degC,Baseload
87
@50degC,Baseload
Bacharach
Later
1.1.14 Fuel specification at terminal point
----------
1.1.14.1
----------
Natural gas:
composition and heating value
pressure
1.1.14.2
Diesel oil
specification
Tab 3.1
bar
Tab 3.1
----------
Tab 3.1
1.1.15 Maximum allowable sound pressure level
Tab 3.1
1.1.16 Ambient conditions
Tab 3.1
Page: 10

1.1.17 Ambient air quality
Unit
Value/Description
Tab 3.1
1.1.18 Air inlet filter
----------
1.1.18.1
----------
1.1.18.2
Filtration efficiency (minimum):

Standard Coarse AC test dust
Later
Standard Fine AC test dust
Later
m/s
Approx. 640
years
Later
Later
mm
Later
Filter medium face velocity
1.1.19 Minimum lifetime for filter elements

1.1.20 Material of filter house
1.1.21 Minimum wall thickness of ducts
Later
1.1.22 Material of frame for individual filter elements
----------
1.1.23 Bypass stack

1.1.23.1
Minimum height
60
----------
1.1.24 Generator
Later
1.1.24.1
Guarantee and tolerance values of

generator
1.1.24.2
Rated voltage at generator terminals
kV
15.75
1.1.24.3
Rated frequency
Hz
50
1.1.24.4
Rated power factor
cos phi
0.80(Lagging)
1.1.24.5
Short-circuit ratio
1.1.24.6
Saturated subtransient reactance x"d

(without minus tolerance and at rated
generator output)
Later
1.1.24.7
Insulation class for generator and exciter
Class F
1.1.24.8

insulation class
0.55
----------
base load
Class F
peak load (if applicable)
N/A
Protection class of generator
Later
1.1.24.10 Current transformer secondary rate
Later
1.1.24.11 Voltage transformer secondary rate
Later
1.1.24.9

Definitions:
Rated generator output
defined to be at GT base-load design rating with fuel
gas at 50 C ambient air temperature, operation
within insulation class B limits and at rated power
factor (lagging).
- Auxiliary transformer 11/0.4 kV
-LV unit boards
-MV Switchboard for start-up system
Batteries, rectifiers, inverters and associated
switchgear
Unit
Page: 11
Value/Description
Page: 12
GAS TURBINE AND GENERATOR

1.2
Unit
Value/Data
----------
GUARANTEES
General Guarantees*)
----------
3300(Trip speed)
1.2.1
Maximum increase in running speed in case

of a sudden total or partial load reduction
1.2.2
Maximum overall peak-to peak unfiltered

amplitude of vibration of the gas turbine
Later
1.2.3
Maximum overall peak-to- peak unfiltered

amplitude of vibration of the generator
Later
Later
Guarantee and tolerance values of generator
1.2.4
Maximum achieved sound pressure level

around the entire GTG-package, measured
at 1m distance and 1m height above
installation level
1.2.5
Special Guarantees
Operation at max. ambient air data, base
load, open cycle
dB(A)
85
----------
1.2.5.1
Ambient air temperature
50
1.2.5.2
Relative humidity
34
1.2.5.3
Site barometric pressure
mbar
10.0
1.2.5.4
Outlet pressure losses
mbar
43.5
Operation mode
100% base load
Fuel
Nat. gas
Diesel
MJ/kg
45.225
42.692
----------
----------
1.2.5.5
LHV of fuel
1.2.5.6
Performance data (each gas turbine

generator package)
Gross power output (generator
terminals)*)
kW
183,000
196,500
Auxiliary power consumption (gas

turbine generator package)
kW
1,473
4,859
Net power output
kW
181,527
191,641
Gross fuel heat rate*)
kJ/kWh
10,897
11,450
Net fuel heat rate
kJ/kWh
10,985
11,741
GAS TURBINE AND GENERATOR
Unit
Value/Data
649.0
644.0
Total pressure loss combustion-air

inlet (clean filter)
mbar
10
10
Total pressure loss exhaust gas outlet
mbar
37
40
NOx - emission of flue gas (at 15% O2

content)*)
mg/Nm
52
87
CO- emission of flue gas (at 15% O2

content)*)
mg/Nm
13
15
SOx - emission of flue gas (at 15% O2

content)*)
mg/Nm
168
Bacharach
mg/Nm
Smoke spot number*)

Maximum particulates in flue gas*)
1.2.6
Page: 13
----------
Criteria for rejection
At deterioration of the guaranteed values by more

than:
----------
1.2.6.1 Gross power output (generator terminals)

at natural gas and diesel oil operation
(see G3.3)
+3
1.2.6.2
Gross fuel heat rate at natural gas and

diesel operation (see G3.3)
-5
1.2.6.3
Fuel gas emission values at natural gas

and diesel oil operation (see G3.3)
mg/Nm
+0
Note: Data marked with *) are guaranteed values
Page: 14
Unit

1.3
Value/Data
----------
GAS TURBINE
1.3.1
Model/Type
PG9351FA / Heavy Duty
1.3.2
Standards to which gas turbine will be

manufactured
Tab 2.1
1.3.3
Air mass flow at 15,1013 mbar inlet

conditions
kg/s
643.1
1.3.4
Maximum continuous power demand for

auxiliaries:
----------
1.3.4.1
at base load
gas fuel/ diesel fuel
kW
1,473 / 4,859
1.3.4.2
at start up
kW
11,848 / 15,234
1.3.5
Allowable fluctuation of the Wobbe -Index

of the fuel gas
+%
Later
1.3.6
Required supply pressure/temperature of

the fuel gas (at package flange)
bar/C
28.0 / 185
1.3.7
Required supply pressure of the diesel fuel

(at package flange)
bar
28.0
1.3.8
Pressure ratio of air compressor (ISO nat.

gas)
1.3.9
Turbine inlet temperature (ISO) at:
15.4
----------
1.3.9.1
base load
C/C
Later
1.3.9.2
start up
C/C
Later
Unit
Value/Data
1.3.10 Operation at design ambient air data,

natural gas firing, base load
----------
Conditions:
----------
1.3.10.1
Inlet/exhaust pressure losses

Relative humidity
mbar
10.0 / 53.8(ISO)
34
1.013
Natural Gas
Fuel
LHV of fuel
Operation mode
MJ/kg
45,225
100% base load

Ambient temperature
Page: 15
Unit
Value/Data
50
40
35
25
15
10^3 kW
212.0
227.8
235.1
248.3
258.1
kW
1473
1473
1473
1473
1473
210.5
226.3
233.6
246.8
256.6
10534 10267 10164
10010
9902
kg/s
583.6
613.6
626.9
651.1
671.9
Performance data:
1.3.10.2

terminal)
1.3.10.3
Auxiliary power consumption
1.3.10.4
Net power Output
10^3 kW
1.3.10.5
Net fuel heat rate
kJ/kWh
Exhaust data:
1.3.10.6
Exhaust mass flow
1.3.10.7
631.7
621.1
616.7
609.4
598.9
1.3.10.8
Exhaust gas specific heat
kJ/kgK
Later
Later
Later
Later
Later
1.3.10.9
NOX
ppm(vd)
25
25
25
25
25
1.3.10.10 CO
ppm(vd)
15
15
15
15
15
1.3.10.11 SOX
ppm(vd)
12
12
12
12
12
1.3.10.12 Smoke spot Number
Bachara
ch
1.3.10.13 CO2
%Vol
3.9
3.9
3.9
3.9
3.9
1.3.10.14 O2
%Vol
11.8
12.2
12.3
12.4
12.6
1.3.10.15 N2
%Vol
71.5
72.8
73.3
74.0
74.5
1.3.10.16 H2O
%Vol
11.9
10.2
9.6
8.7
8.1
1.3.10.17 Ar
%Vol
0.86
0.87
0.88
0.88
0.90
1.3.11 Operation at design ambient air data,

diesel oil firing, base load
----------
Conditions:
mbar
10.0 / 53.8(ISO)
Relative humidity
34
bar
1.013
1.3.11.1 Inlet/exhaust pressure losses
Diesel Oil
Fuel
LHV of fuel
MJ/kg
42,692
Page: 16
Unit
Value/Data
100% base load
Operation mode
Ambient temperature
50
40
35
25
15
Performance data:
1.3.11.2

terminal)
10^3
kW
141.2 154.0 160.6
174.1 185.5
1.3.11.3
Auxiliary power consumption
kW
4859
4859
1.3.11.4
Net power Output
10^3
kW
136.3 149.1 155.7
169.2 180.6
1.3.11.5
Net fuel heat rate
kJ/kWh
1228
3
1097
7
4859
1173
1
4859
1146
7
4859
1067
0
Exhaust data:
kg/s
582.2 611.9 625.0
648.3 668.9
526.1 513.9 508.3
497.2 490.6
1.3.11.8
Exhaust gas specific heat
kJ/kgK
Later
Later
Later
Later
Later
1.3.11.9
NOX
ppm(vd
)
153
190
205
226
237
1.3.11.10 CO
ppm(vd
)
23
22
22
22
22
1.3.11.11 SOX
ppm(vd
)
273
273
273
273
273
1.3.11.12 Smoke spot Number
Bachar
ach
1.3.11.13 CO2
%Vol
3.9
3.9
3.9
3.9
4.0
1.3.11.14 O2
%Vol
14.0
14.3
14.5
14.6
14.7
1.3.11.15 N2
%Vol
72.9
74.3
74.8
75.5
76.0
1.3.11.16 H2O
%Vol
8.4
6.6
6.0
5.1
4.5
1.3.11.17 Ar
%Vol
0.86
0.90
0.89
0.91
0.90
1.3.11.6
Exhaust mass flow
1.3.11.7
----------
1.3.12 Starting and loading times:

1.3.12.1
Starting time from cold start to

synchronizing
1.3.12.2 Normal time from synchronizing to base

load
min
Later
min
Later
Page: 17
Unit
Value/Data
1.3.12.3
Fast time from synchronizing to base

load
min
Later
1.3.12.4
Necessary time from full trip to restart
min
Later
1.3.12.5
Rate of normal loading
MW/mi
n
Later
1.3.12.6
Rate of fast loading
MW/mi
n
Later
----------
1.3.13 Turbine speeds:

1.3.13.1
Compressor washing
rpm
Later
1.3.13.2
Purging of waste heat recovery boiler
rpm
Later
1.3.13.3
Ignition
rpm
420
1.3.13.4
Rated speed
rpm
3,000
1.3.13.5
Over-speed trip
----------
electrical
rpm
3,300
mechanical
rpm
3,300
1.3.13.6
Turning gear speed
rpm
1.3.13.7
Critical speed
1.3.13.8
----------
first
rpm
1,014
second
rpm
1,691
----------
Fuel pressure at burner trip:

Natural gas
barg
28.0(min) / 32.8(max)
@ GT fuel control valve inlet
Diesel
barg
----------
1.3.14 Combustion system:

1.3.14.1
Type of combustion
1.3.14.2
Combustion chamber heat release per

unit volume
1.3.14.3
No. of burners per combustion chamber
1.3.14.4
Type of burners
1.3.14.5
Material of:
Combustion chamber
Later
Can annular reverse flow

kJ/m/s
Later
5
Later
---------Later
Page: 18
Unit
Value/Data
Flame tube
Later
1.3.14.6
Type of igniter
Spark Plug
1.3.14.7
Type of flame scanners
1.3.14.8
No. of flame scanners
Reuter Stokes
4
----------
1.3.15 Compressor materials:

1.3.15.1
Stage 0 8 : C-450
Stationary vanes
Stage 9-17 : AISI-403 + Cb
1.3.15.2
Stage 0 8 : C-450
Rotating blades
Stage 9-17 : AISI-403 + Cb
1.3.15.3
Coating of compressor blades
N/A
1.3.15.4
Number of compressor stages with

coating
N/A
1.3.15.5 Material compressor rotor
Later
1.3.15.6 Material casing
Later
1.3.16 Turbine materials:
----------
1.3.16.1 Stationary vanes
1 : FSX-414
St
nd
1.3.16.2
St
1 : DS-GTD-111
Rotating blades
nd
1.3.16.3
rd
and 3 : GTD-222
rd
and 3 : GTD-111
----------
Coating of turbine blades

1st stage
GE proprietary coating
2st stage
3st stage
4st stage
N/A
1.3.16.4 Material rotor
Later
1.3.16.5 Material casing
Later
1.3.16.6 Material insulation
Later
For details, refer to the attached
documents in Tab 6.2.
(GER-3620G)
1.3.17 Expected life time:
1.3.17.1
Combustion liner
hours
40,000

1.3.17.2
Transition piece
Unit
Value/Data
hours
40,000
----------
1.3.17.3 Stationary turbine vanes:
1.3.17.4
Page: 19
1st stage
hours
48,000
2st stage
hours
48,000
3st stage
hours
72,000
4st stage
hours
N/A
----------
Rotating turbine vanes:

1st stage
hours
72,000
2st stage
hours
24,000
3st stage
hours
24,000
4st stage
hours
N/A
1.3.17.5
Stationary and rotating compressor

blades
hours
Refer to Tab 6.2.

(GER-3620G)
1.3.17.6
Fuel nozzles
hours
24,000
1.3.17.7
Equivalent operating hours
----------
For one normal start
hours
Tab 6.2.
(GER-3620G)
For one fast start
hours
Tab 6.2.
(GER-3620G)
1.3.17.8
Factor of equivalent operation hours for

diesel base load operation
Tab 6.2.
(GER-3620G)
1.3.17.9
Factor of equivalent operation hours for

peak load (nat. gas)
Tab 6.2.
(GER-3620G)
1.3.17.10 Factor of equivalent operation hours for

full load trip
Tab 6.2.
(GER-3620G)
1.3.17.11 Factor of equivalent operation hours for

fast loading
Tab 6.2.
(GER-3620G)
----------
1.3.18 Major Inspection/Overhaul

1.3.18.1
Inspection interval
hours
48,000
1.3.18.2
Inspection duration
days
Later
1.3.18.3
No. of man hours
hours
Later
1.3.19 Combustion chamber inspection
----------
Page: 20
Unit
Value/Data
1.3.19.1
Inspection in equivalent operation

hours
hours
8,000
1.3.19.2
Inspection duration of inspection
days
Later
1.3.19.3
No. of man hours per inspection
hours
Later
----------
1.3.20 Hot gas path inspection

1.3.20.1
Inspection in equivalent operation hours
hours
24,000
1.3.20.2
Inspection duration of inspection
days
Later
1.3.20.3
No. of man hours per inspection
hours
Later
----------
1.3.21 Main dimensions of complete gas turbine

generator set
1.3.21.1
Total length
Approx. 35
1.3.21.2
Total width
Approx. 10
1.3.21.3
total height
Approx. 11
1.3.21.4
Heaviest lift for erection
288
----------
1.3.22 Enclosure of gas turbine and generator

1.3.22.1
Type
1.3.22.2
Manufacturer
1.3.22.3
No. of compartments
1.3.22.4
Max sound pressure level at 1m

distance
1.3.22.5
Insulation material
1.3.22.6
Width of internal walk way
1.3.22.7
Overall size L/W/H
1.3.22.8
Frames/Panels material
1.3.22.9
Panel weight (each)
1.3.22.10 No. of air charges per hour
Waterproof
Later
2
dB(A)
85
Later
Later
m/m/m
19.2 / 9.8 / 10.4

Later
kg
Later
/h
Later
1.3.22.11 Type of fire detection and extinguishing

system
Fixed type temperature sensors
1.3.22.12 Lifting device inside enclosure (yes/no)
yes
1.3.23 Bearings
1.3.23.1 Types of bearings
/ Low pressure CO2
---------Radial type(2) : Tilt pad

Thrust type(1) : Tilt pad

1.3.23.2
Unit
Page: 21
Value/Data
2
No of bearings
----------
1.3.24 Load coupling

1.3.24.1
Type
Rigid
1.3.24.2
Manufacturer
Later
1.3.24.3
Max. allowed transmitted load
kW
Later
1.3.24.4
Max allowable torque
Nm
Later
----------
1.3.25 Lube oil system

1.3.25.1 Tank capacity
liters
23470
AC : Main / Auxiliary oil pump
1.3.25.2 Lube oil drive AC/DC
DC : Emergency oil pump
1.3.25.3
Vapor extractor fan rating
1.3.25.4
Vapor separator
1.3.25.5
No installed
1.3.25.6
Type
1.3.25.7
oil filter
kW
---------1
Later
----------
Manufacturer
Later
Type
Later
Number and capacity of filters
/%
2 / 100%
Bata 41 = 200
Grade of filtration
1.3.25.8
5.6
----------
Lube oil cooler
Later
Manufacturer
Plate and flame
Type
Later
Cooling media
Number and capacity of coolers
/%
2 / 100%
Cooling surface per cooler
Later
m/m
Later
Cooler length/Diameter
Materials :
-
tubes/tubesheet
Boxes/shell
1.3.26 Turbine governor
---------Stainless
Later
----------
Page: 22

1.3.26.1
Type
1.3.26.2
Response time
Unit
Value/Data
Later
ms
Later
1.3.27 Starting system
----------
1.3.27.1 Type of starting equipment (static

frequency converter, etc
----------
Response time
ms
GE
Manufacturer
Load commutating inverter (LCI)

frequency drive
Type
1.3.27.2
----------
Transformer
Later
Manufacturer
ONAF/ONAN
Type of cooling
MVA
350
Ratio
kV/kV
420/15.75
Taps
+%
Later
Rated capacity
1.3.27.3
----------
Switchgear
Manufacturer
Later
Type
Later
Rated voltage
kV
Later
Rated current
Later
kA
Later
Short time withstand current (3)

Number of cubicles
Later
Place and type of installation

(Container or sep. room)
Later
Max power consumption during

starting
1.3.27.4
Later
Turning gear
Manufacturer
Type
kW
Later
---------Later
Motor driven
1.3.28 Air inlet system
----------
1.3.28.1
----------
Air filter house
Unit
Value/Data
Later
Manufacturer
Inlet suction height above ground
Page: 23
22
Material of filter house
Later
Internal coating of filter house
Later
----------
1.3.28.2 Inlet air filtration

Type of air filter system
Later
Manufacturer
Later
Type of pre/ main filter
Self-cleaning, single-stage
No. of filter elements:
----------
pre filter
N/A
main filter
Later
Area of filtration one main filter

Media face velocity
Efficiency of filter
Later
m/s
Later
Later
----------
Particle size removed:

-
greater than 10 m
Later
greater than 5 m
Later
greater than 2 m
Later
----------
pressure loss at base load, 50C,

nat. gas
minimum (clean filter)
mbar
37.4
average (half cleaning period)
mbar
Later
maximum (alarm value)
mbar
Later
min
Later
Duration of cleaning period/section
Later
Average number of cleaning periods

per day
Nm/h
Later
Compressed air pressure required
bar
Later
Volume / number of compressed air

tanks
m/
Later
Compressed air demand during

cleaning period
Page: 24
Unit
Value/Data
Cross section of duct
m/m
Later
Plate thickness
mm
Later

1.3.28.3
1.3.28.4
Air inlet ducting
Material of duct
Later
Cladding of duct
Later
----------
Inlet air cooler

Type of cooler
Evaporative cooler
Manufacturer
Later
Temperature difference at base load,

50C ambient Temp., 34% rel.
humidity ; (ambient/downstream)
Water demand at above conditions
Later
m/h
Later
----------
Type of water used for evaporation:

-
1.3.28.5
Later
demineralised water/ potable

water
----------
Air Inlet Silencer

Type of silencer
Later
Manufacturer
Later
Material for sound absorption
Later
Sound power level at the air inlet
dB(A)
Later
Pressure loss at base load, 50C,

natural gas
mbar
Later
Velocity at GT base load between

the baffles
m/s
Later
----------
1.3.29 Exhaust gas systems

1.3.29.1
Design pressure
bar
25
1.3.29.2
Design Temperature
630
1.3.29.3
Max. allowable time for operation at

peak temperature/peak temperature
min/C
N/A
1.3.29.4
Insulation type, external/ internal
1.3.29.5
Material of diffuser part
C.S.
1.3.29.6
Material of ductwork
C.S.
Rineral wool (Internal)
Page: 25
Unit
Value/Data
1.3.29.7
Corrosion allowance
mm
1.3.29.8
Plate thickness
mm
1.3.29.9
Size of ductwork at diffuser exit
m/m
6,800 x 6,800
m/s
Later
1.3.29.10 Flue-gas velocity at diffuser excit at

base load 50C
Downstream
1.3.29.11 Location of silencer: Upstream/

Downstream of diverter
----------
1.3.29.12 Flue gas silencer

Type of silencer
Stack
Manufacturer
Y.B.D
No
Exchangeable baffles, yes/no

Size and weight of each baffle
m/m/t
Later
Later
Material for sound absorption

dB(A)/d
B(A)
Later
Pressure loss at base load, 50C,

natural gas
mbar
Later
Velocity at GT base load between

the baffles
m/s
Later
Noise power level before/behind

silencer, at base load, 50C, natural
gas
----------
1.3.29.13 Diverter
Single flap toggle drive
Type of diverter
NPS
Manufacturer
Size of diverter flap
Weight of flap
Material of flap
Type of diverter drive
m/m
Later
Later
Later
Hydraulic
Type of flap sealing
Later
Type of seal cooling
Later
Material of sealings
Later
Page: 26
Unit
Value/Data
Later
(Restricted
intermediate
operation)
Possible positions (intermediate

between open /close) for the diverter
flap at base load, , Grad from
horizont.
Time for opening (flow to HRSG) at
base load, 50C (full swing), /closing
min
Later
Number and capacity of seal air

compressors
-/%
1x100%
m/m/t
Later
kW
Later
Size and weight of blanking plate

Power of electrical drive for
installation of blanking plate
----------
1.3.29.14 Bypass stack
Y.B.D.
Manufacturer
Height above ground level
60
Diameter
7.49
m/s
Later
Velocity at exhaust gas outlet, base

load
Internal
Material Insulation Internal/external

Wall thickness max/min
Corrosion allowance
1.3.30 Generator
see Electrical Data Sheets
mm/m
m
Min.8
mm
0
----------
Page: 27
HRSGS AND AUXILIARIES

Item
2.1
Unit
Value/Description
GENERAL INFORMATION
Single Pressure
2.1.1
Type
2.1.2
Manufacturer
2.1.3
Gas Flow Type (horizontal / vertical)
2.1.4
Evaporator Circulation (natural / force)
Natural
2.1.5
Design code for pressure parts
ASME
2.1.6
Design code for steel structure
AISC, DIN
2.1.7
Independent Inspection Authority
2.2
NEM or equiv.
Horizontal
(expected)
BASE LOAD PERFORMANCE DATA
2.2.1
HP steam flow
Kg/s
132.1
2.2.2
HP SH outlet pressures
Bar
88.5
2.2.3
HP SH outlet temperatures
561.8
2.2.4
HP Drum Pressure
Bar
98.4
2.2.5
Feedwater inlet temperature

(economiser inlet)
127.2
2.2.6
HP continuous blow down
Kg/s
1%
2.2.7
Average circulation ratio of the

HP evaporators
Later
2.2.8
Gas temperature at HRSG outlet
146.3
2.2.9
Pinch point (HP)
13.8
M/s
10
2.2.11 Approach Temperature

(evap. temp. econ. outlet)
16.5
2.2.12 Gas side pressure loss total

(from HRSG inlet to stack outlet)
Pa
3,736
2.2.10 Max. gas velocity in the HRSG
2.3
2.3.1
OPERATION CHARACTERISTICS
Cold start
Per
year
Page: 28
Item
Unit
Value/Description
2.3.1.1
Time from HRSG start-up to base load
Minute
s
Later
2.3.1.2
Max. allowable temperature gradient
K/min.
Later
2.3.1.3
HP drum temperature before start
Later
2.3.2
Warm start (after 8 hours shut-down)
per
year
Minute
s
Later
HP drum temperature before start-up
Later
2.3.2.3
HP drum pressure before start-up
Bar
Later
2.3.2.4
K/min.
Later
2.3.2.1
2.3.2.2
2.3.3
Hot start (after 2 hours shut down)
per
year
2.3.3.1
Minute
s
Later
2.3.3.2
K/min
Later
2.3.3.3
HP drum temperature before start-up
Later
2.3.3.4
HP drum pressure before start-up
Bar
Later
2.4
Deaerator EVAP:
2,851 m 2
SIZE OF CONVECTIVE HEATING

SURFACE
2.4.1
FWT Heater (if required)
m2
N.A.
2.4.2
HP Economiser
m2
3,888.3
2.4.3
HP Evaporator
m2
17,123
2.4.4
HP Superheater
m2
8,686
2.5
PRESSURE PARTS
2.5.1
HP drum
2.5.1.1
Material
2.5.1.2
Dimensions
(diameter x wall thickness x length)
2.5.1.3
Volume
SA299
mm x
mm x
mm
2,900x130x12,500
M3
73
Page: 29
Item
Unit
Value/Description
2.5.1.4
Retention Time at Base Load
Minute
s
=3
2.5.1.5
Steam space rating
m 3 /m 2
s
Later
2.5.1.6
Design pressure
Bar(g)
122
2.5.1.7
Design temperature
326
2.5.1.8
Manholes (number/size)
mm
2 / 350x450
2.5.1.9
Type of steam / water separators
2.5.1.10
Time to empty the drum MCR
2.5.2
Tube material
2.5.2.2
Fin material
2.5.2.3
Fin density
2.5.2.4
Material of inlet/outlet header
SA-210-A1
CS
1/m
278
SA-106Gr.B/SA-106Gr.B
HP Evaporator
2.5.3.1
Tube material
2.5.3.2
Fin material
2.5.3.3
Fin density
2.5.3.4
2.5.4
Later
HP Economiser
2.5.2.1
2.5.3
Primary: Plate Type

Secundary: Chevron
SA-210-A1
CS
1/m
125-278
SA-106Gr.B/SA-106Gr.B
HP Superheater
Bar(g)
122
473-596
2.5.4.1
Design pressure
2.5.4.2
Design temperature
2.5.4.3
Tube material
2.5.4.4
Fin material
2.5.4.5
Fin density
1/m
230-278
2.5.4.6
Pressure loss across the superheater
bar
Design Case 8.0
2.5.4.7
2.5.5
T11, T22, T91

T409
P11,P22,P91/
P11,P22,P91
Attemperator
2.5.5.1
Type
2.5.5.2
Injection Water Temperature
Spray
C
292(Design Case)
Page: 30
Item
Unit
Value/Description
2.5.5.3
Water injection flow at full load
kg/s
13.6
2.5.5.4
Water injection points
2.6
Upstream SH3
HP PIPEWORK
2.6.1
Steam Pipework from HRSG Outlet to

Common Header
SA335-P91
2.6.1.1
Material
2.6.1.2
Dimension(diameter x wall thickness)
mm x
mm
457/Later
2.6.1.3
Design pressure
Bar(g)
110
2.6.1.4
Design temperature
569
2.6.1.5
Steam velocity at baseload
M/s
Later
2.7
N.A.
HP BOILER CIRCULATING PUMPS

(IF REQUIRED)
2.7.1
Type
2.7.2
Number
2.7.3
Discharge flow
2.7.4
N.A.
-
N.A.
Kg/s
N.A.
Discharge pressure (pump head)
N.A.
2.7.5
NPSH required
N.A.
2.7.6
Material of:
N.A.
2.7.6.1
Casing
N.A.
2.7.6.2
Impeller
N.A.
2.7.6.3
Shaft
N.A.
2.7.7
2.8
N.A.
Cooling water required (yes / no)
SAFETY VALVES
2.8.1
HP Drum Safety Valves

Spring Loaded
2.8.1.1
Type
2.8.1.2
Number
Nos.
2.8.1.3
Discharge capacity of each
Kg/s
Later
Item
2.8.2
Unit
Page: 31
Value/Description
Spring Loaded
HP Superheater Safety Valves
Spring Loaded
2.8.2.1
Type
2.8.2.2
Number
Nos.
2.8.2.3
Discharge capacity of each
Kg/s
Later
2.9
HP BLOW-OFF VALVE
2.9.1
Manufacturer
Later
2.9.2
Type
6 CV
2.9.3
Capacity
kg/s
Later
kg/s
Later
2.10 FEEDWATER CONTROL VALVES

(1 X 30%)
2.10.1 Start-up Valve
2.10.1.1
Capacity
2.10.1.2
Actuator type
2.10.1.3
Number and size
Later
2.10.1.4
Nominal diameter
mm
Later
kg/s
Later
Later
2.10.2 Full Load Valve (2 x 100%)

2.10.2.1
Capacity
2.10.2.2
Actuator type
2.10.2.3
Number and size
Later
2.10.2.4
Nominal diameter
mm
Later
Later
2.11 HP STEAM STOP VALVES

Gate
2.11.1 Type
2.11.2 Size of steam stop valves
mm
457
2.11.3 Size of bypass valve
mm
N.A.
2.12 SILENCERS
2.12.1 For HP drum safety valves
Page: 32
Item
2.12.1.1
Type
2.12.1.2
Number
2.12.1.3
Sound pressure level in 1 m distance
Unit
Value/Description
Later
1x
dB(A)
115
2.12.2 For HP SH Safety Valves

Later
2.12.2.1
Type
2.12.2.2
Number
nos.
1x
2.12.2.3
dB(A)
115
2.12.3 For HP Blow-off Valve

2.12.3.1
Type
2.12.3.2
Number
2.12.3.3
Later
Nos.
1x
DB(A)
115
1x
Later
Kg/s
Later
Later
2.13 BLOW-DOWN VESSEL

2.13.1 Number
2.13.2 Total volume
2.13.3 Design blow-down inlet flow
2.13.4 Design blow-down inlet temperature
Later
2.13.5 Material of shell/heads
2.14 BLOW-DOWN PUMPS

(IF REQUIRED)
Centrifugal
2.14.1 Type
-
2x100%
Kg/s
Later
2.14.4 Discharge pressure (pump head)
Later
2.14.5 NPSH required
Later
2.14.2 Number
2.14.3 Discharge flow
2.14.6 Material of:
Later
2.14.6.1
Casing
Later
2.14.6.2
Impeller
Later
2.14.6.3
Shaft
Later
Item
Unit
Page: 33
Value/Description
Later
2.14.7 Cooling water required (yes / no)
2.15 STEEL STRUCTURE

AISC/DIN
2.15.1 Design code for static calculation

2.15.2 Material of main structural members
S355
2.15.3 Method of fixing structural members
Bolts
Paint/Grease
2.15.4 Method of protection against corrosion of

bolts
2.16 PLATFORMS, STAIRS, GALLERIES

2.16.1 Design load
N/m 2
3000
Structures:Painting
Gratings:Galvanised
2.16.2 Method of corrosion protection
2.17 HEAT EXCHANGER CHAMBER
N.A.
2.17.1 Material < 400 C
N.A.
2.17.2 Wall thickness
Mm
N.A.
2.17.3 Material 400 C

N.A.
Mm
N.A.
N.A.
2.17.5 Special provision against low temperature

corrosion
2.18 EXHAUST GAS DUCTS

CS
2.18.1 Material
2.18.2 Type of expansion joints
Fabric
2.18.3 Material of expansion joints
Fabric
2.19 MAIN STACK

2.19.1 Height above 0 / cylindrical length
2.19.2 Material of shell
2.19.3 Corrosion protection (inside paint)
M/m
60M
CS
Transport Primer
Page: 34
Item
Unit
Value/Description
2.19.4 Dimension of shell (diam. x wall thickness)
Mm x
mm
Later
175
2.19.5 Design temperature
N.A.
2.19.6 Application of insulation outside

2.19.7 Outlet temperature of main stack
146
2.19.8 Flue gas outlet velocity
M/s
20

2.20.1 HRSG
2.20.1.1
Material of insulation
Carbo Wool/
Basalt Wool
2.20.1.2
Material of lagging
AISI 409/CS
2.20.1.3
Thickness of lagging
Mm
2.0/1.5
2.20.2 Ducts
2.20.2.1
Carbo Wool/
Basalt Wool
2.20.2.2
Material of lagging
AISI 409/CS
2.20.2.3
Mm
2.0/1.5
2.20.3 Piping
Calcium Silicate/
Mineral wool blanket
2.20.3.1 Material of insulation

2.20.3.2
Material of lagging
2.20.3.3
Aluminium
Mm
0.8, 1.0, 1.2
2.21 SUPPLEMENTARY FIRING EQUIPMENT

2.21.1 Burner
2.21.1.1
Type
2.21.1.2
Manufacturer
2.21.1.3
Number of burners
2.21.1.4
NG pressure before burner
2.21.1.5
2.21.1.6
Grid Burner
Later
nos.
Later
Bar(g)
2.0
Max. NG Flow
kg/s
Later
Max. Thermal Power
MW th
157
Item
Unit
Page: 35
Value/Description
2.21.2 Igniter
2.21.2.1
Type
Later
2.21.2.2
Manufacturer
Later
2.21.3 Control System

2.21.3.1
Type
Later
2.21.3.2
Manufacturer
Later
2.21.3.3
Method of flame supervision
Flame Scanners
2.21.4 Gas Control Valve Station

2.21.4.1
Manufacturer
Later
2.21.4.2
Type
Later
2.21.4.3
Turn down ratio
1:10
Page: 37
AUXILIARY BOILERS
Item
3.1
Value/Description
Nos.
Two(2)
GENERAL INFORMATION
3.1.1
Number of ABs
3.1.2
Type
3.1.3
Manufacturer
3.1.4
Overall Design Code
3.1.5
Independent Inspection Authority
3.2
Unit
Single Drum, Radiant

ANSALDO or equivalent
ASME and equivalent
To be finalised during the
Contract
PERFORMANCE DATA
(CASE 1, NATURAL GAS )
3.2.1
SH steam flow
kg/s
152.8(550 T/h)
3.2.2
SH steam pressures at turbine stop valve

inlet
bar
85
3.2.3
SH steam temperatures at turbine stop

valve inlet
560
3.2.4
Feedwater inlet temperature (economizer

inlet)
125
3.2.5
Drum pressure
bar
93
3.2.6
Pressure drop across the superheater
bar
3.2.7
Total pressure drop in the boiler
bar
3.2.8
Flue Gas temperature at AB outlet for NG
190
3.2.9
Max. gas velocity in the AB
m/s
30
3.2.10 Air and gas side pressure loss total

(Counted from FD-fan inlet downstream to
chimney outlet)
Pa
528
3.2.11 AB efficiency (HHV base) for Diesel Oil

firing
3.2.12 AB efficiency (LHV base) for DO
91.7
3.2.13 Flue gas exit temperature when firing DO
205
3.2.14 Oxygen content in flue gas when firing DO

3.2.14.1
After furnace
1.26
3.2.14.2
Before regen. air heater (if applicable)
N.A
Page: 38
Item
3.2.14.3
After regen. air heater (if applicable)
Unit
Value/Description
N.A
3.2.15 Fuel demand

3.2.15.1
NG
kg/s
11.2
3.2.15.2
DO
kg/s
11.9
3.2.16 Power demand

3.2.16.1
Forced draft fan
KW
1,285
3.2.16.2
Regenerative air heater (if applicable)
KW
N.A
3.3
OPERATION CHARACTERISTICS
3.3.1
Cold start (after 36 hours shut down)
per/h
3.3.1.1
Time from AB start-up to full load
Minutes
240
3.3.1.2
Max. allowable temp. gradient
C/min.
1.8
3.3.1.3
Max. allowable pressure gradient
bar/min.
0.1
3.3.1.4
Drum temperature before start
Ambient
Warm start (after 8 hours shut-down)
per/h
3.3.2
3.3.2.1
Drum temperature before start-up
Sat. (250)
3.3.2.2
Drum pressure before start-up
Bar
40
3.3.2.3
Minutes
120
3.3.2.4
Max. allowable pressure gradient
bar/min.
3.3.3
Hot start (after 2 hours shut down)
per/h
3.3.3.1
Drum temperature before-start
Sat. (286)
3.3.3.2
Drum pressure before start-up
Bar
70
3.3.3.3
Minutes
60
3.4
AB PRESSURE PARTS
3.4.1
Not required
FWT Heater (if required)
N.A.
3.4.1.1
Type
3.4.1.2
Design pressure
Bar
N.A.
3.4.1.3
Design temperature
N.A.
3.4.1.4
Fouling factor
N.A.
Item
3.4.2
Unit
Page: 39
Value/Description
Economiser
Segmented Spiral
Finned Tubes
3.4.2.1
Type
3.4.2.2
Design pressure
bar
103
3.4.2.3
Design temperature
335
3.4.2.4
Fouling factor
23.8
M/ms
0.17 (m/sec)/m
3.4.3
Drum
3.4.3.1
Volume
3.4.3.2
Steam space rating
3.4.3.3
Design pressure
bar
99
3.4.3.4
Design temperature
310
3.4.3.5
Manholes (number/size)
mm
2 / 410m
3.4.3.6
Type of steam/water separators
3.4.4
Cyclone
Evaporator
Membranded Waterwalls, pressurised
3.4.4.1
Type
3.4.4.2
Design pressure
bar
99
3.4.4.3
Design temperature
365
3.4.4.4
Fouling factor
nos.
Two (2)
3.4.5
Superheater
3.4.5.1
Number of stages
3.4.5.2
Type
3.4.5.3
Design pressure
bar
99
3.4.5.4
Design temperature
350/500 & 445/615
3.4.5.5
Fouling factor
3.4.5.6
Pressure loss across superheater
bar
nos.
One (1) / Blr
3.4.6
Horizontal and drainable
Attemperators for SH
3.4.6.1
Number
3.4.6.2
Type
Spray
Page: 40
Item
3.5
Unit
Value/Description
WATER VOLUME OF ST EAM

GENERATOR
3.5.1
Water volume filled for pressure test
m3
142
3.5.2
Water volume filled for operation
m3
130
3.6
HP PIPEWORK
A335P12 or Equivalent
3.6.1
Material
3.6.2
Seamless pipe (yes / no)
3.6.3
Design pressure
Bar
99
3.6.4
Design temperature
570
3.6.5
Steam velocity at AB outlet
m/s
40
3.7
Yes
SAFETY VALVES FOR DRUM AND

SUPERHEATER
3.7.1
Drum Safety Valves

Spring
3.7.1.1
Type
3.7.1.2
Design code
3.7.1.3
Number
3.7.1.4
Manufacturer
3.7.1.5
Proposed setting pressure
Bar
99 / 100.5
3.7.1.6
Design pressure
Bar
99
3.7.1.7
Design temperature
310
3.7.2
ASME or equivalent
nos.
Two (2) / Blr

Contract
Superheater Safety Valves

Spring
3.7.2.1
Type
3.7.2.2
Design code
3.7.2.3
Number
3.7.2.4
Manufacturer
3.7.2.5
Design pressure
Bar
99
3.7.2.6
Design temperature
570
ASME or equivalent
nos.
Two (2) / Blr

Contract
Item
3.8
Value/Description
MAIN STEAM STOP VALVE
3.8.1
Type
3.8.2
Number
3.8.3
Manufacturer
3.8.4
Nominal pressure
3.9
Unit
Page: 41
Gate
nos.
One (1) / Blr

Contract
bar

Contract
SILENCERS
3.9.1
Drum Safety Valves
Yes
3.9.2
Superheater Safety Valves
Yes
3.9.3
Start Up Valve
Yes
3.10 BOILER-BLOW-DOWN FLASH VESSEL

nos.
Two (2) / Blr
220 / 200
3.10.3 Total volume
3/6
kg/s
4.6 / 4.6
3.10.1 Number
3.10.4 Design inlet flow
Not Required
3.11 STEAM AIR PREHEATER

(IF REQUIRED)
N.A.
3.11.1 Type
3.11.2 Number
nos.
N.A.
3.11.3 Operating pressure
Bar
N.A.
3.11.4 Operating temperature
N.A.
3.11.5 Air temperature before
N.A.
3.11.6 Air temperature after
N.A.
kg/s
N.A.
3.11.7 Steam capacity (max.)
3.12 REGENERATIVE AIR PREHEATER

(IF REQUIRED)
Not Required
Page: 42
Item
Unit
Value/Description
3.12.1 Type
N.A.
3.12.2 Manufacturer
N.A.
3.12.3 Number
nos.
N.A.
3.12.4 Thickness of elements (hot / cold)
mm
N.A.
N.A.
3.12.5 Material of elements (hot / cold)

3.12.6 Number of drives
nos.
N.A.
3.12.7 Type of drives

3.12.8 Rated capacity of the motor
N.A.
KW
N.A.
N.A.
3.12.9 Type of lubrication
3.13 FORCED DRAUGHT FAN

Centrifugal Type
3.13.1 Type

Contract
3.13.2 Manufacturer
nos.
Two (2) / Blr
3.13.4 Rated capacity
Nm/s
6,700 m3/min
3.13.5 Head total
Mbar
60
3.13.6 Power required
KW
3.13.7 Speed
Rpm
3.13.8 Rated capacity of the motor
KW
3.13.3 Number
950
Oil type
3.13.9 Type of lubrication
3.14 FURNACE
3.14.1 Furnace chamber volume
2,050
3.14.2 Furnace metal temperature
340
3.14.3 Furnace pressure
Mbar
3.15 FIRING SYSTEM

3.15.1 Number of burners
3.15.2 Location of burners
Nos.
Nine (9) / Blr

Furnace front wall
Item
Unit
Page: 43
Value/Description
TEA BI-AIR 42 or
equivalent
3.15.3 Type
3.15.4 Output per burner NG (max/min)
Kg/s
1.39
3.15.5 Output per burner DO (max/min)
Kg/s
1.47
3.15.6 Fuel pressure before burner, NG
Bar
0.8 bar g
3.15.7 Fuel pressure before burner, DO
Bar
11 bar g
Yes for DO burners
3.15.8 Atomizing system (if required)
Steam )Air for Start-up)
3.15.8.1
Medium (Air/Steam)
3.15.8.2
Pressure
bar
12 bar g
3.15.8.3
Temperature (max/min)
Sat.
3.15.8.4
Capacity
kg/s
0.97 to 1.1
Not required
3.16 SOOT-BLOWERS (IF REQUIRED)

3.16.1 Number of blowers
nos.
N/A
3.16.2 Type
N/A
3.16.3 Manufacturer
N/A
3.16.4 Steam conditions
N/A
3.16.4.1
Temperature
N/A
3.16.4.2
Pressure
bar
N/A
KN/m 2
3.5
3.17 PLATFORMS, STAIRS, GALLERIES

3.17.1 Design load
3.18 AIR DUCTS

S275-JR or equivalent
3.18.1 Material
3.18.1.1
Type of expansion joints
3.18.1.2
Material of expansion joints
3.18.2 Ducts thickness
Textile or equivalent
Multi-sheet or equivalent
mm
Page: 44
Item
Unit
Value/Description
3.19 EXHAUST GAS DUCTS

3.19.1 Material
Textile or equivalent
3.19.2 Type of expansion joints
Multi-sheet or equivalent
3.19.3 Material of expansion joints

3.19.4 Ducts thickness
mm
3.20 STACK
Self Supporting
3.20.1 Type
3.20.2 Height above 0
60
3.20.3 Material of shell

Mm
10 - 15
220
3.20.6 Outlet temperature of stack
180
Internal Painting
3.20.7 Special provision against low temperature

corrosion

3.21.1 AB
3.21.1.1
3.21.1.2
Thermal conductivity
3.21.1.3
Material of lagging
3.21.1.4
Mineral Wool
W/(m K)
0.1
Aluminium
Mm
1.2
3.21.2 Air Ducts

3.21.2.1
3.21.2.2
3.21.2.3
Material of lagging

Contract
W/(m K)

Contract
Contract
3.21.3 Flue Gas Ducts
Item
3.21.3.1
3.21.3.2
3.21.3.3
Material of lagging
Unit
Page: 45
Value/Description
Contract
W/(m K)

Contract
Contract
3.21.4 Piping
3.21.4.1

Contract
3.21.4.2 Thickness of insulation

(feedwater pipework)
Mm

Contract
3.21.4.3 Thickness of insulation

(steam pipework)
Mm

Contract
W/(m K)

Contract
3.21.4.4
3.21.4.5
Material of lagging

Contract
3.21.5 Stack
3.21.5.1
3.21.5.2
Thickness of insulation
3.21.5.3
Thermal Conductivity

Contract
Mm

Contract
W/(m K)

Contract
Page: 47
FUEL OIL STORAGE AND SUPPLY SYSTEM FOR GTS AND BOILERS
Item
Unit
Value/Description
DIESEL OIL FORWARDING PUMPS FOR

THE 24 PIPELINE
(see below)
4.1.1
Number of pumps (Minimum 2 x 100%)
2x100%
4.1.2
Type
4.1.3
Manufacturer
4.1.4
Construction standard
4.1.5
Performance Requirements
4.1
Horizontal, Centrifugal
Ebara, Yoshikura,
Torishima, Weir, or
equiv.
API610
(see below)
4.1.5.1
Duty capacity
m3 / h
2,400
4.1.5.2
Capacity at best efficiency
m3 / h
Later
4.1.5.3
Minimum continuous flow
m3 / h
Later
4.1.5.4
Suction head
Bar(a)
Later
4.1.5.5
Total head
Bar(a)
10
4.1.5.6
Total head of close valve
Bar(a)
Later
4.1.5.7
Efficiency
Later
4.1.5.8
NPSH required
Bar(a)
Later
4.1.5.9
NPSH available
Bar(a)
Later
4.1.6
(see below)
Material
4.1.6.1
Casing
Cast Steel
4.1.6.2
Impeller
Stainless Steel
4.1.6.3
Impeller shaft
Stainless Steel
4.1.6.4
Shaft sleeves
Stainless Steel
4.1.6.5
Casing wear rings
Later
4.1.6.6
Impeller wear rings
Later
4.1.6.7
Base plate
Later
Kg
Later
4.1.7
Weight
4.1.8
Pump Motor
(see below)
4.1.8.1
Type
Squirrel Cage
4.1.8.2
Manufacturer
Later
Page: 48
Item
Unit
Value/Description
Later
4.1.8.3
Construction Standard
4.1.8.4
Rated power
KW
Later
4.1.8.5
Speed
Rpm
Later
4.1.8.6
Voltage
AC11,000
4.1.8.7
Weight
Kg
Later
4.2
METERING FOR THE 24 PIPELINE
4.2.1
Number
Later
4.2.2
Type
Later
4.2.3
Manufacturer
Later
4.2.4
Measuring Range
Later
4.2.5
Measuring Accuracy
Later
4.3
CATHODIC CORROSION PRODUCTION

SYSTEM FOR THE 24 PIPELINE
4.3.1
Number of systems
Later
4.3.2
Number of anodes per system
250
4.3.3
Material of anodes
4.3.4
Current density per anode
4.3.5
Number of reference electrodes per system
N.A.
4.3.6
Material of electrodes
N.A.
4.4
Aluminium Alloy
A / m2
Later
PIPE FOR 24 PIPELINE
4.4.1
Material
4.4.2
Dimension(diameter x wall thickness)
4.4.3
Material of coating
4.4.4
Thickness of coating
ASTM A53Gr.B
mm x mm
609.6x9.5
Polyethylene
Mm
Item
4.5
Unit
Page: 49
Value/Description
DIESEL OIL FORWARDING PUMPS FOR

GTS
6 unit (per three (3)
GTs)
4.5.1
Number of pumps (Minimum 2 x 100%)
4.5.2
Type
4.5.3
Manufacturer
Later
4.5.4
Later
4.5.5
horizontal, centrifugal
type
4.5.5.1
Duty capacity
m3 / h
63 t/h /unit
4.5.5.2
m3 / h
Later
4.5.5.3
m3 / h
Later
4.5.5.4
Suction head
bar(a)
4.5.5.5
Total head
bar(a)
4.5.5.6
bar(a)
Later
4.5.5.7
Efficiency
Later
4.5.5.8
NPSH required
bar(a)
Later
4.5.5.9
NPSH available
bar(a)
Later
4.5.6
Material
4.5.6.1
Casing
Cast Iron
4.5.6.2
Impeller
Later
4.5.6.3
Impeller shaft
Steel
4.5.6.4
Shaft sleeves
Carbon Graphite
4.5.6.5
Casing wear rings
Later
4.5.6.6
Impeller wear rings
Later
4.5.6.7
Base plate
Later
4.5.7
Weight
4.5.8
Pump Motor
kg
Later
TEFC, Squirrel Cage
4.5.8.1
Type
4.5.8.2
Manufacturer
Later
4.5.8.3
Later
Page: 50
Item
Unit
Value/Description
kW
11
4.5.8.4
Rated power
4.5.8.5
Speed
Rpm
220
4.5.8.6
Voltage
380
4.5.8.7
Weight
Kg
Later
4.6
(see below)
DIESEL OIL RETURN PUMPS (FROM THE

SLOPE OIL TANKS TO T HE STORAGE
TANKS)
4.6.1
Number of pumps (Minimum 2 x 100 %)
4.6.2
Type
4.6.3
Manufacturer
4.6.4
4.6.5
2x100%
Ebara, Yoshikura,
Torishima, Weir, or
equiv.
API610
(see below)
4.6.5.1
Duty capacity
m3 / h
30
4.6.5.2
m3 / h
Later
4.6.5.3
m3 / h
Later
4.6.5.4
Suction head
Bar(a)
Atmospheric
4.6.5.5
Total head
Bar(a)
4.6.5.6
Bar(a)
Later
4.6.6
(see below)
Material
4.6.6.1
Casing
Cast Steel
4.6.6.2
Impeller
Stainless Steel
4.6.6.3
Impeller shaft
Stainless Steel
Kg
Later
4.6.7
Total weight including motor
4.6.8
Pump Motor
(see below)
4.6.8.1
Type
Squirrel Cage
4.6.8.2
Manufacturer
Later
4.6.8.3
Later
4.6.8.4
Rated power
KW
Later
4.6.8.5
Speed
Rpm
Later
Item
4.6.8.6
4.7
Voltage
Unit
Value/Description
AC380
Tank to tank / black start
DIESEL OIL FILLING PUMPS (TRANSFER

PUMPS TANK TO TANK / BLACK START
DIESEL STORAGE)
4.7.1
Number of pumps
4.7.2
Type
4.7.3
Manufacturer
4.7.4
4.7.5
Page: 51
2x100%/1x100%
Ebara, Yoshikura,
Torishima, Weir, or
equiv.
API610
(see below)
4.7.5.1
Duty capacity
m3 / h
1,100/35
4.7.5.2
m3 / h
Later
4.7.5.3
m3 / h
Later
4.7.5.4
Suction head
bar(a)
Later
4.7.5.5
Total head
bar(a)
3/3
4.7.5.6
bar(a)
Later
4.7.6
(see below)
Material
4.7.6.1
Casing
Cast Steel
4.7.6.2
Impeller
Stainless Steel
4.7.6.3
Impeller shaft
Stainless Steel
kg
Later
4.7.7
4.7.8
Pump Motor
(see below)
4.7.8.1
Type
Squirrel Cage
4.7.8.2
Manufacturer
Later
4.7.8.3
Later
4.7.8.4
Rated power
kW
Later
4.7.8.5
Speed
rpm
Later
4.7.8.6
Voltage
AC380/AC380
4.8
DIESEL OIL PUMPS (AU XILIARY BOILER)
Page: 52
Item
4.8.1
Number of pumps
4.8.2
Type
4.8.3
Manufacturer
4.8.4
4.8.5
Unit
Value/Description
2x100%
Ebara, Yoshikura,
Torishima, Weir, or
equiv.
API610
(see below)
4.8.5.1
Duty capacity
m3 / h
106
4.8.5.2
m3 / h
Later
4.8.5.3
m3 / h
Later
4.8.5.4
Suction head
Bar(a)
Later
4.8.5.5
Total head
Bar(a)
15
4.8.5.6
Bar(a)
Later
4.8.6
(see below)
Material
4.8.6.1
Casing
Cast steel
4.8.6.2
Impeller
Stainless Steel
4.8.6.3
Impeller shaft
Stainless Steel
Kg
Later
4.8.7
4.8.8
Pump Motor
(see below)
4.8.8.1
Type
Squirrel Cage
4.8.8.2
Manufacturer
Later
4.8.8.3
Later
4.8.8.4
Rated power
KW
Later
4.8.8.5
Speed
Rpm
Later
4.8.8.6
Voltage
AC380
4.9
SLOP OIL TANKS

1x100%
4.9.1
Number
4.9.2
Type
4.9.3
Manufacturer
Later
4.9.4
Later
Horizontal Cylindrical
Item
4.9.5
Capacity
4.9.5.1
Page: 53
Unit
Value/Description
M3
5
Carbon Steel
Material
4.10 FILTER / STRAINERS (SUCTION LINE)

10
4.10.1 Number
Duplex
4.10.2 Type
INDUFIL or equivalent
4.10.3 Manufacturer
m3 / h
Later
4.10.5 Solids carry over (Maximum 200)
Micron
200
4.10.6 Design Conditions

4.10.6.1
Pressure
Bar
Later
4.10.6.2
Temperature
Later
4.10.6.3
Pressure drop
Bar
Later
4.10.7 Working Conditions

4.10.7.1
Pressure
Bar
Later
4.10.7.2
Temperature
Later
4.10.7.3
Pressure drop
Bar
Later
Later
4.10.8 Sediment hold up volume

4.10.9 Material
4.10.9.1
Vessel
Carbon Steel
4.10.9.2
Basket
Stainless Steel
4.11 FILTER / STRAINERS (DISCHARGE LINE)

20
4.11.1 Number
Coalescer Filter
4.11.2 Type
Later
4.11.3 Manufacturer
m3 / h
Later
4.11.5 Solids carry over (Maximum 80)
Micron
80
Bar
Later
4.11.6 Design Conditions

4.11.6.1
Pressure
Page: 54
Item
Unit
Value/Description
4.11.6.2
Temperature
Later
4.11.6.3
Pressure drop
Bar
Later
4.11.7 Working Conditions

4.11.7.1
Pressure
Bar
Later
4.11.7.2
Temperature
Later
4.11.7.3
Pressure drop
Bar
Later
Later
4.11.8 Sediment hold up volume

4.11.9 Material
4.11.9.1
Vessel
Later
4.11.9.2
Basket
Later
(see below)
4.12 STORAGE TANKS
4x25%
4.12.1 Number
4.12.2 Type of tanks
Vertical Cylindrical
4.12.3 Manufacturer
Vijay Tanks & Co / eq.

(see below)
4.12.4 Size
4.12.4.1
Outer Diameter
34
4.12.4.2
Height
10
m3
8,500
mbar(g)
Atmospheric
5-65
4.12.5 Net Capacity (Minimum 8.500)

4.12.6 Design pressure
4.12.8 Hydro test
Full of Water
4.12.9 Corrosion Allowances (Minimum as

specified)
(see below)
4.12.9.1
Steel structures
mm
4.12.9.2
Bottom
mm
4.12.9.3
Shell
mm
4.12.9.4
Roof
mm
4.12.10
Weight (empty)
kg
283,000
4.12.11
Weight (test)
kg
9,366,000
Item
Unit
Page: 55
Value/Description
4.12.12
Corrosion protection internal
Epoxy Polyamide
4.12.13
Corrosion protection external
Epoxy Polyamide
4.12.14
Shell
(see below)
C. S. A283 Gr. C /eq.
4.12.14.1 Plate Material

4.12.14.2 Plate thickness
4.12.15
mm
(see below)
Bottom
C. S. A283 Gr. C /eq.

4.12.16
mm
C. S. A283 Gr. C /eq.
9
(see below)
Roof
9 14.8
mm
Page: 57
GAS SYSTEMS FOR GAS TURBINES AND BOILERS

Item
5.1
Unit
Value/Description
PIPE SIZES TIE IN TO THE EXISTING

PIPELINES OF THE SUPPLIER IF
REQUIRED
5.1.1
Hot tap to existing gas pipelines 24
inch
24
5.1.2
Hot tap to existing gas pipelines 48
inch
48
5.2
TERMINAL GAS CONDITIONS
5.2.1
Minimum gas pressure
bar(a)
21
5.2.2
Maximum gas pressure
bar(a)
50
5.2.3
Normal gas pressure
bar(a)
23 to 25
5.2.4
Minimum gas temperature
2.8
5.2.5
Maximum gas temperature
32
5.2.6
Normal gas temperature
18 to 32
5.3
GAS FUEL OPERATING FLOW RATE
5.4
DESIGN CRITERIA FOR PIPING AND

EQUIPMENT
54.78 ton/h per 1GT
bar(g)
38
Design Temperature
Later
5.4.3
Maximum velocity
m/s
Later
5.4.4
Material according to
ASME
5.4.5
Corrosion allowance in carbon steel
mm
Later
5.4.1
Design Pressure
5.4.2
5.5
GAS FUEL QUALITY (IMPURITIES,

LIQUIDS, DROPLETS, ETC.) WITH THE
MINIMUM CONDITIONS
5.5.1
Particle size
Later
5.5.2
Temperature
2.8
5.5.3
Pressure Tolerances by 10-100% of max

fuel flow rate
Later
Page: 58
Item
5.5.4
Pressure Tolerances by 0-10% of max fuel

flow rate
5.6
NOISE LEVEL AT 1 M (MAX)
5.7
EMERGENCY SHUT-DOWN VALVES

(INCOMING LINE TO GAS RECEIVING
STATION)
Unit
Value/Description
Later
DB(A)
Approx. 85
5.7.1
Number
4 for 1 GT
5.7.2
Type
Ball Valve
5.7.3
Manufacturer
Later
5.7.4
Later
5.7.5
Flange rating
5.7.6
Material of construction:
DN300 ANSI600RF
5.7.6.1
Body
Later
5.7.6.2
Trim
Later
5.7.6.3
Stem
Later
5.7.6.4
Plug
Later
5.7.6.5
Seats
Later
5.7.7
Valve actuator
5.7.7.1
Later
Manufacturer
Spring return pneumatic

acotuator
5.7.7.2 Type
5.7.8
5.8
Total weight with actuator
SLAM SHUT OFF VALVES (FOR GTS)
Kg
Later
1 for 1 GT
5.8.1
Number
Later
5.8.2
Type
Later
5.8.3
Manufacturer
Later
5.8.4
Later
5.8.5
Flange Rating
Later
Item
5.8.6
Unit
Page: 59
Value/Description
5.8.6.1
Body
Later
5.8.6.2
Trim
Later
5.8.6.3
Stem
Later
5.8.6.4
Plug
Later
5.8.6.5
Seats
Later
5.8.7
Valve actuator
5.8.7.1
Manufacturer
Later
5.8.7.2
Type
Later
5.8.8
5.9
kg
Later
SLAM SHUT OFF VALVES (FOR HRSGS)
5.9.1
Number
Later
5.9.2
Type
Later
5.9.3
Manufacturer
Later
5.9.4
Later
5.9.5
Flange Rating
Later
5.9.6
5.9.6.1
Body
Later
5.9.6.2
Trim
Later
5.9.6.3
Stem
Later
5.9.6.4
Plug
Later
5.9.6.5
Seats
Later
5.9.7
Valve actuator
5.9.7.1
Manufacturer
Later
5.9.7.2
Type
Later
5.9.8
5.10 SLAM SHUT OFF VALVES (FOR

AUXILIARY BOILERS)
kg
Later
Page: 60
Item
Unit
Value/Description
5.10.1 Number
Later
5.10.2 Type
Later
5.10.3 Manufacturer
Later
5.10.4 Construction Standard
Later
5.10.5 Flange Rating
Later
5.10.6 Material of construction:

5.10.6.1
Body
Later
5.10.6.2
Trim
Later
5.10.6.3
Stem
Later
5.10.6.4
Plug
Later
5.10.6.5
Seats
Later
5.10.7 Valve actuator

5.10.7.1
Manufacturer
Later
5.10.7.2
Type
Later
5.10.8 Total weight with actuator
Kg
Later
5.11 PRESSURE REDUCING AN D CONTROL

VALVES (FOR GTS)
5.11.1 Number
3x50%, 1x10%
5.11.2 Type
Later
5.11.3 Manufacturer
Later
Later
5.11.5 Calculated Cv
Later
5.11.6 Selected Cv
Later
5.11.7 Plug type
Later
5.11.8 Valve Size
Later
Later
5.11.10
5.11.10.1 Body
Later
5.11.10.2 Trim
Later
Item
Unit
Page: 61
Value/Description
5.11.10.3 Stem
Later
5.11.10.4 Plug
Later
5.11.10.5 Seats
Later
5.11.11
Valve actuator
5.11.11.1 Manufacturer
Later
5.11.11.2 Type
Later
5.11.12
kg
Later
5.12 PRESSURE REDUCING AND CONTROL

VALVES (FOR HRSGS)
5.12.1 Number
Later
5.12.2 Type
Later
5.12.3 Manufacturer
Later
Later
Later
5.12.6 Selected Cv
Later
5.12.7 Plug type
Later
5.12.8 Valve Size
Later
Later
5.12.10
5.12.10.1 Body
Later
5.12.10.2 Trim
Later
5.12.10.3 Stem
Later
5.12.10.4 Plug
Later
5.12.10.5 Seats
Later
5.12.11
Valve actuator
Later
5.12.11.2 Type
Later
5.12.12
kg
Later
Page: 62
Item
Unit
Value/Description
5.13 PRESSURE REDUCING AN D CONTROL

VALVES (FOR AUXILIAR Y BOILERS)
5.13.1 Number
Later
5.13.2 Type
Later
5.13.3 Manufacturer
Later
Later
Later
5.13.6 Selected Cv
Later
5.13.7 Plug type
Later
5.13.8 Valve Size
Later
Later
5.13.10
5.13.10.1 Body
Later
5.13.10.2 Trim
Later
5.13.10.3 Stem
Later
5.13.10.4 Plug
Later
5.13.10.5 Seats
Later
5.13.11
Valve actuator
Later
5.13.11.2 Type
Later
5.13.12
kg
Later
5.14 COMBINED MONITOR CONTROL / SLAM

SHUT OFF VALVES (FOR GTS)
5.14.1 Number
Later
5.14.2 Type
Later
5.14.3 Manufacturer
Later
Later
Later
5.14.6 Selected Cv
Later
5.14.7 Plug type
Later
Item
Unit
Page: 63
Value/Description
5.14.8 Valve Size
Later
Later
5.14.10
5.14.10.1 Body
Later
5.14.10.2 Trim
Later
5.14.10.3 Stem
Later
5.14.10.4 Plug
Later
5.14.10.5 Seats
Later
5.14.11
Valve actuator
Later
5.14.11.2 Type
Later
5.14.12
kg
Later

SHUT OFF VALVES (FOR HRSGS)
5.15.1 Number
Later
5.15.2 Type
Later
5.15.3 Manufacturer
Later
Later
Later
5.15.6 Selected Cv
Later
5.15.7 Plug type
Later
5.15.8 Valve Size
Later
Later
5.15.10
5.15.10.1 Body
Later
5.15.10.2 Trim
Later
5.15.10.3 Stem
Later
5.15.10.4 Plug
Later
5.15.10.5 Seats
Later
Page: 64
Item
5.15.11
Unit
Value/Description
Later
Valve actuator
Later
5.15.11.2 Type
Later
5.15.12
kg
Later

SHUT OFF VALVES (FOR AUXILIARY
BOILERS)
5.16.1 Number
Later
5.16.2 Type
Later
5.16.3 Manufacturer
Later
Later
Later
5.16.6 Selected Cv
Later
5.16.7 Plug type
Later
5.16.8 Valve Size
Later
Later
5.16.10
5.16.10.1 Body
Later
5.16.10.2 Trim
Later
5.16.10.3 Stem
Later
5.16.10.4 Plug
Later
5.16.10.5 Seats
Later
5.16.11
Valve actuator
Later
5.16.11.2 Type
Later
5.16.12
kg
Later
5.17 GAS FILTER / SEPARAT OR

5.17.1 Description
5.17.2 Number
2x100% for 1 GT
Item
Unit
Page: 65
Value/Description
5.17.3 Type
Later
5.17.4 Manufacturer
Later
5.17.5 Construction standard
Later
Nm3/h
54.78 ton/h
5.17.7 Rated Capacity (Liquid)
m 3/h
Later
5.17.7.1
Liquid density
kg/m 3
Later
5.17.7.2
Solids carry over
micron
Later
5.17.7.3
Liquid carry over
ppm/V
Later
bar (a)
24
18
bar (a)
23 to 25
18 to 32
m3
Later
5.17.10.1 Internal Diameter
mm
Later
5.17.10.2 Length
mm
Later
5.17.10.3 Corrosion Allowance
mm
Later
5.17.11.1 Filter Elements
Yes/No
Later
5.17.11.2 Demisters
Yes/No
Later
Description
Later
5.17.6 Rated Capacity (Gas)
5.17.8 Design Conditions:

5.17.8.1
Pressure
5.17.8.2
Temperature
5.17.9 Working Conditions:

5.17.9.1
Pressure
5.17.9.2
Temperature
5.17.10
5.17.11
Liquid Hold Up Volume
Internals
5.17.11.3 Others
5.17.12
Material of Construction:
5.17.12.1 Vessel
Later
Later
5.17.12.3 Demisters
Later
5.17.13
Total Volume
m3
Later
5.17.14
Total Weight
kg
Later
5.18 FINAL FILTER (FOR GT S)
Page: 66
Item
Unit
Value/Description
5.18.1 Description
2x100%
5.18.2 Number
5.18.3 Type
Later
5.18.4 Manufacturer
Later
Later
Nm3/h
54.78 ton/h
5.18.7 Rated Capacity (Liquid)
m 3/h
Later
5.18.7.1
Liquid density
kg/m 3
Later
5.18.7.2
Solids carry over
micron
Later
5.18.7.3
Liquid carry over
ppm/V
Later
bar (a)
34
18
bar (a)
34
18 to 32
m3
Later
5.18.10.1 Internal Diameter
mm
Later
5.18.10.2 Length
mm
Later
5.18.10.3 Corrosion Allowance
mm
Later
Yes/No
Later
5.18.11.2 Demisters
Yes/No
Later
Description
Later
5.18.6 Rated Capacity (Gas)

5.18.8.1
Pressure
5.18.8.2
Temperature

5.18.9.1
Pressure
5.18.9.2
Temperature
5.18.10
5.18.11
Liquid Hold Up Volume
Internals
5.18.11.3 Others
5.18.12
5.18.12.1 Vessel
Later
Later
5.18.12.3 Demisters
Later
5.18.13
Total Volume
m3
Later
5.18.14
Total Weight
kg
Later
Item
Unit
Page: 67
Value/Description
5.19 CONDENSATE TANK

1
5.19.1 Number
5.19.2 Type
Later
5.19.3 Manufacturer
Later
Later
m3
Not less than 4 (Min. 4

weeks storage)
bar (a)
Atmosphere
100
bar (a)
Atmosphere
100
5.19.8 Internal Diameter
mm
Later
5.19.9 Length
mm
Later
mm
Later
5.19.5 Capacity
5.19.6.1
Pressure
5.19.6.2
Temperature

5.19.7.1
Pressure
5.19.7.2
Temperature
5.19.10
Corrosion Allowance
5.19.11
Later
5.19.11.1 Vessel
5.19.12
Total Volume
m3
Later
5.19.13
Total Weight
kg
Later
5.20 CONDENSATE PUMP

2x100%
5.20.1 Number
Centrifugal
5.20.2 Type
Later
5.20.3 Manufacturer
ASME, HI, JIS or equiv.

5.20.5 Pumped Fluid
5.20.5.1
Density
5.20.5.2
Temperature
kg/m 3
Later
Later
Page: 68
Item
Unit
Value/Description
cP
Later
bar(a)
Later
Duty capacity
m 3/s
Later
Minimum continuos flow
m 3/s
Later
Total head
bar(a)
Later
kW
Later
5.20.5.3
Viscosity
5.20.5.4
Vapour Pressure
5.20.5.5
Absorbed power
5.20.5.6
5.20.5.7
Casing
Later
Impeller
Later
Shaft
Later
Motor
Type
Later
Manufacturer
Later
Later
Rated Power
kW
Later
Speed
rpm
Later
Voltage
Later
5.21 NATURAL GAS HEATERS

2 (per one (1) GT)
5.21.1 Number
Tube & shell
5.21.2 Type
Later
5.21.3 Manufacturer
5.21.4 Rating
kW
Later
Later
5.21.6 Tubes
Later
5.21.6.1
Temperature in
Later
5.21.6.2
Temperature out
Later
5.21.6.3
Tube outside diameter/wall thickness
mm/mm
Later
Item
Unit
Page: 69
Value/Description
5.21.6.4
Tube materials
Stainless Steel
5.21.6.5
Tube plate materials
Stainless Steel
5.21.6.6
Corrosion allowance
mm
Later
bar (a)
Later
Later
5.21.7 Design conditions:

5.21.7.1
Pressure
5.21.7.2
Temperature
5.21.8 Overall size

5.21.8.1
Diameter
mm
Later
5.21.8.2
Length
mm
Later
kg
Later
5.21.9 Total Weight
5.22 VENT/FLARE CUM - INCINERATOR

SYSTEM
5.22.1 Description
Later
5.22.2 Number off
5.22.3 Flare type
Later
5.22.4 Manufacturer
Later
m
Later
5.22.6 Purge gas requirement
Nm3/h
Later
5.22.7 Pilot gas requirement
Nm3/h
Later
kg/h
Later
kg
Later
5.22.5 Flare stack height
5.22.8 Flow rate

5.22.9 Total weight
5.22.10
Number of burners for condensate
5.22.11
Capacity of one burner
5.22.12
Number of stand by burners
Later
l/s
Later
Later
5.23 GAS BOOSTING COMPRESSORS

5.23.1 Number
5.23.2 Type
Single Stage Centrifugal
5.23.3 Manufacturer
Atlas, Kobelco, or equiv.
Page: 70
Item
Unit
Value/Description
Manufacturers Standards

5.23.5 Gas inlet pressure min/max
bar (a)
22
5.23.6 Gas outlet pressure min/max
bar (a)
34
Nm3/h
54.78 ton/h
5.23.8 Min. load capacity
Nm3/h
Later
bar (a)
42
dB(A)
Approx. 85dB(A) with

sound enclosure
Approx. 20-30 sec
5.23.10
Pressure tolerance
5.23.11
Noise level
5.23.12
Start-up time (to 100%)
5.23.13
Compressor drive
6
5.23.13.1 Number
5.23.13.2 Type
Electric Motor
ABB or Equiv.
5.23.13.4 Enclosure classification
WP II
5.23.13.5 Cooling classification
Later
5.23.13.6 Rated power
kW
2424
5.23.13.7 Speed
rmp
2980
5.23.13.8 Voltage
11kV
5.23.13.9 Full load current
Later
5.23.14
Cooler
1 per 1 unit
5.23.14.1 Number
Air cooled heat

exchanger
5.23.14.2 Type
Amercool or equiv.
ASME/Manufacturers
standard
5.23.14.4 Construction standard

kW
N.A.
5.23.15.1 Temperature in
Later
5.23.15.2 Temperature out
Later
5.23.14.5 Rating
5.23.15
Shell side
Item
Page: 71
Unit
Value/Description
m 3/h
Later
5.23.16.1 Temperature in
74
5.23.16.2 Temperature out
32
m 3/h
5,637
5.23.15.3 Flow rate

5.23.16
Tube side
5.23.16.3 Flow rate

5.23.17
Fan
Induction
5.23.17.1 Type
Reliance or Equiv.
5.23.17.3 Rated Power
5.23.17.4 Speed
5.23.17.5 Voltage
5.23.17.6 Full load current
5.23.17.7 Size Cooler / Fan
5.23.17.8 Weight Cooler + Fan
kW
20x2
rmp
1580
380
Later
mm/mm
Approx. 10,000
Length/ Approx.3048 dia.
Approx. 12,000
kg
5.24 METERING (DOWNSTREAM PRESSURE

REDUCING STATION)
5.24.1 Number
Later
5.24.2 Type
Later
5.24.3 Manufacturer
Later
5.24.4 Measuring Range
Later
5.24.5 Measuring Accuracy
Later
5.25 FINAL METERING

5.25.1 Number
Later
5.25.2 Type
Later
5.25.3 Manufacturer
Later
Later
5.25.5 Measuring Accuracy
Later
Page: 72
Item
Unit
Value/Description
5.26 GAS CHROMATOGRAPH

Later
5.26.1 Number
5.26.2 Type
--
Later
5.26.3 Manufacturer
--
Later
5.26.4 Sensitivity
% FSD
Later
5.26.5 Linearity
FSD
Later
5.26.6 Repeatability
FSD for the

range 0.05%-2%
Later
5.26.7 Kind of connection to the DCS
Later
Page: 73
STEAM TURBINE UNITS AND AUXILIARIES

Item
6.1
Unit
Value/Description
TURBINE
Min. Requirements
Later
6.1.1.1
Turbine type
Back Pressure Steam

Turbine
6.1.1.2
Operation mode
Constant Pressure
6.1.1.3
Turbine design
According to GT/HRSG
and desalination plant
requirements at any
ambient conditions;
6.1.1.4
Permissible deviations of live steam

pressure and live steam temperature
According to IEC
recommendations, latest
edition
6.1.1.5
Absorption capacity at 96% nominal live

steam pressure, throughput ref. MCR
(Maximum Continuous Rating, i. e. max.
load demand of plant system plus all
MSF units at fouled condition)
107
6.1.1.6
Permissible tolerance of absorption

capacity
Later
6.1.1.7
Frequency
Hz
50
6.1.1.8
Permissible frequency deviations at MCR
6.1.1
6.1.1.9
without limitations

exceeding 2 hours per year

exceeding 1 hour per year
-5 to +3
-4
-5
Following operating cases are to be

considered as minimum:
Operation time
6.1.1.10
47.5 to 52.5
30
Cold starts (ambient temperature)
100
Cold starts (50 h standstill period)
600
Warm starts (8 h standstill period)
5,000
Hot starts (2 h standstill period)
2,000
Max. overspeed in case of full load

rejection
Page: 74
Item
Unit
Value/Description
bar (a)
2.30.2
6.1.1.11
Exhaust pressure at inlet MSF units
6.1.1.12
Exhaust steam conditions and heating

steam temperature at MSF units
-/C
Dry/132
6.1.1.13
Exhaust steam flow rate at MSF units
t/h
1521
6.1.2
Steam turbine generator
6.1.2.1
Total number
6.1.2.2
Steam pressure at turbine inlet at MCR
6.1.2.3
Steam temperature at turbine inlet at

MCR
6.1.2.4
Live steam flow at MCR
6.1.2.5
Exhaust pressure (min./max.)
6.1.2.6
1x2 unit
bar(a)
85
559
kg/s
463
bar (a)
Exhaust steam temperature (min./max.)
157
6.1.2.7
Exhaust moisture
Later
6.1.2.8
Exhaust flow rate (min./max.)
t/h
Later
6.1.2.9
No-load steam consumption
kg/s
Later
6.1.2.10
Maximum Continuous Rating (MCR)
MW
175650
6.1.2.11
Nominal speed
Rpm
3000
6.1.2.12
Coupled critical speeds up to 150% of

nominal speed
Rpm
Later
6.1.3
Steam Turbine
6.1.3.1
Manufacturer
TOSHIBA
6.1.3.2
Type
Back Pressure Steam

Turbine
6.1.3.3
Sectional drawing No.
Later
1x2 unit
6.1.4
Casings
6.1.4.1
Number of casings
6.1.4.2
Casing design HP
Type of manufacture (cast / welded /

built-up + cast and welded)
Cast
Item
6.1.4.3
Unit
Value/Description
Material of outer casing
CrMoV Steel
Material of inner casing
N.A.
Casing design LP
N.A.
(HILP Single Casing)
Type of manufacture (cast / welded /

built-up + cast and welded)
Material of outer casing
N.A.
Material of inner casing
N.A.
Number of rupture discs
N.A.
Test pressure for LP turbine exhaust

casing
Bar (a)
N.A.
N.A.
Location of casing fixed point
6.1.5
Page: 75
Rotors
6.1.5.1
Number of turbine shafts
6.1.5.2
Distance between bearing centres

HP shaft
LP shaft
6.1.5.3
HP Rotor
1x2 unit
mm
mm
Approx. 5950
(Preliminary Data)
Forged/welded
Forged
Monobloc / built-up rotor
Monoblock
Material
CrMoV Steel
Type of coupling at front/rear end
Rear End
Type of coupling attachment to rotor

(integral / welded / other at front/rear
end)
Integral
Critical (flexural) speeds: Uncoupled

speeds shall be given assuming rigid
bearings, coupled speeds (including
LP rotor and generator) for rigid and
elastic bearings.
Later
First uncoupled
rpm
Later
Second uncoupled
rpm
Later
Page: 76
Item
Unit
Value/Description
Third uncoupled
rpm
Later
First coupled
rpm
Later
Second coupled
rpm
Later
Third coupled
rpm
Later
Expected bearing elasticity

front/rear bearing
m/kg
Later
Vibration intensities:
6.1.5.4
Maximum deflection of shaft in any

direction
Later
Maximum single amplitudes of

turbine bearing vibration, front/rear
bearing
Later
Maximum radial vibration velocity
mm/s
Later
LP Rotor
N.A.
(HILP Single Casing)
Forged/welded
N.A.
Monobloc / built-up rotor
N.A.
Material
N.A.
Type of coupling at front/rear end
N.A.
Type of coupling attachment to rotor

(integral/welded/ other at front/rear
end)
N.A.
Critical (flexural) speeds:
N.A.
First uncoupled
rpm
N.A.
Second uncoupled
rpm
N.A.
Third uncoupled
rpm
N.A.
Vibration intensities:
N.A.
Item
6.1.6
6.1.6.1
Unit
Value/Description
Maximum deflection of shaft in any

direction
N.A.
Maximum single amplitudes of

turbine bearing vibration, front/rear
bearing
N.A.
Maximum radial vibration velocity
mm/s
N.A.
Blading
HP regulating stage:
N.A.
-
N.A.
Mean blading diameter
mm
N.A.
Pressure in the regulating wheel

chamber at MCR
bar
N.A.
Type of H.P. blading

(impulse/reaction)
Impulse
Number of stages
8*
mm
Approx. 120*
Type of wheel
6.1.6.2
HP blading:
Length of blades last row
CrMoVNbN Steel, Cr
Steel
Material
-
Later
Type of LP blading (impulse/reaction)
Impulse
Number of stages
5*
mm
260
Mean blading diameter last row

6.1.6.3
Page: 77
LP blading:
Length of blades last row
Cr Steel
Material
Mean blading diameter last row
mm
Later
Exhaust area of last row (axially)
m2
Later
*Preliminary Data
6.1.7
6.1.7.1
Emergency stop valves

Number of valves
Page: 78
Item
6.1.7.2
Size (Diameter of one valve)
6.1.7.3
Material of casing
6.1.7.4
Steam strainer separate or integral to

valve
6.1.8
Value/Description
mm
330.2
Cr-Mo-V Casting Steel
Integral Type
HP-steam governor valve
6.1.8.1
Number of valves
6.1.8.2
Size (Diameter of one valve)
6.1.8.3
Type
6.1.8.4
Actuator
6.1.8.5
Material of casing
6.1.9
Unit
2
mm
304.8
Venturi
Hydraulic Type
Cr-Mo-V Casting Steel
N.A.
LP-steam governor valve (if applicable)
N.A.
6.1.9.1
Number of valves
6.1.9.2
Size (diameter of one valve)
6.1.9.3
Type
N.A.
6.1.9.4
Actuator
N.A.
6.1.9.5
Material of casing
N.A.
Mm
N.A.
6.1.10 Bleed steam emergency shut-off valves
N.A.
6.1.10.1
Manufacturer
N.A.
6.1.10.2
Type
N.A.
6.1.10.3
Type of driver
N.A.
6.1.11 Turbine glands

6.1.11.1
Type of sealing (labyrinth/other)
Labyrinth
6.1.12 Bearings
6.1.12.1
Number of journal/thrust bearings
6.1.12.2
Type: Journal
Thrust
2/1
Journal: Pad or Elliptical
Thrust : Taper Land or Pad
Item
Unit
Page: 79
Value/Description
Toshiba or Others
6.1.12.3
Manufacturer
6.1.12.4
(Journal bearing) Specific load of oil film

by rotor weight, front/rear
Bar
Later
6.1.12.5
(Thrust bearing) Max. specific loading of

pad area, regulator/generator side
Bar
Later
6.1.12.6
(Journal bearing) Lining material,

front/rear
White Metal
6.1.12.7
(Thrust bearing) Lining material,

regulator / generator side
White Metal
6.1.12.8
Maximum oil outlet temperature
79
6.1.13 Dimensions
6.1.13.1
Total length of turbine HP, LP
Later
6.1.13.2
Length of turbine foundation
Later
6.1.13.3
Width of turbine foundation
Later
6.1.13.4
Height of turbine foundation
Approx. 7
6.1.14 Weights of turbine

6.1.14.1
Weight of rotor HP / LP
Approx. 27 ton
6.1.14.2
Weight of heaviest part to be handled by

crane
HLP Rotor/27 ton
6.1.14.3
Operating weight of complete turbine
Approx. 77 ton
6.1.15 Starting and loading time of the steam

turbine to MCR
Later
6.1.15.1
Cold start from ambient temperature
Later
warming-up time
Later
starting time up to nominal speed
Later
loading time up to full load
Later
Warm start after 8 hours
Later
warming-up time
Later
Later
Later
6.1.15.2
Page: 80
Item
6.1.15.3
Unit
Value/Description
Hot start after 2 hours
Later
warming-up time
Later
Later
Later
6.1.16 Turning device

6.1.16.1
Method of operation
6.1.16.2
Turbine rotor speed
6.1.16.3
Drive
6.1.16.4
Rating
Motor Operated,
Automatic Disengaged
Rpm
Approx. 4
AC Motor
KW
Later
6.1.17 Gland steam condenser

6.1.17.1
Number of condensers
6.1.17.2
Cooling surface (outside diameter)
6.1.17.3
Materials:
2
m2 / m
100 / 0.9
SS316
Tubes
Tube plates
C.S.
Shell
C.S.
6.1.18 Gland exhauster

4
6.1.18.1
Number of units and unit capacity in % of

required total flow
6.1.18.2
Type
6.1.18.3
Capacity each
M3/h
480
6.1.18.4
Nameplate rating of motor
KW
11
M3
Approx. 24
Single stage
6.1.19 Oil Supply

6.1.19.1
Oil filling quantity
6.1.19.2
Oil specification
Item
6.1.19.3
Required oil quantity for one year of unit

operation
6.1.19.4
Tank capacity
6.1.19.5
Type of inner coating of the tank
6.1.19.6
Number of recirculations (per hour)
6.1.19.7
Lubrication oil system pressure
Page: 81
Unit
m
m3
Value/Description
Approx. 1
18 (Under Nor. Oil Revel)
Phenolic Resin Paint
l/h
7.7
bar(g)
1.8
6.1.20 Main oil pump

6.1.20.1
Type
6.1.20.2
Driving machine
6.1.20.3
Speed
6.1.20.4
Material of pump casing
6.1.20.5
Capacity
6.1.20.6
Total dynamic head
6.1.20.7
Power absorbed
Centrifugal Type
AC Motor
rpm
1500
Cast Iron
m 3/h
2.3
Bar
Approx. 5
KW
55
-/%
1(one)/100%
6.1.21 Auxiliary oil pump

6.1.21.1
Number/capacity of pumps
6.1.21.2
Type
6.1.21.3
Rating
6.1.21.4
Speed
6.1.21.5
6.1.21.6
Capacity
Centrifugal Type
KW
55
rpm
1500
Cast Iron
m 3/h
2.3
6.1.22 Emergency oil pump

6.1.22.1
Number of pumps
6.1.22.2
Type
6.1.22.3
Drive
6.1.22.4
Rating
6.1.22.5
Speed
6.1.22.6
1
Centrifugal Type
DC Motor
KW
27
Rpm
1750
Cast Iron
Page: 82
Item
6.1.22.7
Capacity
Unit
Value/Description
m 3/h
N.A.
6.1.23 HP jacking oil pump

6.1.23.1
Number of pumps
6.1.23.2
Type
6.1.23.3
Rating
6.1.23.4
Speed
6.1.23.5
6.1.23.6
Capacity
N.A.
N.A.
kW
N.A.
rpm
N.A.
N.A.
m 3/h
N.A.
6.1.24 Oil vapour extraction

6.1.24.1
Number of extraction fans
6.1.24.2
Type
6.1.24.3
Rating
2x100%
Centrifugal Type
KW
3.7
6.1.25 Oil cooler

6.1.25.1
Number of coolers
6.1.25.2
Capacity per cooler
6.1.25.3
Oil flow rate each
6.1.25.4
Oil temperature inlet/outlet
6.1.25.5
Oil pressure inlet/outlet
6.1.25.6
Water flow rate, each
6.1.25.7
Water velocity within tubes
6.1.25.8
Water temperature inlet/outlet
6.1.25.9
Water pressure inlet/outlet
4
%
100
m 3/h
132
61.5 / 46
bar(a)
Later
m 3/h
347
m/s
1.6
44 / 46.3
bar(a)
Later
Vertical
6.1.25.10 Erection (horiz./vert.)

6.1.25.11 Cooling surface per cooler (outside
diameter)
6.1.25.12 Max. oil outlet temperature
6.1.25.13 Cooler length
m2
325
Later
Mm
6300
6.1.25.14 Tubes
Item
Outer diameter x wall thickness
Page: 83
Unit
Value/Description
mm / mm
25.4 / 1.24
SS316
Material
C.S.
Material Tube plate

6.1.25.15 Shell
Outer diameter x wall thickness
mm / mm
660 / Later
C.S.
Material
6.1.26 Oil separator

6.1.26.1
Manufacturer
6.1.26.2
Type
6.1.26.3
Flow rate per separator of lubrication oil

flow
6.1.26.4
Heat rating
6.1.26.5
Rating of drive
Alfa-Laval or Equivalent
Centrifugal Type
%
11
kW
Later
kW
Later
6.1.27 Lubrication oil filter

6.1.27.1
Type
6.1.27.2
Flow rate per filter
6.1.27.3
Grade of filtration
Duplex
%
Later
80 mesh
bar(g)
169
6.1.28 Control oil system

6.1.28.1
System pressure
6.1.29 Control oil pump (where applicable)

2
6.1.29.1
Number of pumps
6.1.29.2
Capacity per pump
6.1.29.3
Type
6.1.29.4
Rating
kW
45
6.1.29.5
Speed
rpm
970
6.1.29.6
100
Piston Type
Carbon Steel
Page: 84
Item
Unit
Value/Description
6.1.30 Control oil filter

6.1.30.1
Type
6.1.30.2
Flow rate per filter
6.1.30.3
Grade of filtration
6.1.31 Turbine protection system

6.1.32 Manufacturer
6.1.33 Designation of system
6.1.34 Type or name of system
6.1.35 Principle of monitoring (e.g. 1 out of 2, 2 out
of 3, 2 out of 2 with selfmonitoring etc.) to be
entered for:
6.1.35.1
Speed, high
6.1.35.2
Exhaust pressure, high
6.1.35.3
Temperature of exhaust steam, high
6.1.35.4
Relative expansion, high
6.1.35.5
Shaft displacement, high
6.1.35.6
Difference temperature of casing

(diametrical clearance), high
6.1.35.7
Vibration, high
6.1.35.8
Bearing metal temperature, high
6.1.35.9
Lube oil pressure, low
6.1.35.10 Fire protection

6.1.35.11 Generator protection
6.1.35.12 Lube oil tank level, low
Fiber Type
%
100
?m
Later
Later
Later
Later
Later
Later
Later
Later
Later
Later
Later
Later
Later
Later
Later
Later
Later
6.1.36 Vibration Measurements

6.1.36.1
Manufacturer
6.1.36.2
Designation of system
6.1.36.3
Type or name of system
Later
Later
Later
Item
6.1.36.4
Total number of shaft vibration sensors
6.1.36.5
Total number of bearing vibration

sensors
Unit
Page: 85
Value/Description
Later
Later
6.1.37 Downtime ventilation plant

6.1.37.1
Manufacturer
6.1.37.2
Maximum air humidity downstream the

turbine
(ref. To ambient temperature)
6.1.37.3
Method of operation
Later
%
Later
Later
6.1.38 Fire protection system

6.1.38.1
System pressure required
6.1.38.2
Pressure vessel (if applicable)
bar
Later
No. of vessels
Volume
Design pressure
Safety valve design flow
6.1.38.3
Later
m3
Later
bar
Later
m 3/h
Later
Booster pumps (if applicable)

Later
No. of pumps
Capacity of pumps
Delivery head
m 3/h
Later
Later
Page: 87
STEAM SYSTEMS
Item
7.1
Unit
Value/Description
PRESSURE REDUCING AN D
DESUPERHEATING STATIONS
7.1.1
HP / LP Reducing Station
7.1.1.1
Number of stations
7.1.1.2
Type of desuperheating (integral /

separately)
7.1.1.3
Pressure Control Valve
Later
mm / mm
Later
Diameter of bored
mm
Later
Capacity per valve
t/h
Later
Pressure rating
bar
Later
Temperature rating
Later
Diameter Inlet / Outlet
Material
-
Body
Later
Shaft / trim
Later
Later
Type of actuator
7.1.1.4
7.1.1.5
7.1.2
7.1.2.1
Temperature Control
Type of desuperheater
Later
Type of control valve
Later
Type of actuator
Later
Injection water
Quantity
t/h
Later
Temperature
Later
Pressure
bar
Later
HP / IP Reducing Station
Number of stations
Later
Page: 88
Item
7.1.2.2
Type of desuperheating (integral /

separately)
7.1.2.3
Pressure Control Valve
Unit
Value/Description
Later
mm / mm
Later
Diameter of bored
mm
Later
Capacity per valve
t/h
Later
Pressure rating
bar
Later
Temperature rating
Later
Diameter Inlet / Outlet
Material
-
Body
Later
Shaft / trim
Later
Later
Type of actuator
7.1.2.4
7.1.2.5
Temperature Control
Type of desuperheater
Later
Type of control valve
Later
Type of actuator
Later
Injection water
Quantity
t/h
Later
Temperature
Later
Pressure
bar
Later
Page: 89
CONDENSATE AND FEEDWATER SYSTEM

Item
8.1
Unit
Value/Description
inch
20
MAIN CONDENSATE LINE
8.1.1
Size
8.1.2
Design Pressure
8.1.3
Design Flow
Kg/h
1735100
8.1.4
Velocity
m/s
2.84
8.2
Later
CLEAN DRAIN FLASH VESSEL
8.2.1
Number
8.2.2
Material of shell/heads
8.2.3
Design Pressure
8.2.4
1
C.S.
barA
Volume
m3
0.65
8.2.5
Design Steam Temperature
Later
8.2.6
Design Steam Flow
kg/s
Later
8.2.7
Vent Pipe Diameter
mm
100
8.2.8
Silencer Type
8.3
Later
CLEAN DRAIN TANK
8.3.1
General
8.3.1.1
Number
no.
8.3.1.2
Useful tank capacity
m3
8.3.2
Operating Conditions
8.3.2.1
Maximum admissible filling rate
kg/s
Later
8.3.2.2
Maximum discharge rate
m 3/h
Later
barA
Later
8.3.3
Mechanical Design Data
8.3.3.1
Design pressure, max./min.
8.3.3.2
Design temperature
Later
8.3.3.3
Operating pressure
barA
Later
8.3.3.4
Operating temperature
Later
Page: 90
Item
8.4
Unit
Value/Description
CLEAN DRAIN PUMPS
8.4.1
Type
8.4.2
Number
8.4.3
Discharge flow
8.4.4
Horizontal Centrifugal
-
kg/s
Later
Discharge pressure (pump head)
Later
8.4.5
NPSH required
Later
8.4.6
Material of:
8.4.6.1
Casing
Later
8.4.6.2
Impeller
Later
8.4.6.3
Shaft
Later
8.5
CONDENSATE CONTROL VALVES

FOR HRSG FWTS
8.5.1
Start-up Valve
8.5.1.1
Number and size
8.5.1.2
Capacity
8.5.1.3
Actuator type
8.5.1.4
Nominal diameter
8.5.2
Later
kg/s
Later
Later
mm
Later
Later
kg/s
Later
Full Load Valve
8.5.2.1
Number and size
8.5.2.2
Capacity
8.5.2.3
Actuator type
8.5.2.4
Nominal diameter
8.6
Later
mm
Later
Later
kg/s
Later
CONDENSATE CONTROL VALVES

FOR AUXILIARY BOILER FWTS
8.6.1
Start-up Valve
8.6.1.1
Number and size
8.6.1.2
Capacity
8.6.1.3
Actuator type
8.6.1.4
Nominal diameter
Later
mm
Later
Item
8.6.2
Unit
Value/Description
Later
kg/s
Later
Full Load Valve
8.6.2.1
Number and size
8.6.2.2
Capacity
8.6.2.3
Actuator type
8.6.2.4
Nominal diameter
8.7
Page: 91
Later
mm
Later
FEEDWATER TANK AND DEAERATOR

FOR HRSGS
8.7.1
Technical Data
8.7.1.1
Volume of feedwater tank
m3
Later
8.7.1.2
Net capacity
m3
Later
8.7.1.3
Retention Time at Design Flow
min
Later
8.7.1.4
Design pressure/operating pressure
bar
Later
8.7.1.5
Design temperature/operating
temperature
Later
8.7.1.6
Material of
Shell
Later
Ends
Later
Internals
Later
Later
mm
Later
yes/no
Later
8.7.1.7
Heat insulation
Type
Thickness
8.7.1.8
8.7.2
Deaerator
8.7.2.1
8.7.2.2
8.8
Platforms, landings, stairways
Later
Material
Spray nozzles
Later
Other nozzles
Later
Trays
Later
ppm
Later
O2-content
FEEDWATER TANK AND DEAERATOR

FOR AUXILIARY BOILERS
Page: 92
Item
8.8.1
Unit
Value/Description
Technical Data
8.8.1.1
Volume of feedwater tank
m3
165
8.8.1.2
Net capacity
m3
150
8.8.1.3
Retention Time at Design Flow
min
15
8.8.1.4
Design pressure/operating pressure
bar
Later / 2.32
8.8.1.5
Design temperature/operating
temperature
Later / 125.0
8.8.1.6
Material of
Shell
C.S.
Ends
C.S.
Internals
C.S.
Later
mm
Later
yes/no
Yes
Spray nozzles
S.S.
Other nozzles
C.S.
Trays
S.S.
ppm
0.07
8.8.1.7
Heat insulation
Type
Thickness
8.8.1.8
8.8.2
Deaerator
8.8.2.1
8.8.2.2
8.9
Platforms, landings, stairways
Material
O2-content
FEEDWATER PUMPS FOR AUXILIARY

BOILERS
8.9.1
General Information
8.9.1.1
Feedpump configuration
8.9.1.2
Number of pumps
8.9.1.3
Later
no.
Later
Manufacturer
Later
8.9.1.4
Type
Later
8.9.1.5
Number of Stages
Later
8.9.2
Codes and Regulations
Later
Item
8.9.2.1
8.9.3
Unit
Page: 93
Value/Description
Later
Test code for performance

Pump Materials
8.9.3.1
Pump casing
Later
8.9.3.2
Guide vane ring
Later
8.9.3.3
Impeller
Later
8.9.3.4
Shaft
Later
8.9.4
Operational and Performance Data
8.9.4.1
Percentage of load
Later
8.9.4.2
Discharge flow
t/h
Later
8.9.4.3
Discharge pressure
bar
Later
8.9.4.4
NPSH required at pump suction
Later
8.9.4.5
NPSH available at pump suction
Later
8.9.4.6
Pressure at zero flow
bar
Later
8.9.4.7
Overall efficiency according to ISO 3555
Later
rpm
Later
Later
8.9.5
Functional Data
8.9.5.1
8.9.6
Critical speed
Design Data Type Driving Motor
8.9.6.1
Type
8.9.6.2
Manufacturer
8.9.6.3
Nameplate rating
kW
Later
8.9.6.4
Motor efficiency
Later
Later
Later
8.9.7
Design Data Minimum Flow Control Valve
8.9.7.1
8.9.8
Later
Type
Design Data Shut-off Valves
8.9.8.1
Type
8.10 FEEDWATER PUMPS FOR HRSGS

8.10.1 General Information
8.10.1.1
Feedpump configuration
8.10.1.2
Number of pumps
2x100% per 1 HRSG

no.
Page: 94
Item
Unit
Value/Description
Ebara, Sulzer, Weir or

equiv.
8.10.1.4 Type
Horizontal multistage,
ring section, single
casing
8.10.1.5
8.10.1.3
Manufacturer
Number of Stages
8.10.2 Codes and Regulations
JIS, ASME or equiv.
8.10.2.1
JIS, ASME or equiv.
Test code for performance
8.10.3 Pump Materials

ASTM A487 Gr.CA6NM
8.10.3.1 Pump casing
Later
8.10.3.2
Guide vane ring
8.10.3.3
Impeller
ASTM A487 Gr.CA6NM
8.10.3.4
Shaft
ASTM A287 Type 410H
8.10.4 Operational and Performance Data

8.10.4.1
Percentage of load
100
8.10.4.2
Discharge flow
t/h
10.3
8.10.4.3
Discharge pressure
bar
136
8.10.4.4
NPSH required at pump suction
10
8.10.4.5
NPSH available at pump suction
32
8.10.4.6
Pressure at zero flow
bar
164
8.10.4.7
Overall efficiency according to ISO 3555
76.5
rpm
Later
8.10.5 Functional Data

8.10.5.1
Critical speed
8.10.6 Design Data Type Driving Motor

-
8.10.6.1
Type
8.10.6.2
Manufacturer
8.10.6.3
Nameplate rating
kW
3500
8.10.6.4
Motor efficiency
Later
Later
Later
Later
8.10.7 Design Data Minimum Flow Control Valve

8.10.7.1
Type
8.10.8 Design Data Shut-off Valves

8.10.8.1
Type
Page: 95
CLOSED COOLING WATER SYSTEM

Item
9.1
Value/Description
GENERAL
9.1.1
Primary circuit coolant
9.1.2
Water analysis
9.1.3
Water temperatures
9.1.4
Design seawater temperature
9.1.5
Secondary circuit coolant
9.2
Unit
Seawater
39
Demineralized water
AUXILIARY COOLERS
9.2.1
Number of coolers
9.2.2
Capacity of cooler, referred to plant demand
9.2.3
Manufacturer
9.2.4
Type
9.2.5
Heat capacity
9.2.6
Heat exchanging surface (outside diameter)
9.2.7
Shell side:
9.2.7.1
Design Temperatures
9.2.7.2
Flow rate
9.2.8
50
TOSHIBA
Shell and tube
kJ/s
22213
m2
2030
Later
m 3/h
2700
Later
m 3/h
3248
mm / mm
19.05 / 0.5
Tube side
9.2.8.1
Design Temperatures
9.2.8.2
Flow rate
9.2.8.3
Tube outside diameter/wall thickness
9.2.9
Materials:
9.2.9.1
Tubes
9.2.9.2
Tube plates
9.2.9.3
Shell
9.2.9.4
Tubebox
9.2.9.5
Tubebox cladding
9.2.9.6
Sacrificial anode
Titanium
Titanium clad
C.S.
C.S.
Epoxy coating
N.A.
Page: 96
Item
9.3
Unit
Value/Description
AUXILIARY CLOSE COOLING WATER

PUMPS
9.3.1
Number of pumps
9.3.2
Manufacturer
9.3.3
Type
9.3.4
Characteristic pump curve no.
9.3.5
Delivery rate (design point)
9.3.6
Delivery head (design point)
9.3.7
Speed
9.3.8
Type of bearings
9.3.9
Type of bearing lubrication
3
Ebara, Yoshikura,
Torishima, Weir, or
equiv.
POBCA7793020-001
m 3/h
61
50
rpm
1000
Ball
Grease
9.3.10 Materials:
9.3.10.1
Pump casing
9.3.10.2
Shaft
FCD400
Stainless Steel
9.3.11 Driving motor

9.3.11.1
Manufacturer
9.3.11.2
Rated power
9.3.11.3
Type of bearings
9.3.11.4
Insulation class
9.4
Later
V
11kV
Later
Later
HIGH LEVEL COOLING WATER TANK

2
9.4.1
Number of tanks
9.4.2
Nominal capacity
m3
10
9.4.3
Outside diameter
mm
1800
9.4.4
Total length
9.4.5
Material
9.4.6
Inside coating
9.4.7
Corrosion allowance
C.S.
Epoxy coating
mm
1.6
Page: 97
10 BLACK START / EMERGENCY POWER SUPPLY

Item
Unit
Value/Description
10.1 EMERGENCY DIESEL GENERATOR

Later
10.1.1 Generator
10.1.3 Power factor
10.1.5 Frequency
kVA
Later
Later
Later
Hz
Later
Later
10.1.6 Terminals
10.1.7 Voltage
10.1.8 Neutral
10.1.10
10.1.11
10.1.12
10.1.13
exciter
10.1.14
insulation class
Later
Later
Later
Later
Later
Later
Later
Later
kVA
-
To cover load
requirement to start 2
GTs
0.8
Air
Hz
50 (+ / - 5%)
10.2 BLACK START DIESEL GENERATOR

10.2.1 Generator
10.2.3 Power factor
10.2.5 Frequency
6 terminals
10.2.6 Terminals
10.2.7 Voltage
10.2.8 Neutral
11,000
Page: 98
Item
10.2.10
10.2.11
10.2.12
10.2.13
exciter
10.2.14
insulation class
Unit
Value/Description
Automatic +/- 10%
+/- 0.5
+15
+10
Page: 99
11 INSTRUMENT AND SERVICE AIR SYSTEM

Item
Unit
Value/Description
11.1 GENERAL DESIGN DATA

11.1.1 General
11.1.1.1
Number of compressor trains
11.1.1.2
Capacity each compressor train
Nm3/h
960
11.1.1.3
Operating pressure
barabs
11.1.1.4
Design pressure
barabs
Subject to
subcontractors standard
design
11.1.1.5
Design inlet air temperature
50
11.1.1.6
Max. humidity
100
11.1.1.7
Max. cooling water temperature
50
11.1.1.8
Average atmospheric air pressure
mbar
1.013
11.1.1.9
Tests to be performed on system
11.2 COMPRESSOR
11.2.1 General
11.2.1.1
Number
11.2.1.2
Type
11.2.1.3
Manufacturer
4
Rotary Screw
Kaiji, Kwangshin
Machine Ltd.
Mikunikikai, Seah, Sinil
Machine Co. or Equiv.
11.2.1.4
Suction temperature, max.
11.2.1.5
Suction pressure.
11.2.1.6
Intermediate temperature
11.2.1.7
Intermediate pressure
50
barabs
Subject to
design
Subject to
design
barabs
Subject to
design
Page: 100
Item
Unit
Value/Description
C.
Subject to
design
barabs
Subject to
design
11.2.1.10 Operating discharge pressure
barabs
11.2.1.11 Test discharge pressure.
barabs
45
11.2.1.13 Rated flow
Nm3/h
960
11.2.1.14 Flow when compressors operate in

parallel
Nm3/h
Subject to
design
11.2.1.15 Compressor speed
1/min
Subject to
design
Subject to
design
kW
Subject to
design
11.2.1.8
Discharge temperature
11.2.1.9
Design discharge pressure
11.2.1.12 Final temperature after compressor (after

cooler)
11.2.1.16 Compressor efficiency
11.2.1.17 Power required at compressor coupling
11.2.1.18 Type of drive (direct, belt, gear)
Subject to
design
11.2.1.19 Standards for compressor performance
Subject to
design
11.2.1.20 Tests concerning performance
Subject to
design
11.2.2 Construction
11.2.2.1
Number of stages
Subject to
design
11.2.2.2
Compression ratio per stage
Subject to
design
Item
Page: 101
Unit
Value/Description
mm x mm
Subject to
design
11.2.2.3
Overall dimensions (length x width)
11.2.2.4
Number of cylinders LP/HP
11.2.2.5
Piston diameter LP/HP
mm/mm
Subject to
design
11.2.2.6
Piston speed LP/HP
m/s / m/s
Subject to
design
11.2.2.7
Cylinder Arrangement
Subject to
design
11.2.2.8
Oil pump Bearing Lubrication
Subject to
design
11.2.2.9
Cooling Water inlet temperature
11.2.2.10 Cooling Water outlet temperature
11.2.2.11 Total cooling water flow
11.2.2.12 Total weight of compressor set
11.2.2.13 Standards for design, materials and

stress calculations
Subject to
design
Subject to
design
Subject to
design
m 3/h
Subject to
design
kg
Subject to
design
Subject to
design
11.2.3 Driving Motors

11.2.3.1
Manufacturer
Subject to
design
11.2.3.2
Type
Subject to
design
Page: 102
Item
Unit
Value/Description
11.2.3.3
Type of enclosure
Subject to
design
11.2.3.4
Class of insulation
Subject to
design
11.2.3.5
Nameplate rating
11.2.3.6
Rated voltage
11.2.3.7
Permissible frequency of starts
11.2.3.8
Speed
11.2.3.9
Efficiency at full load
11.2.3.10 Weight
kW
Subject to
design
V AC
Subject to
design
1/h
48.5 to 51.5 Hz
1/min
Subject to
design
Subject to
design
kg
Subject to
design
11.3 COMPRESSOR ANCILLARIES

11.3.1 Compressor Intermediate Cooler
11.3.1.1
Heat emission
kJ/s
Subject to
design
11.3.1.2
Cooling water flow
m 3/h
Subject to
design
11.3.1.3
Heat exchange area
m2
Subject to
design
11.3.1.4
Design pressure
barabs
Subject to
design
11.3.1.5
Standards for design, materials and tests
Subject to
design
Item
Page: 103
Unit
Value/Description
11.3.2 Compressor After Coolers

11.3.2.1
Heat emission
kJ/s
Subject to
design
11.3.2.2
Cooling water flow
m 3/h
Subject to
design
11.3.2.3
Heat exchange area
m2
Subject to
design
11.3.2.4
Design pressure
barabs
Subject to
design
11.3.2.5
Standards for design, materials and tests
Subject to
design
11.3.3 Air Receivers

4
11.3.3.1
Number
11.3.3.2
Manufacturer
Subject to
design
11.3.3.3
Type
Subject to
design
11.3.3.4
Total capacity
m3
11.3.3.5
Overall length (height)
mm
Subject to
design
11.3.3.6
Diameter
mm
Subject to
design
11.3.3.7
Design pressure.
barabs
Subject to
design
11.3.3.8
Operating pressure
barabs
Subject to
design
11.3.3.9
Material
Subject to
design
Page: 104
Item
11.3.3.10 Wall thickness
Unit
Value/Description
mm
Subject to
design
11.3.3.11 Type of inside protective coating
Subject to
design
11.3.3.12 Type of outside protective coating
Subject to
design
11.3.3.13 Total weight
kg
Subject to
design
11.3.3.14 Standards for design
Subject to
design
11.3.3.15 construction and materials
Subject to
design
11.3.4 Air Dryers

4
11.3.4.1
Number
11.3.4.2
Manufacturer
Subject to
design
11.3.4.3
Type
Subject to
design
11.3.4.4
Overall length (height)
mm
Subject to
design
11.3.4.5
Diameter
mm
Subject to
design
11.3.4.6
Heat exchange area
m2
Subject to
design
11.3.4.7
Rated flow
Nm3/h
Subject to
design
11.3.4.8
Design pressure
barabs
Subject to
design
Item
Page: 105
Unit
Value/Description
barabs
Subject to
design
11.3.4.10 Inlet air temperature
Subject to
design
11.3.4.11 Outlet air temperature
Subject to
design
11.3.4.12 Dew point
-40 deg C at
atmospheric pressure
Motor
11.3.4.9
Max./min. operating pressure
11.3.4.13 Compressor driven by
Auxiliary cooling water
11.3.4.14 Condenser cooling by

11.3.4.15 Coolant flow
m 3/h
Subject to
design
11.3.4.16 Total weight
kg
Subject to
design
11.3.5 Driving Motor

11.3.5.1
Manufacturer
11.3.5.2
Nameplate rating
11.3.5.3
Subject to
design
KW
Subject to
design
Rated voltage
V AC
Subject to
design
11.3.5.4
Speed
l/min
Subject to
design
11.3.5.5
Weight
kg
Subject to
design
11.3.6 Air Filters

Suction Filters
11.3.6.1
Number
11.3.6.2
Type
4
Subject to
design
Page: 106
Item
Unit
Value/Description
Nm3/h
960
microns
Subject to
design
11.3.6.3
Rated flow
11.3.6.4
Average particle size retained
11.3.6.5
Effective filter area
m2
Subject to
design
11.3.6.6
Weight
kg
Subject to
design
Subject to
design
11.3.7 Air Filters

After Filters
11.3.7.1
Number
11.3.7.2
Type
11.3.7.3
Rated flow
11.3.7.4
Average particle size retained
11.3.7.5
11.3.7.6
4
Subject to
design
Nm3/h
960
microns
Subject to
design
Effective filter area
m2
Subject to
design
Weight
kg
Subject to
design
11.3.8 Air Silencers

11.3.8.1
Number
Subject to
design
11.3.8.2
Type
Subject to
design
11.3.8.3
Rated flow
11.3.8.4
Pressure drop allowed/calculated
Nm3/ h
Subject to
design
bar / bar
Subject to
design
Page: 107
Item
Unit
Value/Description
11.3.8.5
Average sound level decrease
dB
Subject to
design
11.3.8.6
Weight
kg
Subject to
design
12 NOT USED
Page: 109
Page: 111
13 STEAM / WATER SAMPLING SYSTEM

Item
Unit
Value/Description
no.
41
13.1 COOLER
13.1.1 Number of sample coolers
Indoor
13.1.2 Location
13.1.3 Temperature of sample at cooler exit
13.1.4 Pressure behind pressure reducing valve
25
bar (g)
13.1.5 Material of coolers

13.1.5.1
Tube bundle
316 stainless steel
13.1.5.2
Shell
304 stainless steel
13.2 ANALYSER FOR CONDUCT IVITY

13.2.1 Number
no.
42
13.2.2 Type
Electrode
13.2.3 Manufacturer
DKK-TOA
13.3 ANALYSER FOR PH-VALUE

13.3.1 Number
no.
36
13.3.2 Type
Electrode
13.3.3 Manufacturer
DKK-TOA
13.4 ANALYSER FOR OXYGEN

13.4.1 Number
no.
6
Poralography
13.4.2 Type
DKK-TOA
13.4.3 Manufacturer
13.5 STRONG ACID CATION EXCHANGER
13.5.1 Number
no.
Later
13.5.2 Manufacturer
13.5.3 Volume
26
liter
Later
Page: 113
14 STEAM/WATER CIRCUIT CHEMISTRY/DOSING

Item
Unit
Value/Description
no.
14.1 AMMONIA DOSING STATION

14.1.1 Number of stations (skids)
14.1.2 Preparation and Dosing Tanks: each skid
14.1.2.1
Number
no.
14.1.2.2
Capacity
m3
Later
Later
14.1.3 Materials of construction

14.1.4 Dosing Pumps: each skid
14.1.4.1
Number
14.1.4.2
Type
14.1.4.3
Maximum output
14.1.4.4
Maximum pressure
14.1.4.5
Material
no.
2
Diaphragm
liter/h
Later
bar
Later
Later
14.1.5 Tank Agitators: each skid

no.
14.1.5.1
Number
14.1.5.2
Type
Later
14.1.5.3
Shaft and impeller material
Later
14.2 TRISODIUMPHOSPHATE DOSING

STATION
no.

14.2.2.1
Number
no.
14.2.2.2
Capacity
m3
Later
14.2.2.3
Material of construction
Later
14.2.2.4
Dissolving basket material
Later

14.2.3.1
Number
14.2.3.2
Type
14.2.3.3
Maximum output
no.
6
Diaphragm
liter/h
Later
Page: 114
Item
14.2.3.4
Maximum pressure
14.2.3.5
Material
Unit
Value/Description
bar
Later
Later

no.
14.2.4.1
Number
14.2.4.2
Type
Later
14.2.4.3
Later
14.3 HYDRAZINE DOSING STATION

no.

14.3.2.1
Number
no.
14.3.2.2
Capacity
m3
Later
Later
14.3.3 Materials of construction

14.3.4.1
Number
14.3.4.2
Type
14.3.4.3
Maximum output
14.3.4.4
Maximum pressure
14.3.4.5
Material
no.
2
Diaphragm
liter/h
Later
bar
Later
Later

no.
14.3.5.1
Number
14.3.5.2
Type
Later
14.3.5.3
Later
Page: 115
15 DEMINERALISED WATER PLANT

Item
Unit
Value/Description
15.1.1 Number of trains
no.
15.1.2 Number of max. possible simultaneously

operating trains
no.
15.1.3 Number of candle filters per train
no.
15.1.4 Number of mixed bed ion exch. per train
no.
15.1.5 Pressure rating of ion exchanger
bar
15.1 DESIGN DATA
m 3/h
270
m3
19,440
15.1.8 Operating time between two regenerations
72
15.1.9 Total required ground area for entire water

treatment plant
Later
15.1.6 Net flow rate of one train

15.1.7 Net capacity between two regenerations
(one train)
15.2 CANDLE FILTERS

Later
15.2.1 Manufacturer
15.2.2 Number of units
no.
15.2.3 Maximum working pressure
bar
bar
60
Later
15.2.6 Materials of Construction

15.2.7 Number of manholes
no.
15.2.8 Manhole size
mm
Later
15.3 MIXED BED EXCHANGERS

Later
15.3.1 Manufacturer
15.3.2 Number of units
no.
Bar
Bar
60
Page: 116
Item
Unit
Carbon Steel with RL
15.3.6 Materials of Construction

15.3.7 Inside lining/thickness
Value/Description
mm
Later
Later
15.3.8 Type of underdrain

15.3.9 Number of manholes
no.
15.3.10Manhole size
mm
Later
15.4 REGENERATION CHEMICALS

HCL
15.4.1 Type of acid for regeneration

15.4.2 Concentration for Acid
30
NaOH
15.4.3 Type of caustic for regeneration

%
40
month
3 for acid 1 for caustic
kg/Reg.
546
15.5.2 Acid regeneration strength
15.5.3 % of theoretic calculation
Later
15.5.4 Caustic-demand
kg
836
15.5.5 Caustic regeneration strength
15.5.6 % of theoretic calculation
Later
15.5.7 Overall reg. water demand
m3
136
mm
Later
15.4.4 Concentration of caustic

15.4.5 Chemical storage capacity
15.5 CHEMICAL CONSUMPTION PER

REGENERATION (CHEMICAL AS 100%
CONCENTRATION) OF MIXED BED
EXCHANGER
15.5.1 Acid-demand
15.6 MAIN PIPING

15.6.1 Size
Later
15.6.2 Screwed or flanged

15.6.3 Material/lining
mm
Later
15.7 RESINS
Item
Unit
Page: 117
Value/Description
15.7.1 Cation resins for mixed bed exchangers

Strong
15.7.1.1
Type
15.7.1.2
Manufacturer
15.7.1.3
Quantity per unit
litre
4,200
15.7.1.4
Bed depth
mm
625
15.7.1.5
Operating capacity
val/ltr
0.81eq/l
15.7.1.6
Anion resins for mixed bed exchangers
Rohm and Haas or

Equiv.
Strong
15.7.2 Anion type
Rohm and Haas or

Equiv.
15.7.2.1
Manufacturer
15.7.2.2
Quantity per unit
litre
7,600
15.7.2.3
Bed depth
mm
1,238
15.7.2.4
Operating capacity
val/ltr
0.45eq/l
(see below)
15.8 DISTILLATE WATER BUFFER TANK

15.8.1 Number supplied
no.
1x100%
15.8.2 Manufacturer
Vertical cylindrical
closed
15.8.3 Type (open or closed)

15.8.4 Effective volume
100
15.8.5 Total volume
118
bar
Atmospheric
bar
Atmospheric
5-65
S.S. TP-316
15.8.9 Material of Construction

mm
N.A.
15.8.10
Inside lining/thickness
15.8.11
Type of underdrain
15.8.12
Number of manholes
no.
15.8.13
Manhole diameter
mm
900
N.A.
Page: 118
Item
Unit
(see below)
15.9 MAKE UP WATER STORAG E TANK

15.9.1 Number supplied
Value/Description
no.
2x50%
15.9.2 Manufacturer
Vertical cylindrical
Closed
15.9.3 Type (open or closed)

15.9.4 Effective volume
1,500
15.9.5 Total volume
1,540
bar
Atmospheric
bar
Atmospheric
5-65
S. S. TP-316

mm
N.A.
15.9.10
15.9.11
Type of underdrain
15.9.12
Number of manholes
no.
15.9.13
Manhole diameter
mm
900
no.
N.A.
15.10 ACID STORAGE TANKS

15.10.1
Number supplied
15.10.2
Manufacturer
15.10.3
Type
15.10.4
Stock capacity for operation
months
15.10.5
Net storage capacity per unit
m3
24
15.10.6
Design temperature
60
15.10.7
Materials of Construction
15.10.8
15.10.9
Later
CS with HRL
mm
Later
Later
15.11 CAUSTIC STORAGE TANK

15.11.1
Number supplied
15.11.2
Manufacturer
no.
2
Later
Item
15.11.3
Type
15.11.4
Stock for operation
15.11.5
Unit
Page: 119
Value/Description
months
Net storage capacity per unit
m3
7.5
15.11.6
Design temperature
60
15.11.7
15.11.8
15.11.9
CS
mm
Later
Later
15.12 VENT TRAP

no.
Later
15.12.1
Number supplied
15.12.2
Manufacturer
Later
15.12.3
Type
Later
15.12.4
Effective volume
m3
Later
15.12.5
Design temperature
Later
15.12.6
Later
15.12.7
Inside coating painting
Later
15.13 NEUTRALISATION TANK

no.
15.13.1
Number supplied
15.13.2
Manufacturer
15.13.3
Type
15.13.4
Effective volume
m3
900
15.13.5
Total volume
m3
Later
15.13.6
Working pressure
bar
Atmospheric
15.13.7
Design pressure
bar
Atmospheric
15.13.8
Design temperature
60
15.13.9
Material of Construction
15.13.10
mm
Later
15.13.11
Number of mixing ejectors
no.
15.13.12
Number of manholes/shape
no.
N.A.
Later
Underground
RC
Page: 120
Item
Unit
Value/Description
15.13.13
Manhole size
mm
N.A.
15.13.14
Later
15.14 DISTILLATE WATER TRANSFER PUMPS

15.14.1
Number
15.14.2
Manufacturer
15.14.3
Type
15.14.4
Design capacity
no.
3
Later
litres/h
270,000
no.
15.15 DISTILLATE WATER BOOSTER PUMPS

15.15.1
Number
15.15.2
Manufacturer
15.15.3
Type
15.15.4
Design capacity
Later
litres/h
270,000
no.
2x100%
15.16 MAKE UP WATER DISCHARGE PUMPS

15.16.1
Number
15.16.2
Manufacturer
15.16.3
Type
15.16.4
Design capacity
Ebara, Yoshikura,
Torishima, Weir, or
equiv.
litres/h
270,000
no.
15.17 DILUTION/REGENERATION PUMPS

15.17.1
Number
15.17.2
Manufacturer
15.17.3
Type
15.17.4
Design capacity
Later
litres/h
90,000
no.
15.18 NEUTRALISATION PUMPS

15.18.1
Number
Item
15.18.2
Manufacturer
15.18.3
Type
15.18.4
Design capacity
Unit
Page: 121
Value/Description
Later
litres/h
220,000
no.
15.19 ACID DOSING PUMPS

15.19.1
Number
15.19.2
Manufacturer
15.19.3
Type
15.19.4
Design capacity
Later
Magnetic Centrifugal
litres/h
5,000
no.
15.20 CAUSTIC DOSING PUMPS

15.20.1
Number
15.20.2
Manufacturer
15.20.3
Type
15.20.4
Design capacity
Later
Magnetic Centrifugal
litres/h
3,000
no.
15.21 ACID UNLOADING PUMPS

15.21.1
Number
15.21.2
Manufacturer
15.21.3
Type
15.21.4
Design capacity
Later
m/h
10
no.
15.22 CAUSTIC UNLOADING PUMPS

15.22.1
Number
15.22.2
Manufacturer
15.22.3
Type
15.22.4
Design capacity
15.23 CAUSTIC SOLUTION TRANSFER PUMPS
Later
m/h
10
Page: 122
Item
15.23.1
Number
15.23.2
Manufacturer
15.23.3
Type
15.23.4
Design capacity
Unit
Value/Description
no.
2
Later
m/h
10
16 NOT USED
Page: 123
17 CHEMICAL LABORATORY
Not applicable
Page: 125
Page: 127
18 WASTE WATER TREATMENT PLANT

Item
Unit
Value/Description
18.1.1 Maximum capacity of waste water treatment

plant:
oil contaminated drains
m/h
10.5
18.1.2 Capacity of waste water precipitation tank for

treatment of wash waters
18.1 MAIN DESIGN DATA
40
18.2 OILY WATER BASIN

no.
18.2.1 Number
1
RC
18.2.2 Material
18.2.3 Volume
250
no.
18.3 OILY WATER DELIVERY PUMPS

18.3.1 Number
Later
18.3.2 Manufacturer/Model
Progressive Cavity
18.3.3 Type
18.3.4 Capacity
18.3.5 Discharge Head
litres/s
2.92
bar
18.4 PORTABLE OIL SKIMMER

18.4.1 Number
no.
Later
18.4.3 Type
Later
18.4.4 Capacity
litres/s
Later
18.5 OIL SKIMMER SYSTEM

18.5.1 Length of tube or belt
316SS
18.5.2 Material
18.5.3 Collecting pipe, size
1.2
Later
Page: 128
Item
18.5.4 Collecting pipe, capacity
18.5.5 Number
Unit
Value/Description
litres
Later
no.
18.6 OIL SLUDGE TANK

18.6.1 Type
MSEP

18.6.3 Capacity
litres
1300
18.7 OIL HOLDING TANK

18.7.1 Type
MSEP

18.7.3 Capacity
1300
no.
18.8 OIL TRANSFER PUMP

18.8.1 Number
Later
18.8.3 Type
18.8.4 Capacity
18.8.5 Discharge pressure
litre/s
2.7
bar
no.
18.9 OILY SLUDGE TRANSFER PUMP

18.9.1 Number
Later
Progressive Cavity
18.9.3 Type
18.9.4 Capacity
18.9.5 Discharge pressure
litre/s
0.28
bar
no.
litres/s
2.7
18.10 OIL/WATER SEPARATOR

18.10.1
Number
18.10.2
Flow Rate
Item
18.10.3
Unit
Page: 129
Value/Description
Later
Performance
18.10.3.1 Minimum size globules removed
Later
18.10.3.2 Removal
Later
18.10.4
Later
Material
18.10.5
Protective Treatment Thickness
and Material
mm
Later
18.10.5.1 Inside Surface
Later
18.10.5.2 Outside Surface
Later
18.11 CHEMICAL WASTE WATER TREATMENT

TANK
18.11.1
Manufacturer
18.11.2
Type
18.11.3
Tank Capacity
18.11.4
Capacity of charging pump
Later
Hopper Bottom Tank
m
40
m/h
10
18.11.5
Capacity of treated water discharge
pump
m/h
10
18.11.6
m/h
Capacity of sludge discharge pump
18.12 CHEMICAL WASTE WATER RETENTION

PIT
18.12.1
Type
18.12.2
Inside coating material
18.12.3
Capacity
RC Basin
Later
m
250
18.13 WASTE WATER COOLING AND

MONITORING BASIN
18.13.1
Type
18.13.2
Inside coating material
18.13.3
Capacity
Concrete Made Basin

Later
m
Later
Page: 131
19 SEWAGE TREATMENT PLANT

Item
Unit
Value/Description
19.1 PERFORMANCE DATA

19.1.1 Manufacturer
Later
19.1.2 Type of Treatment System
Later
m/day
50
19.2.1 Suspended Solids
mg/l
25
19.2.2 BOD5
mg/l
20
19.2.3 COD
mg/l
125
19.2.4 Oil and Grease
mg/l
10
MPN/ 100 ml
1000
19.1.3 Treatment Capacity
19.2 GUARANTEED QUALITY OF TREATED

WATER AT THE SYSTEM OUTLET
19.2.5 Faecal Coliforms
Page: 133
20 SUMP PUMPS
Item
Unit
Value/Description
no.
20.1 OILY DRAIN SUMP PUMPS

20.1.1 Number
Later
20.1.2 Manufacturer
Submergible
20.1.3 Type
20.1.4 Design capacity
Litres/h
4800
no.
20.2 CHEMICAL DRAIN SUMP PUMPS

20.2.1 Number
Later
20.2.2 Manufacturer
Stainless Submergible
20.2.3 Type
Litres/h
1200
no.
Later
20.3 SEWAGE SUMP PUMPS

20.3.1 Number
20.3.2 Manufacturer
Later
20.3.3 Type
Later
litres/h
Later
Page: 135
21 CRANES AND HOISTS

The next Data Sheets shall be copied in sufficient number of copies and filled in for following
cranes and lifting equipment including but not limited to:
Overhead travelling cranes:
-
Gas turbine hall crane
Steam turbine hall crane
Gas compressor room crane
Workshop and store crane
Emergency diesel generator building crane
Air compressor and boiler feedwater pumps building crane
Motor hoists with trolleys:

-
Gas turbine compartment hoists
Steam turbine ancillary equipment hoists
Other installations
Manual hoists:
-
Fire pump house hoist
Store hoist
Steam turbine ancillary equipment hoist
Other hoists
Item
Unit
Value/Description
21.1 OVERHEAD TRAVELLING CRANES

Gas Turbine Hall
21.1.1 Location
21.1.2 Number off
21.1.3 Manufacturer
Dematic, Kone, Korea

Hoist, Namsung,
Samwon, Rank Crane,
Anupam Industries
Limited or Equiv.
21.1.4 Design according standard
Subject to
design
Page: 136
Item
Unit
Subject to
design
21.1.5 Stress class
21.1.6 Type of crane girder
Value/Description
Subject to
design
21.1.7 Nominal carrying capacity:

21.1.7.1
Main hoist
90
21.1.7.2
Auxiliary hoist
15
Subject to
design
21.1.8 Total weight of crane
Subject to
design
21.1.9 Crane dimensions
21.1.9.1
Overall width
Approx. 40
21.1.9.2
Overall length
Approx. 110
21.1.10
Span between rail centres
mm
Subject to
design
21.1.11
Rail height over operating floor
mm
Subject to
design
mm
Subject to
design
21.1.12
Max. deflection of crane bridge with
nominal load and crab in centre position
21.1.13
Control positions
Subject to
design
21.1.14
Number of bridge beams
Subject to
design
Subject to
design
21.1.15
Lifting height over operating floor
(max.)
21.1.15.1 Main hoist
mm
Subject to
design
21.1.15.2 Auxiliary hoist
mm
Subject to
design
Item
21.1.16
Unit
Value/Description
Subject to
design
Lowest hook position
21.1.17
Min. spacing between crane grap and
highest equipment
Page: 137
mm
Subject to
design
21.1.18
hoist
Crane travelling speed at SWL, main
m/min
Subject to
design
21.1.19
hoist
Crab traversing speed at SWL, main
m/min
Subject to
design
21.1.20
Crane travelling speed at SWL, aux.
Hoist
m/min
Subject to
design
21.1.21
Crab traversing speed at SWL, aux.
Hoist
m/min
Subject to
design
21.1.22
Cross travel speed
m/min
Subject to
design
21.1.23
Longitudinal travel speed
m/min
Subject to
design
21.1.24
Hoisting motors
Subject to
design
21.1.24.1 Number off
kW
Subject to
design
21.1.24.3 Speed
rpm
Subject to
design
21.1.24.4 Voltage
Subject to
design
21.1.25
Crane travelling motors
Subject to
design
Subject to
design
Page: 138
Item
Unit
Value/Description
kW
Subject to
design
21.1.25.3 Speed
rpm
Subject to
design
21.1.25.4 Voltage
Subject to
design

Steam Turbine Hall
21.2.1 Location
21.2.2 Number off
21.2.3 Manufacturer

Hoist, Namsung,
Samwon, Rank Crane,
Anupam Industries
Limited or Equiv.
Subject to
design
Subject to
design
21.2.5 Stress class
Subject to
design

21.2.7.1
Main hoist
60
21.2.7.2
Auxiliary hoist
15
Subject to
design
Subject to
design
21.2.9.1
Overall width
Approx. 25
21.2.9.2
Overall length
Approx. 80
mm
Subject to
design
21.2.10
Item
21.2.11
21.2.12
Page: 139
Unit
Value/Description
mm
Subject to
design
mm
Subject to
design
21.2.13
Control positions
Subject to
design
21.2.14
Subject to
design
Subject to
design
21.2.15
(max.)
mm
Subject to
design
mm
Subject to
design
21.2.16
Subject to
design
21.2.17
highest equipment
mm
Subject to
design
21.2.18
hoist
m/min
Subject to
design
21.2.19
hoist
m/min
Subject to
design
21.2.20
Hoist
m/min
Subject to
design
21.2.21
Hoist
m/min
Subject to
subcontrac tors standard
design
21.2.22
Cross travel speed
m/min
Subject to
design
21.2.23
m/min
Subject to
design
Page: 140
Item
21.2.24
Unit
Value/Description
Hoisting motors
Subject to
design
kW
Subject to
design
21.2.24.3 Speed
rpm
Subject to
design
21.2.24.4 Voltage
Subject to
design
21.2.25
Subject to
design
Subject to
design
kW
Subject to
design
21.2.25.3 Speed
rpm
Subject to
design
21.2.25.4 Voltage
Subject to
design

Gas Compressor Room
Crane
21.3.1 Location
21.3.2 Number off
21.3.3 Manufacturer

Hoist, Namsung,
Samwon, Rank Crane,
Anupam Industries
Limited or Equiv.
Subject to
design
21.3.5 Stress class
Subject to
design
Item
Page: 141
Unit
Value/Description
Subject to
design

21.3.7.1
Main hoist
10
21.3.7.2
Auxiliary hoist
NA
Subject to
design
Subject to
design
21.3.9.1
Overall width
Approx. 13
21.3.9.2
Overall length
Approx. 100
21.3.10
mm
Subject to
design
21.3.11
mm
Subject to
design
mm
Subject to
design
21.3.12
21.3.13
Control positions
Subject to
design
21.3.14
Subject to
design
Subject to
design
21.3.15
(max.)
mm
Subject to
design
mm
Subject to
design
21.3.16
Subject to
design
Page: 142
Item
Unit
Value/Description
21.3.17
highest equipment
mm
Subject to
design
21.3.18
hoist
m/min
Subject to
design
21.3.19
hoist
m/min
Subject to
design
21.3.20
Hoist
m/min
Subject to
design
21.3.21
Hoist
m/min
Subject to
design
21.3.22
Cross travel speed
m/min
Subject to
design
21.3.23
m/min
Subject to
design
21.3.24
Hoisting motors
Subject to
design
kW
Subject to
design
21.3.24.3 Speed
rpm
Subject to
design
21.3.24.4 Voltage
Subject to
design
21.3.25
Subject to
design
Subject to
design
kW
Subject to
design
Page: 143
Item
Unit
Value/Description
21.3.25.3 Speed
rpm
Subject to
design
21.3.25.4 Voltage
Subject to
design

Work Shop and Store
Crane
21.4.1 Location
21.4.2 Number off
21.4.3 Manufacturer

Hoist, Namsung,
Samwon, Rank Crane,
Anupam Industries
Limited or Equiv.
Subject to
design
Subject to
design
21.4.5 Stress class
Subject to
design

21.4.7.1
Main hoist
21.4.7.2
Auxiliary hoist
NA
Subject to
design
Subject to
design
21.4.9.1
Overall width
Approx. 30
21.4.9.2
Overall length
Later
21.4.10
mm
Subject to
design
21.4.11
mm
Subject to
design
Page: 144
Item
Unit
Value/Description
21.4.12
mm
Subject to
design
21.4.13
Control positions
Subject to
design
21.4.14
Subject to
design
Subject to
design
21.4.15
(max.)
mm
Subject to
design
mm
Subject to
design
21.4.16
Subject to
design
21.4.17
highest equipment
mm
Subject to
design
21.4.18
hoist
m/min
Subject to
design
21.4.19
hoist
m/min
Subject to
design
21.4.20
Hoist
m/min
Subject to
design
21.4.21
Hoist
m/min
Subject to
design
21.4.22
Cross travel speed
m/min
Subject to
design
21.4.23
m/min
Subject to
design
21.4.24
Hoisting motors
Item
Unit
Page: 145
Value/Description
Subject to
design
kW
Subject to
design
21.4.24.3 Speed
rpm
Subject to
design
21.4.24.4 Voltage
Subject to
design
21.4.25
Subject to
design
Subject to
design
kW
Subject to
design
21.4.25.3 Speed
rpm
Subject to
design
21.4.25.4 Voltage
Subject to
design

Emergency DG Buld
Crane
21.5.1 Location
21.5.2 Number off
21.5.3 Manufacturer

Hoist, Namsung,
Samwon, Rank Crane,
Anupam Industries
Limited or Equiv.
Subject to
design
21.5.5 Stress class
Subject to
design
Page: 146
Item
Unit
Value/Description
Subject to
design

21.5.7.1
Main hoist
21.5.7.2
Auxiliary hoist
NA
Subject to
design
Subject to
design
21.5.9.1
Overall width
Approx. 20
21.5.9.2
Overall length
Later
21.5.10
mm
Subject to
design
21.5.11
mm
Subject to
design
mm
Subject to
design
21.5.12
21.5.13
Control positions
Subject to
design
21.5.14
Subject to
design
Subject to
design
21.5.15
(max.)
mm
Subject to
design
mm
Subject to
design
21.5.16
Subject to
design
Page: 147
Item
Unit
Value/Description
21.5.17
highest equipment
mm
Subject to
design
21.5.18
hoist
m/min
Subject to
design
21.5.19
hoist
m/min
Subject to
design
21.5.20
Hoist
m/min
Subject to
design
21.5.21
Hoist
m/min
Subject to
design
21.5.22
Cross travel speed
m/min
Subject to
design
21.5.23
m/min
Subject to
design
21.5.24
Hoisting motors
Subject to
design
kW
Subject to
design
21.5.24.3 Speed
rpm
Subject to
design
21.5.24.4 Voltage
Subject to
design
21.5.25
Subject to
design
Subject to
design
kW
Subject to
design
Page: 148
Item
Unit
Value/Description
21.5.25.3 Speed
rpm
Subject to
design
21.5.25.4 Voltage
Subject to
design

Air Comp and Boiler
Feed Water Pumps Buld
Crane
21.6.1 Location
21.6.2 Number off
21.6.3 Manufacturer

Hoist, Namsung,
Samwon, Rank Crane,
Anupam Industries
Limited or Equiv.
Subject to
design
Subject to
design
21.6.5 Stress class
Subject to
design

21.6.7.1
Main hoist
10
21.6.7.2
Auxiliary hoist
NA
Subject to
design
Subject to
design
21.6.9.1
Overall width
Approx. 13
21.6.9.2
Overall length
Later
mm
Subject to
design
21.6.10
Item
21.6.11
21.6.12
Page: 149
Unit
Value/Description
mm
Subject to
design
mm
Subject to
design
21.6.13
Control positions
Subject to
design
21.6.14
Subject to
design
Subject to
design
21.6.15
(max.)
mm
Subject to
design
mm
Subject to
design
21.6.16
Subject to
design
21.6.17
highest equipment
mm
Subject to
design
21.6.18
hoist
m/min
Subject to
design
21.6.19
hoist
m/min
Subject to
design
21.6.20
Hoist
m/min
Subject to
design
21.6.21
Hoist
m/min
Subject to
design
21.6.22
Cross travel speed
m/min
Subject to
design
21.6.23
m/min
Subject to
design
Page: 150
Item
21.6.24
Unit
Value/Description
Hoisting motors
Subject to
design
kW
Subject to
design
21.6.24.3 Speed
rpm
Subject to
design
21.6.24.4 Voltage
Subject to
design
21.6.25
Subject to
design
Subject to
design
kW
Subject to
design
21.6.25.3 Speed
rpm
Subject to
design
21.6.25.4 Voltage
Subject to
design
21.7 ELECTRICAL HOIST

GT BULD
21.7.1 Location
Later
21.7.2 Number off

21.7.3 Manufacturer

Hoist, Namsung,
Samwon, Rank Crane,
Anupam Industries
Limited or Equiv.
21.7.4 Type of drive
Subject to
design
21.7.5 Safe working load
10
Item
Unit
Page: 151
Value/Description
Subject to
design
21.7.6 Control positions
21.7.7 Rail height over operating floor
mm
Subject to
design
21.7.8 Length of runway
mm
Subject to
design
kg
Subject to
design
21.7.9 Total weight of the complete assembly
21.7.10
Lifting height
mm
Subject to
design
21.7.11
Operating floor level
mm
Subject to
design
21.7.12
Lifting speed
m/min
Subject to
design
21.7.13
Sliding speed of traverse
m/min
Subject to
design
21.7.14
Sliding speed of trolley
m/min
Subject to
design
21.7.15
Hoisting motor
Subject to
design
kW
Subject to
design

21.8.1 Location
21.8.2 Number off
21.8.3 Manufacturer
Water Treatment Pump

House
Later
Hoist, Namsung,
Samwon, Rank Crane,
Anupam Industries
Limited or Equiv.
Page: 152
Item
Unit
Subject to
design
Value/Description
Later
Subject to
design
mm
Subject to
design
mm
Subject to
design
kg
Subject to
design
21.8.10
Lifting height
mm
Subject to
design
21.8.11
mm
Subject to
design
21.8.12
Lifting speed
m/min
Subject to
design
21.8.13
m/min
Subject to
design
21.8.14
m/min
Subject to
design
21.8.15
Hoisting motor
Subject to
design
kW
Subject to
design

21.9.1 Location
21.9.2 Number off
Steam Turbine Ancillary

Equipment
Later
Item
Unit
Page: 153
Value/Description
21.9.3 Manufacturer

Hoist, Namsung,
Samwon, Rank Crane,
Anupam Industries
Limited or Equiv.
Subject to
design
Later
Subject to
design
mm
Subject to
design
mm
Subject to
design
kg
Subject to
design
21.9.10
Lifting height
mm
Subject to
design
21.9.11
mm
Subject to
design
21.9.12
Lifting speed
m/min
Subject to
design
21.9.13
m/min
Subject to
design
21.9.14
m/min
Subject to
design
21.9.15
Hoisting motor
Subject to
design
kW
Subject to
design
Page: 154
Item
Unit
Value/Description
Condensate Pump Area
21.10.1
Location
21.10.2
Number off
21.10.3
Manufacturer

Hoist, Namsung,
Samwon, Rank Crane,
Anupam Industries
Limited or Equiv.
21.10.4
Type of drive
Subject to
design
21.10.5
Safe working load
21.10.6
Control positions
21.10.7
mm
Subject to
design
21.10.8
Length of runway
mm
Subject to
design
kg
Subject to
design
21.10.9
Total weight of the complete
assembly
Later
Later
Subject to
design
21.10.10
Lifting height
mm
Subject to
design
21.10.11
mm
Subject to
design
21.10.12
Lifting speed
m/min
Subject to
design
21.10.13
m/min
Subject to
design
21.10.14
m/min
Subject to
design
21.10.15
Hoisting motor
Subject to
design
kW
Subject to
design
Item
Unit
Page: 155
Value/Description

For Other Installations
21.11.1
Location
21.11.2
Number off
21.11.3
Manufacturer

Hoist, Namsung,
Samwon, Rank Crane,
Anupam Industries
Limited or Equiv.
21.11.4
Type of drive
Subject to
design
21.11.5
Safe working load
21.11.6
Control positions
21.11.7
mm
Subject to
design
21.11.8
Length of runway
mm
Subject to
design
kg
Subject to
design
21.11.9
assembly
Later
Later
Subject to
design
21.11.10
Lifting height
mm
Subject to
design
21.11.11
mm
Subject to
design
21.11.12
Lifting speed
m/min
Subject to
design
21.11.13
m/min
Subject to
design
21.11.14
m/min
Subject to
design
21.11.15
Hoisting motor
Subject to
design
Page: 156
Item
Unit
Value/Description
kW
Subject to
design
21.12 MECHANICAL HOIST

Fire Pump House
21.12.1
Location
21.12.2
Number off
21.12.3
Manufacturer
21.12.4
Safe working load
21.12.5
Subject to
design
21.12.6
Length of runway
Subject to
design
21.12.7
assembly
Later
Hoist, Namsung,
Samwon, Rank Crane,
Anupam Industries
Limited or Equiv.
Later
kg
Subject to
design
21.12.8
Lifting height
mm
Subject to
design
21.12.9
mm
Subject to
design

21.13.1
Location
21.13.2
Number off
21.13.3
Manufacturer
21.13.4
Safe working load
21.13.5
For Store Equipment

Later
Hoist, Namsung,
Samwon, Rank Crane,
Anupam Industries
Limited or Equiv.
t
Later
Subject to
design
Item
21.13.6
Unit
Value/Description
Subject to
design
Length of runway
21.13.7
assembly
Page: 157
kg
Subject to
design
21.13.8
Lifting height
mm
Subject to
design
21.13.9
mm
Subject to
design

For Other Hoists
21.14.1
Location
21.14.2
Number off
21.14.3
Manufacturer
21.14.4
Safe working load
21.14.5
Subject to
design
21.14.6
Length of runway
Subject to
design
21.14.7
assembly
Later
Hoist, Namsung,
Samwon, Rank Crane,
Anupam Industries
Limited or Equiv.
t
Later
kg
Subject to
design
21.14.8
Lifting height
mm
Subject to
design
21.14.9
mm
Subject to
design
Page: 159
22 WORKSHOP AND STORE EQUIPMENT

Item
Country of
Origine
Manufacturer
Japan, Korea,
Germany
Later
22.1.1 Digital hand held multimeters for AC/DC, 4 digit display
- ditto -
Later
22.1.2 Digital hand-held multimeters, 3-1/2 digit

display
- ditto -
Later
22.1.3 Frequency meter/timer/counter, 8 digit

display
- ditto -
Later
22.1.4 Pulse/function generator 20 MHz with digital

display
- ditto -
Later
22.1.5 Multifrequency LCR meter, resolution 5 1/2

digit
- ditto -
Later
22.1.6 Set of precision resistance decades
- ditto -
Later
22.1.7 Portable pneumatic line recorder
- ditto -
Later
22.1.8 Portable 4 line recorder
- ditto -
Later
22.1.9 Portable 6 points recorder
- ditto -
Later
22.1.10
Double channel digital storage
oscilloscope 100 MHz
- ditto -
Later
22.1.11
Hand-held Graphical Display Meter
(DSO-meter)
- ditto -
Later
22.1.12
Clip-on Ammeter
- ditto -
Later
22.1.13
Relay tester
- ditto -
Later
22.1.14
Variable transformer (variac), single
phase, 231 V 1000 VA
- ditto -
Later
22.1.15
Variable transformer (variac), three
phase, 400V 5000 VA
1 piece
- ditto -
Later
22.1.16
DC power supply laboratory-type
- ditto -
Later
22.1.17
Synchronoscope
- ditto -
Later
22.1.18
Thermocouple/RTD simulation
equipment
- ditto -
Later
22.1.19
Direct temperature indicating meter
- ditto -
Later
22.1.20
Temperature baths with cooling coil
- ditto -
Later
22.1.21
Current and voltage sources 0 - 20
mA/0 - 10V
- ditto -
Later
22.1 I&C WORKSHOP
Page: 160
Item
Country of
Origine
Manufacturer
Japan, Korea,
Germany
Later
22.1.23
Manometers for very low and low
pressure measurements
- ditto -
Later
22.1.24
Portable pressure source for low
pressure and vacuum (pneumatic measuring
box)
- ditto -
Later
22.1.25
Calibration pressure pump 0-20 bar
- ditto -
Later
22.1.26
Deadweight testers
- ditto -
Later
22.1.27
Ph tester
- ditto -
Later
22.1.28
BACHARACH combustion testing kit
- ditto -
Later
22.1.29
Portable gas detector with test gas
bottle
- ditto -
Later
22.1.30
Anemometer
- ditto -
Later
22.1.31
Portable sound level (dBA) meter
- ditto -
Later
22.1.32
Barometer
- ditto -
Later
22.1.33
Speedometer (RPM), optical/digital
- ditto -
Later
22.1.34
Megger insulation tester
- ditto -
Later
22.1.35
Sets of standard instrument
technician tools
- ditto -
Later
22.1.36
Bench drilling machine
- ditto -
Later
22.1.37
Portable drilling machine
- ditto -
Later
22.1.38
Mini drilling machine set
- ditto -
Later
22.1.39
Coil winding machine
- ditto -
Later
22.1.40
Watchmaker lathe
- ditto -
Later
22.1.41
Watchmaker tools.
- ditto -
Later
22.1.42
Storage metal cabinets
- ditto -
Later
- ditto -
Later
22.1.22
Precision pressure gauges,
22.1.43
Heavy duty chairs for the
workbenches
Page: 161
23 STATION FIRE FIGHTING AND FIRE DETECTION SYSTEMS

Item
Unit
Value/Description
23.1 FIRE FIGHTING PUMPS

Later
23.1.1 Potable Water Pump

23.1.1.1
Manufacturer
23.1.1.2
Type
23.1.1.3
Rated pressure
23.1.1.4
Rated flow
23.1.1.5
Speed
23.1.1.6
Power required
23.1.1.7
Material impeller
Horizontal
9.0
bar
600
m/h
1500
rpm
200
kW
SCS13
23.1.2 Seawater Pump

23.1.2.1
Manufacturer
23.1.2.2
Type
23.1.2.3
Rated pressure
23.1.2.4
Rated flow
23.1.2.5
Speed
23.1.2.6
Power required
23.1.2.7
Material impeller
Later
Vertical
bar
9.0
m/h
600
rpm
1500
kW
210
SCS16
23.2 ELECTRIC MOTOR DRIVE FOR PUMPS

23.2.1.1
Manufacturer
23.2.1.2
Type
23.2.1.3
Speed
23.2.1.4
Rating

23.2.2.1
Manufacturer
Later
Horizontal
rpm
3000
kW
20
N.A.
N.A.
Page: 162
Item
23.2.2.2
Type
23.2.2.3
Speed
23.2.2.4
Rating
Unit
Value/Description
N.A.
rpm
N.A.
kW
N.A.
23.3 DIESEL ENGINE DRIVE FOR PUMPS

23.3.1.1
Manufacturer
23.3.1.2
Type
23.3.1.3
Speed
23.3.1.4
Rating at site
23.3.1.5
Fuel consumption
Later
Horizontal
rpm
Later
kW
Later
g/kWh
Later

23.3.2.1
Manufacturer
23.3.2.2
Type
23.3.2.3
Speed
23.3.2.4
Rating at site
23.3.2.5
Fuel consumption
Vertical
rpm
Later
kW
Later
g/kWh
Later
23.4 UNDERGROUND FIRE SERVICE MAIN

23.4.1 Manufacturer
23.4.2 Material
Later
Plastics-Polyethylene
23.5 OUTDOOR HYDRANTS

23.5.1 Manufacturer
Later
23.6 INDOOR HYDRANTS

23.6.1 Manufacturer
Later
Item
Unit
Page: 163
Value/Description
23.7 SPRINKLER SYSTEMS

Later
23.7.1 Manufacturer
23.8 WATER SPRAY FIXED SYSTEMS

Later
23.8.1 Manufacturer
23.9 FOAM SYSTEMS

Later
23.9.1 Manufacturer
Protein foam pressure

Pro portioner
23.9.2 Type of foam
23.10 CO2 SYSTEMS

23.10.1
Later
Manufacturer
23.11 HUMAN SAFE INERT GAS SYSTEM

23.11.1
Manufacturer
23.11.2
Type of Inert Gas Mixture
Later
FM200
23.12 TANK SHELL COOLING SYSTEMS

23.12.1
Later
Manufacturer
23.13 FIRE DETECTION AND FIRE ALARM

SYSTEM
23.13.1
Manufacturer
23.13.2
Type
23.13.3
Number of signalling lines
Later
Binary Method
no.
1000
23.14 FIRE EXTINGUISHERS

23.14.1
Manufacturer
23.14.2
Type of dry powder
Later
ABC Type
Page: 165
24 HEATING, VENTILATION AND AIR CONDITIONING

Two independent, identical air conditioning / ventilation units for 100% standby, complete with all
accessories for accurate operation for all rooms.
Item
Unit
Data
m 3/h
71740
24.1 CONTROL AND SWITCHGEAR BUILDING

24.1.1 Control Room, Electronic Room, MV + LV
Rooms, I&C Workshop, Telecommunications
Room and Offices
Variable volume a/c system with temperature and
humidity control for control room, electronic room,
telecommunication rooms and offices.
24.1.1.1
Essential Technical Data (for each unit)

Supply air:
-
Air volume
Fan static pressure
Pa
500
Motor power required
kW
45
Motor Speed
rpm
Later
m 3/h
64330
Return air:
-
Air volume
Fan static pressure
Pa
500
kW
22
Motor Speed
rpm
Later
Outside Air rate
m 3/h
7410
Cooling Capacity
kW
365.8
Heating Capacity
KW
51.1
Max. water consumption of air washer
m 3/h
Later
Later
Efficiency of air washer

Efficiency of filters (to ASHRAE 52-68)
-
Primary filter
90
Secondary filter
95
Make :
Later
Type:
Later
Page: 166
Item
Unit
Data
Later
Size
24.1.2 Switchgear Rooms, UPS-Rooms multi-zone A/C
unit
24.1.2.1
Essential Technical data for each unit

Supply air:
M3/h
45930
Fan static pressure
Pa
500
kW
30
Motor Speed
rpm
Later
m 3/h
41325
Air volume
Return air:
-
Air volume
Fan static pressure
Pa
500
kW
15
Motor Speed
rpm
Later
Cooling Capacity
kW
227.5
Heating Capacity
kW
42.7
m 3/h
Later
Later
Outside Air Volume

-
Primary filter
90
Secondary filter
95
Make:
Later
Type:
Later
Size:
Later
24.1.3 Basement
24.1.3.1
A ventilation system with fans
24.1.3.2
No. of exhaust air fans
24.1.3.3
For each fan:

Air volume
No.
Later
m 3/h
Later
Page: 167
Unit
Data
Fan static pressure
Pa
Later
kW
Later
Motor Speed
rpm
Later
Item
Make:
Later
Type:
Later
Size:
Later
24.1.4 Battery Rooms

24.1.4.1
Essential Technical Data

Battery room ventilation fan
m 3/h
19440
Fan pressure
Pa
147.1
kW
2.5
Motor Speed
s -1
16
Air quantity
Make:
Later
Type:
Axial
Size:
f 800
24.1.5 Kitchen
24.1.5.1

M3/h
840
Fan pressure
Pa
147.1
kW
0.085
Motor Speed
s -1
35
Air quantity
Make:
Later
Type:
INLINE
Size:
f 250
24.1.6 Toilet
Exhaust ventilation system complete with all
accessories
24.1.6.1
Essential Technical data

Exhaust Air Fan:
Page: 168
Item
Unit
Data
M3/h
740
Air volume
Fan static pressure
Pa
147.1
KW
0.128
Motor Speed
Rpm
2450
24.1.6.2
Make:
Later
24.1.6.3
Type:
INLINE
24.1.6.4
Size:
f 200
24.1.7 Refrigeration Equipment

Two or more air-cooled chillers, circulating pumps,
pipes and fittings complete with all accessories
24.1.7.1

No. Of Chillers
No.
For each chiller:

-
Refrigeration capacity
KW
1008
No. Of compressors
No.
Type of refrigerant
No. Of Fans
No.
24
Total air flow through condenser
M3/h
454510
Water-flow rate: chilled water
M3/h
147
Air cooled screw type
Make:
Later
Type:
Later
Size:
Mm
H2220xW2107xL11540
M3/h
150
25
Circulation pumps
-
Volume
Head
Make:
Later
Type:
Later
Size:
Mm
H695xW500XL1280
Expansion vessel
-
Size:
Later
Item
Page: 169
Unit
Data
Make:
Later
Type:
Later
24.2 SWITCHGEAR FOR DESAL INATION PLANT

24.2.1 LV and MV - Switchgear-rooms
.
24.2.1.1

Supply air
m 3/h
5260
Fan static pressure
Pa
500
kW
2.2
Motor Speed
rpm
Later
Air volume
N.A.
Return Air:
m 3/h
N.A.
Fan static pressure
Pa
N.A.
kW
N.A.
Motor Speed
rpm
N.A.
Cooling Capacity
kW
N.A.
No. Of cooling coil stages
No.
N.A.
Heating capacity
kW
N.A.
Air volume
Efficiency of air filter (to ASHRAE 52-68)

-
Primary Filter
90
Secondary Filter
95
Make of a/c units:

-
Type:
Later
Size:
Later
24.2.2 Office
24.2.2.1
Variable volume unit

Number of units
No.
10
Air volume
m 3/h
6580
Page: 170
Item
Unit
Data
Size:
Later
Make:
Later
Type:
Later
24.2.3 Local Electronic room
Including 24.2.2
24.2.3.1
Variable Volume units

No. of units
No.
Later
Air volume
m 3/h
Later
Sizes of units:
Later
Make:
Later
Type:
Later

24.2.4.1
Battery room ventilation fan:

M3/h
650
Fan pressure
Pa
0.085
KW
0.4
Motor Speed
Rpm
2600
Air quantity
Make:
Type:
Axial
Size:
f 315
Make of disc valves:
Later
24.2.5 Toilet:
Exhaust ventilation by roof fan complete with all
accessories
M3/h
150
Fan pressure
Pa
58.8
24.2.5.3
KW
0.053
24.2.5.4
Motor Speed
Rpm
520
24.2.5.5
Make:
Later
24.2.5.6
Type:
Ceiling Mounted
24.2.5.7
Size:
Later
24.2.5.1
Air quantity
24.2.5.2
Page: 171
Unit
Data
Condenser cooling capacity
kW
Later
No. of fans
No.
Later
Total air-flow volume through condenser
m 3/h
Later
No. of compressors
No.
Later
Total power input
kW
Later
Item
24.2.6.1
For each unit:
Make of condensing unit:

-
Type:
Later
Size:
Later
24.3 DEMINERALISATION PLANT

24.3.1 Treatment Plant and 0.4 kV Distribution Room
Air conditioning unit with supply air to water treatment
plant and switchgear room. Partially exhaust air from
water treatment Plant.
24.3.1.1
Supply air fan:

m 3/h
16120
Fan static pressure
Pa
500
kW
Later
Motor Speed
rpm
Later
Air volume
24.3.1.2
N.A.
Return air fan:

M3/h
N.A.
Fan static pressure
Pa
N.A.
24.3.1.3
Motor Power required
KW
Later
24.3.1.4
Motor speed
Rpm
Later
24.3.1.5
Cooling coil capacity
KW
81.6
24.3.1.6
Number of cooling coil stages
No.
Later
24.3.1.7
Air Quantity
Page: 172
Unit
Data
Primary Filter
90
Secondary Filter
95
Item
24.3.1.8
Make:
Later
24.3.1.9
Type:
Later
24.3.1.10 Size:
Later
24.3.2 Fresh air intake system

24.3.2.1
Sand Trap:
Number of units
No.
Later
Air flow at 20oC
m 3/h
Later
Clean sir volume at 20oC
m 3/h
Later
Pressure drop
Pa
Later
Face area
m2
Later
Dust weight separation efficiency

according to ASHRAE Standard 52.1
Later
Manufacturer
Later
Type
Later
Dimensions:
-
Width
mm
Later
Height
mm
Later
Separator depth
mm
Later
Mass (weight)
kg
Later
Pocket Filter:
-
Number of units
No.
Later
Air volume
m 3/h
Later
Filter Material
Pressure drop initial/final
Pa
Later
Atmospheric dust spot efficiency

Later
Air velocity across
m/s
Later
Manufacturer
Later
Type
Later
Later
Item
Page: 173
Unit
Data
Overall dimensions:
-
Length
mm
Later
Width
mm
Later
Height
mm
Later
Mass (weight)
kg
Later
Including 24.3.1
24.3.3 Local Control Room

Air conditioning with central air handling unit:
24.3.3.1

Supply air fan:
m 3/h
Later
Fan static pressure
Pa
Later
kW
Later
Motor Speed
rpm
Later
m 3/h
Later
Pa
Later
kW
Later
Motor speed
rpm
Later
kW
Later
No.
Later
Air volume
Return air fan:

-
Air Quantity
Fan static pressure

-
Primary Filter
Later
Secondary Filter
Later
Make:
Later
Type:
Later
Size:
Later
24.3.4 Refrigeration equipment

Air cooled condensing unit for each air handling unit
24.3.4.1
Refrigeration equipment for Treatment Plant

Condenser rating
kW
Later
Page: 174
Unit
Data
No. Of fans
No.
Later
Total-air-flow volume through condenser
m 3/h
Later
No. Of compressors
No.
Later
Total power input
kW
Later
Item

-
Type:
Later
Size:
Later
Make of cooling coil:
24.3.4.2
Type:
Later
Size:
Later
Refrigeration equipment for Local Control

Room
Condenser rating
kW
Later
No. of fans
No.
Later
m 3/h
Later
No. Of compressors
No.
Later
Total power input
kW
Later

-
Type:
Later
Size:
Later

-
Type:
Later
Size:
Later
24.4 CHLORINATION PLANT

24.4.1 Treatment Plant and 0.4 kV Distribution Room
Air conditioning unit with supply air to treatment plant
and switchgear room. Partially exhaust air from
treatment Plant.
24.4.1.1
Supply air fan:

Air volume
m 3/h
10940
Unit
Data
Fan static pressure
Pa
500
kW
Later
Motor Speed
rpm
Later
Item
24.4.1.2
Page: 175
N.A.
Return air fan:

m 3/h
N.A.
Fan static pressure
Pa
N.A.
24.4.1.3
Motor Power required
kW
N.A.
24.4.1.4
Motor speed
rpm
N.A.
24.4.1.5
kW
55.0
24.4.1.6
No.
Later
24.4.1.7

Primary Filter
Later
Secondary Filter
Later
Air Quantity
24.4.1.8
Make:
Later
24.4.1.9
Type:
Later
24.4.1.10 Size:
Later
24.4.2 Fresh air intake system

24.4.2.1
Sand Trap:
Number of units
No.
Later
Air flow at 20oC
m 3/h
Later
Clean sir volume at 20oC
m 3/h
Later
Pressure drop
Pa
Later
Face area
m2
Later
Dust weight separation efficiency

Later
Manufacturer
Later
Type
Later
Dimensions:
-
Width
mm
Later
Height
mm
Later
Page: 176
Item
-
Separator depth
Mass (weight)
Unit
Data
mm
Later
kg
Later
Pocket Filter:
-
Number of units
No.
Later
Air volume
m 3/h
Later
Filter Material
Pressure drop initial/final
Pa
Later
Atmospheric dust spot efficiency

Later
Air velocity across
m/s
Later
Manufacturer
Later
Type
Later
Later
Overall dimensions:
-
Length
mm
Later
Width
mm
Later
Height
mm
Later
Mass (weight)
kg
Later
m 3/h
Later

Air conditioning with central air handling unit:
24.4.3.1

Supply air fan:
-
Air volume
Fan static pressure
Pa
Later
kW
Later
Motor Speed
rpm
Later
m 3/h
Later
Pa
Later
kW
Later
Motor speed
rpm
Later
Return air fan:

-
Air Quantity
Fan static pressure
Page: 177
Unit
Data
kW
Later
No.
Later
Item

-
Primary Filter
Later
Secondary Filter
Later
Make:
Later
Type:
Later
Size:
Later
24.4.4 Refrigeration equipment

Air cooled condensing unit for each air handling unit
24.4.4.1
Refrigeration equipment for Treatment Plant

Condenser rating
kW
Later
No. Of fans
No.
Later
m 3/h
Later
No. Of compressors
No.
Later
Total power input
kW
Later

-
Type:
Later
Size:
Later
24.4.4.2
Type:
Later
Size:
Later
Refrigeration equipment for Local Control

Room
Condenser rating
kW
Later
No. of fans
No.
Later
m 3/h
Later
No. Of compressors
No.
Later
Total power input
kW
Later
Later
Page: 178
Item
Unit
Data
Type:
Later
Size:
Later

-
Type:
Later
Size:
Later
N.A.
24.5 WASTE WATER TREATMENT BUILDING

24.5.1 Low Voltage Switchgear Rooms
Air conditioning by packaged air conditioning unit on
the roof of the building.
24.5.1.1
Supply air:
m 3/h
Later
Fan static pressure
Pa
Later
Motor power rating
kW
Later
Motor Speed
rpm
Later
m 3/h
Later
Fan static pressure
Pa
Later
Motor power rating
kW
Later
Motor Speed
rpm
Later
24.5.1.3
Cooling capacity
kW
Later
24.5.1.4
No. of cooling coil stages
No.
Later
24.5.1.5
Heating capacity
kW
Later
24.5.1.6

Primary Filter
Later
Secondary Filter
Later
No. of compressors
No.
Later
No. of fans
No.
Later
Air volume
24.5.1.2
Return air:
Air volume
24.5.1.7
Refrigeration System (Condensing Unit):
Type of refrigerant
Later
Page: 179
Unit
Data
Capacity of Condensing Unit
kW
Later
Total Power input
kW
Later
Air flow volume (at max. ambient

temperature)
m 3/h
Later
Item
Make:
Later
Type:
Later
Size:
Later

Air conditioning with split system air conditioning.
24.5.2.1
Air handling unit
24.5.2.2

Supply air fan:
m 3/h
Later
Fan static pressure
Pa
Later
Motor power rating
kW
Later
Motor Speed
rpm
Later
m 3/h
Later
Air volume
Return air fan:

-
Air quantity
Fan static pressure
Pa
Later
kW
Later
Motor speed
rpm
Later
kW
Later
No.
Later
24.5.2.3
Primary filter
Later
Secondary filter
Later
Make:
Later
Type:
Later
Size:
Later
Condensing unit
Page: 180
Unit
Data
Condensing rating
kW
Later
No. of fans
No.
Later
Total air-flow volume condenser
m 3/h
Later
No. of compressors
No.
Later
Total power input
kW
Later
Item

-
Type:
Later
Size:
Later
Make of cooling coil

-
Type:
Later
Size:
Later
24.6 SEA WATER PUMPING ST ATION

SWITCHGEAR BUILDING
24.6.1 Switchgear Room
24.6.1.1
For each unit:

Supply air fan:
m 3/h
6060
Fan static pressure
Pa
500
Motor power rating
kW
2.2
Motor Speed
rpm
Later
Air volume
N.A.
Return air fan:

m 3/h
Later
Fan static pressure
Pa
Later
KW
Later
Motor speed
Rpm
Later
KW
30.0
No.
Later
Air quantity
Item
Page: 181
Unit
Data
Primary filter
Later
Secondary filter
Later
Make:
Later
Type:
Later
Size:
Later
Refrigeration
-
Condenser rating
kW
Later
No. of fans
No.
Later
Total-air-volume thorough condenser
m 3/h
19213
No. of compressors
No.
Total power input
kW
15.4
Make of condensing unit

-
Type:
Later
Size:
Later
Make of cooling coil

-
Later
Type:
24.6.2 Relay Room and Local Control Room

24.6.2.1
Volume control unit. Relay Room

Air volume (low pressure side)
Diff. Pressure (high and low)
24.6.2.2
m 3/h
Later
Pa
Later
m 3/h
Later
Pa
Later
m 3/h
Later
Pa
Later
Volume control Unit Control Room:

Air volume (low pressure side)
Diff. Pressure (high and low)
24.6.2.3
Make:
24.6.2.4
Type:
24.6.3 Cable Basement

24.6.3.1
Ventilation by supply fans and exhaust fans

Supply air fan:
-
Air volume
Fan static pressure
Page: 182
Item
Unit
Data
kW
Later
Motor Speed
rpm
Later
Sand Trap:
-
Pressure drop
Pa
Later
Face area
m2
Later
Dust weight separation efficiency to

ASHRAE 52.1
Later
Manufacturer
Type:
Filter
-
Pressure drop clean:
Pa
Later
Clogged max:
Pa
Later
Filter material
Atmospheric dust spot efficiency acc To

ASHRAE 52.1
Later
Manufacturer:
Later
Type
m 3/h
Later
Exhaust Fan (Roof Fan):

-
Air quantity
Fan static pressure
Pa
Later
kW
Later
Motor Speed
rpm
Later
m 3/h
290
Fan static pressure
Pa
58.8
kW
0.055
24.6.4 Toilet
Exhaust ventilation system complete with all accessories
24.6.4.1
Exhaust air fan

Air volume
Make:
Type:
Ceiling Mounted
Size:
f 320
Item
Page: 183
Unit
Data
24.6.5 Refrigeration
24.6.5.1
Condenser rating
kW
Later
24.6.5.2
No. of fans
No.
Later
24.6.5.3
m 3/h
Later
24.6.5.4
No. of compressors
No.
Later
24.6.5.5
Total power input
kW
Later
24.6.5.6

Type:
Later
Size:
Later
24.7 POTABLE WATER AND FIRE PUMP HOUSE

24.7.1 Switchgear-rooms
24.7.1.1

9180
Supply air
m 3/h
500
Fan static pressure
Pa
3.7
kW
Later
Motor Speed
rpm
N.A.
m 3/h
Later
Air volume
Return Air:
-
Air volume
Fan static pressure
Pa
Later
kW
Later
Motor Speed
rpm
Later
Cooling Capacity
kW
Later
No. Of cooling coil stages
No.
Later
Heating capacity
kW
Later
Later

-
Primary Filter
Page: 184
Item
-
Secondary Filter
Unit
Data
Later
Make of a/c units:

-
Type:
Later
Size:
Later

Two or more condensing units mounted on the roof of
the switchgear building
24.7.2.1
For each unit:

Condenser cooling capacity
kW
45.8
No. of fans
No.
Later
m 3/h
19213
No. of compressors
No.
Total power input
kW
19.0

-
Type:
Later
Size:
Later
24.8 400 KV-GIS CONTROL BUILDING

24.8.1 Control Room, Offices, Electronic, Switchgear
and Telecommunications Room
24.8.1.1
Air conditioning for each unit

Supply air fan:
m 3/h
8460
Fan static pressure
Pa
500
kW
3.7
Motor Speed
rpm
Later
Air volume
N.A.
Return air fan:

-
Air quantity
m 3/h
Item
Page: 185
Unit
Data
Fan static pressure
Pa
Later
kW
Later
Motor speed
rpm
Later
kW
41.9
No.
Later

-
Primary filter
90
Secondary filter
95
Make:
Later
Type:
Later
Size:
Later

24.8.2.1

m 3/h
1260
Fan static pressure
Pa
147.1
kW
0.4
Motor Speed
Rpm
2600
Air quantity
Make:
Later
Type:
Axial
Size:
f 315
24.8.3 Cable Basement

24.8.3.1
Ventilation by supply and exhaust air fans

No. of supply air fans
No.
Later
m 3/h
Later
For each fan:

-
Air volume
Fan static pressure
Pa
Later
kW
Later
Motor Speed
rpm
Later
Make:
Page: 186
Item
Unit
Data
Type:
Later
Size:
Later
No. of return air fans
No.
Later
m 3/h
Later
For each fan:

-
Air volume
Fan static pressure
Pa
Later
kW
Later
Motor Speed
rpm
Later
Make:
Later
Type:
Later
Size:
Later
24.8.4 Toilet
Exhaust ventilation system complete with all accessories
24.8.4.1

Exhaust air fan:
m 3/h
290
Fan static pressure
Pa
58.8
kW
0.055
Motor Speed
rpm
67.5
Air volume
Make:
Type:
Ceiling Mounted
Size:
f 320
24.8.5 Refrigeration
24.8.5.1
For each unit:

Condensing rating
kW
Later
No. of fans
No.
Later
Total air-flow volume condenser
m 3/h
19123
No. of compressors
No.
Total power input
kW
19.0
Item
Page: 187
Unit
Data
Make of condensing unit

-
Type:
Later
Size:
Later

-
Type:
Later
Size:
Later
24.9 400 KV GIS SWITCHGEAR BUILDING

Force ventilation by one or more ventilation units
Multifunctional roof ventilators for the exhaust air.
24.9.1 No. of supply air units
No.
32
m 3/h
21490
24.9.2 For each unit

24.9.2.1
Air quantity
24.9.2.2
Fan static pressure
Pa
98.1
24.9.2.3
kW
2.3
24.9.2.4
Motor Speed
rpm
1420
24.9.2.5
Sand Trap:
Pressure drop
Pa
Later
Face area
m2
Later
Dust weight separation efficiency to

ASHRAE 52.1
Later
24.9.2.6
Manufacturer:
Later
Type:
Later

Primary filter
Later
Secondary filter
Later
m2
Later
24.9.2.7
No. of malfunction roof ventilators
24.9.2.8
Free area of each ventilator
24.10 STEAM TURBINE HALL
Page: 188
Unit
Data
No.
60
m 3/h
25820
24.10.2.2 Fan static pressure
Pa
98.1
24.10.2.3 Motor power required
kW
1.4
24.10.2.4 Motor Speed
rpm
940
24.10.3.1 Pressure drop
Pa
Later
24.10.3.2 Face area
m2
Later
24.10.3.3 Dust weight separation efficiency to

ASHRAE 52.1
Later
Primary filter
Later
Secondary filter
Later
24.10.4.1 Water consumption
kg/h
Later
24.10.4.2 Pump capacity
m 3/h
Later
Later
m2
Later
No.
96
Item
Force ventilation by one or more central ventilation units
Multifunctional roof ventilators for the exhaust air
24.10.1
No. of supply air units
24.10.2
For each unit
24.10.2.1 Air quantity
24.10.3
Sand Trap:
24.10.3.4 Manufacturer:
24.10.3.5 Type:
24.10.3.6 Efficiency of air filter (to ASHRAE 52-68)
24.10.4
Humidifier (air washer):
24.10.4.3 Efficiency
24.10.5
No. of multifunction roof ventilators
24.10.5.1 Free area of each window
24.11 GAS TURBINE HALL

Force ventilation by one or more central ventilation units
Multifunction roof ventilators for the exhaust air.
24.11.1
No. of air supply units
24.11.2
For each unit
Page: 189
Unit
Data
m 3/h
25950
24.11.2.2 Fan static pressure
Pa
98.1
24.11.2.3 Motor power required
kW
1.4
24.11.2.4 Motor Speed
rpm
940
24.11.3.1 Pressure drop
Pa
Later
24.11.3.2 Face area
m2
Later
24.11.3.3 Dust weight separation efficiency to

ASHRAE 52.1
Later
Item
24.11.2.1 Air quantity
24.11.3
Sand Trap:
24.11.4
Manufacturer:
Later
24.11.5
Type:
Later
24.11.6
24.11.6.1 Primary filter
Later
24.11.6.2 Secondary filter
Later
24.11.7.1 Water consumption
kg/h
Later
24.11.7.2 Pump capacity
m 3/h
Later
Later
m2
Later
No.
16
m 3/h
11620
Fan static pressure
Pa
49
kW
1.6
Motor Speed
rpm
1290
24.11.7
Humidifier (air washer):
24.11.7.3 Efficiency
24.11.8
No. of multifunction roof ventilators
24.11.9
Free area of each ventilator
24.12 MECHANICAL AND ELECTRICAL STORES

24.12.1
Store area
24.12.1.1 A ventilation system with fans

24.12.1.2 No. of exhaust air fans
24.12.1.3 For each fan:
Air volume
Page: 190
Item
Unit
Data
Make:
Later
Type:
Roof Fan
Size:
f 630
24.12.2
Office, Toilet

accessories
24.12.2.1 Essential Technical data
Exhaust Air Fan:
m 3/h
80
Fan static pressure
Pa
58.8
kW
0.033
Motor Speed
rpm
520
Air volume
24.12.2.2 Make:
Later
24.12.2.3 Type:
Ceiling Mounted
24.12.2.4 Size:
f 270
24.13 HEAT TREATMENT BUILDING

accessories
24.13.1
Essential Technical data
24.13.1.1 Exhaust Air Fan:

m 3/h
9000
Fan static pressure
Pa
49
kW
1.1
Motor Speed
rpm
900
Air volume
24.13.1.2 Make:
Later
24.13.1.3 Type:
Roof Fan
24.13.1.4 Size:
f 710
24.14 ADMINISTRATION BUILDING
Item
Page: 191
Unit
Data
m 3/h
24780/46830
24.14.1
Entrance Hall, Amphitheater, Mess,
Conference Rooms, Switchgear,
Telecommunications Room and Offices
24.14.1.1 Essential Technical Data (for each unit)
Supply air:
-
Air volume
Fan static pressure
Pa
500/500
kW
18.5/30.0
Motor Speed
Rpm
Later
M3/h
9040/42125
Return air:
-
Air volume
Fan static pressure
Pa
500/500
kW
4.0/15.0
Motor Speed
rpm
Later
Outside Air rate
m 3/h
15740/4705
Cooling Capacity
kW
389.9/235.8
Heating Capacity
kW
50.8/37.5
m 3/h
Later
Later

24.14.2
Primary filter
90
Secondary filter
95
Make :
Later
Type:
Later
Size
Later
Kitchen
24.14.2.1 Essential Technical Data

Air quantity
m 3/h
1410
Page: 192
Unit
Data
Fan pressure
Pa
147.1
kW
0.2
Motor Speed
s -1
46
Item
Make:
Type:
INLINE
Size:
f 315
24.14.3
Toilet

accessories
24.14.3.1 Essential Technical data
Exhaust Air Fan:
m 3/h
200
Fan static pressure
Pa
58.8
kW
0.033
Motor Speed
rpm
520
Air volume
24.14.3.2 Make:
Ceiling Mounted
24.14.3.3 Type:
f 170
24.14.3.4 Size:
24.14.4
Refrigeration Equipment
Two or more air-cooled chillers, circulating pumps,

pipes and fittings complete with all accessories
24.14.4.1 Essential Technical Data
No. Of Chillers
No.
For each chiller:

-
Refrigeration capacity
kW
900
No. Of compressors
No.
Type of refrigerant
No. Of Fans
No.
24
Total air flow through condenser
m 3/h
414920
Water-flow rate: chilled water
m 3/h
130.2
Make:
Cooled screw type
Later
Item
Page: 193
Unit
Data
Type:
Later
Size:
H2200xW2107xL11540
Circulation pumps
-
Volume
Head
m 3/h
140
25
Make:
Type:
Horizontal
Size:
H695xW500xL1280
Expansion vessel
-
Size:
Later
Make:
Later
Type:
Later
Page: 195
25 EMISSION MONITORING SYSTEM

Item
Unit
Value/Description
25.1 MULTI COMPONENT GAS ANALYSER

(IF APPLICABLE)
8
25.1.1 Number of Multi Component Analysers
NOx, SOx, O2, CO2
25.1.2 Each Multi Component Analyser:
HORIBA
NOx, SOx, O2, CO2
25.1.2.2 Number of Analysers/Sensors Included
25.1.2.3 Number of Sampling Probes required
Three stage
dehumiditying system
25.1.2.4 Type of Sample Gas Conditioning

25.1.2.5 Size of Weatherproof Cabinet
m, m, m
800x775x1800
Carbon steeel
25.1.2.6 Material of Cabinet
25.1.2.7 Number of Calibration Gas Bottles

Alternatively:
We will define after the

decision of subvendor
for HRSG and Bypass
Stack
25.2 CONTAINER WITH SINGLE GAS

ANALYSERS FOR EACH COMPONENT (IF
APPLICABLE)
25.2.1 Number of Analyser Containers
25.2.2 Each Analyser Container:
25.2.2.1 Size of Weatherproof Container
m, m, m
25.2.2.2 Material of Container

Analysers included in the respective
case:
25.3 SO2 GAS ANALYSER

25.3.1 Analysis Method
Non-DISOERSIVE
INFRARED (NDIR)
25.3.2 Manufacturer
HORIBA
25.3.3 Kind of Sampling Extraction (single/collective

sample probes)
Collective
25.3.4 Type of Sample Line
Heated
Page: 196
Item
Unit
Value/Description
Three stage
25.3.5 Sample Gas Conditioning
25.3.6 Number of Calibration Gas Bottles
1/week
25.3.7 Auto Calibration

ppm
0-200 to 5000
25.3.9 Resolution
% of full Scale
25.3.10
mm, mm,3mm
N.A.
Size of Analyser Module
25.4 NOX GAS ANALYSER

NDIR

25.4.2 Manufacturer
HORIBA

sample probes)
Collective
Heated
Three stage

1/yr
1/week
ppm
0-200 to 5000
25.4.9 Resolution
% of full Scale
25.4.10
mm, mm, mm
N.A.
Analysers included in the respective

case:
25.5 O2 GAS ANALYSER
Magnet pneumatic
25.5.2 Manufacturer
HORIBA

sample probes)
Collective

Heated
Three stage
1
Item
Unit
Page: 197
Value/Description
1/week

ppm
0-25%
25.5.9 Resolution
% of full Scale
25.5.10
mm, mm, mm
N.A.
25.6 DUST ANALYSER

OPTICAL
DURAG
25.6.2 Manufacturer
25.6.3 Number of Sensor Arrangements required at

the Stack
AUTO
25.6.4 Method of Calibration

1/yr
1/week
mg/m
0-200 to 4000
25.6.7 Resolution
% of full Scale
Later
25.6.8 Size of Analyser Module
mm, mm, mm
N.A.
25.6.5 Recommended Frequency of Calibration

25.7 TEMPERATURE SENSOR

RTD
OKAZAKI
25.7.2 Manufacturer
C
0-150
25.7.4 Resolution
% of full Scale
Later
mm, mm, mm
N.A.
25.8 PRESSURE SENSOR

Later
YOKOGAWA
25.8.2 Manufacturer
Mbar
0-1200
25.8.4 Resolution
% of full Scale
0.3
mm, mm, mm
N.A.
Page: 198
Item
Unit
Value/Description
25.9 PORTABLE NOISE MONITORING

EQUIPMENT
Later
25.9.1 Manufacturer
Subject to
subcontractors
standardized design
25.9.2 Number of Microphones included
25.9.4 Resolution
25.9.5 Weight of Noise Level Meter
25.9.6 Size of Noise Level Meter
dB(A)
Subject to
subcontractors
standardized design
% of full Scale
Subject to
subcontractors
standardized design
kg
Subject to
subcontractors
standardized design
mm, mm, mm
Subject to
subcontractors
standardized design
20
25.10 EMISSION MONITORING FACILITY

25.10.1
Required minimum Floor Space
25.10.2
Number of Workplaces
25.10.3
Number of Modems
1
Colour
25.10.4
Number of Laser Printers
(colour/monochrome)
25.11 DATA ACQUISITION MODULE(S)

25.11.1
Number of Modules
25.11.2
Manufacturer
25.11.3
Battery backed circular buffer of 1
hour averages and corresponding status
information
8
ABB
days
Subject to
subcontractors
standardized design
Item
Unit
Page: 199
Value/Description
25.12 PC WORKPLACE
25.12.1
General:
Later
25.12.1.1 Manufacturer of PC
25.12.1.2 Number and Capacity of Harddisks for
main Data Storage
Gbyte
20
25.12.1.3 Type of Processor and Cock Rate
MHz
700
MByte
128
25.12.1.4 RAM Storage

25.12.1.5 Type and manufacturer of Printer
Subject to
subcontractors
standardized design
25.12.1.6 Type and manufacturer of Monitor
Subject to
subcontractors
standardized design
Page: 201
26 ELECTRICAL EQUIPMENT
Item
Unit
Value/Description
26.1 GENERATORS AND AUXILIARY

EQUIPMENT
26.1.1 Main Design Data
26.1.1.1
Manufacturer
26.1.1.2
Third party test report on offered

equipment is available
Toshiba
yes/no
IC8A1W7
26.1.1.3 Type
26.1.1.4 Rated capacity at IEC conditions
Later
MVA
220
26.1.1.5
Rated voltage
kV
17.5
26.1.1.6
Voltage range
26.1.1.7
Rated power factor (lagging)
26.1.1.8
Rated frequency
Hz
50
26.1.1.9
Continuous unbalanced load referred to

rated current
I2<8%
F/F
F/F
stator winding
73.5
rotor winding
73
at no-load
Later
at rated load
Later
26.1.1.13 Max. c.w. inlet temperature
44
26.1.1.14 Max. c.w. outlet temperature
Later
26.1.1.15 Max. c.w. requirements
m 3/h
Later
26.1.1.16 Noise level
dba
Avg. 96 without hood
26.1.1.10 Insulation class stator / rotor
0.8
26.1.1.11 Max. temperature rises at MCR at site

conditions: (operation shaded area of
diagram of IEC 34-3)
26.1.1.12 Max. magnetic flux
26.1.2 Losses
26.1.2.1
Friction and windage losses
kW
1460
26.1.2.2
Iron losses
kW
480
26.1.2.3
Copper and add. Losses at 75C
kW
470
Page: 202
Item
26.1.2.4
Rotor field losses at 75C
Unit
Value/Description
kW
370
Drwg. No.
ES-DUBAIa-5,6
26.1.3 Enclosed Characteristics Generator Curves

and Drawings
26.1.3.1 Unbalanced load versus Diagrams
26.1.3.2
26.1.3.3
Generator capability diagrams

GT
Drwg. No.
ST
Drwg. No
ES-DUBAIa-3
No-load and short circuit curves
Drwg. No.
ES-DUBAIa-1
26.1.3.4 Site ratings versus ambient temperature of:

turbine output
Drwg. No.
generator capacity
Drwg. No.
ES-DUBAIa-4
unit transformer capacity
Drwg. No.
Later
26.1.3.5
Transfer function diagram of excitation

control
Drwg. No.
ES-DUBAI-PEE1
26.1.3.6
Generator dimension
Drwg. No.
3KC002548
26.1.4.1 Inertia constant of TG set in kW sec/KVA

on machine base MVA
Hc
1.44
26.1.4.2 Per unit armature resistance on machine

base MVA (75C)
RA
0.00071
26.1.4 Generator Resistance/ Reactances /

Capacitance referred to Rated Capacity
26.1.4.3
Synchronous reactance (unsaturated)
Xd%/Xq%
212/204
26.1.4.4
Synchronous reactance (saturated)
Xd%/Xq%
183/176
26.1.4.5
Transient reactance (unsaturated)
Xd%
16.9
26.1.4.6
Direct axis per unit sub-transient

reactance on machine base MVA
Xd%
12.1
26.1.4.7
Potier reactance
Xp%
21.2
26.1.4.8
Qadrature axis per unit transient

reactance on machine base MVA
Xq%
24.2
26.1.4.9
Quadrature axis per sub-transient

synchronous reactance on machine base
MVA
Xq%
12.1
26.1.4.10 Negative phase sequence reactance
X2%
12.1
26.1.4.11 Zero sequence reactance
X0%
8.9
Item
Page: 203
Unit
Value/Description
F/phase
0.63
TD Os
N/A
26.1.5.2 Direct axis open circuit transient time

constant
Tdo
12.5
26.1.5.3
Quadrature axis open circuit transient

time constant in sec.
Tqo
2.6
26.1.5.4
Transient time constant
T1Ds
1.0
26.1.5.5
Subtransient time constant
T2Ds
0.025
26.1.5.6
DC time constant
TAs
0.53
W/kg
Later
26.1.4.12 Capacitance to ground

26.1.5 Generator Time Constants
26.1.5.1 No load time constant
26.1.6 Generator Stator

26.1.6.1
Magnetization losses of lamination at 10

T
26.1.7 Generator Excitation System

26.1.7.1
Rated voltage
V DC
Later
26.1.7.2
Ceiling voltage
V DC
Later
A DC
Later
Later
26.1.7.5 Response time
ms
Later
26.1.7.6 Amplifier gain of Exciter
KA
Later
26.1.7.7 Main Exciter feedback ratio
KE
Later
26.1.7.8
Damping transformer feedback ratio
KF
Later
26.1.7.9
Regulator time constant
TR
Later
26.1.7.10 Amplifier time constant
TA
Later
26.1.7.11 Exciter time constant
TE
Later
26.1.7.12 Damping transformer time constant
TF
Later
26.1.7.13 Positive maximum amplifier Ceiling

voltage in P.U. of no load exciter
VAmax
Later
26.1.7.14 Negative minimum amplifier Ceiling

VAmin
Later
EFDmax
Later
26.1.7.3 Impulse current

26.1.7.4 Duration
26.1.7.15 Positive maximum field voltage or ceiling

Page: 204
Item
Unit
Value/Description
26.1.7.16 Negative minimum field voltage or ceiling

EFDmin
Later
26.1.8.1 Accuracy of regulation
Later
26.1.8.2
Max. generator voltage after full load

rejection referred to rated voltage
Later
26.1.8.3
Max. time to restore generator voltage

after sudden load variation within 2% of
preset value
Later
KDRP
Later
26.1.8 Automatic Voltage Regulator (AVR)
26.1.9 Governor Parameters

26.1.9.1
Speed droop gain
26.1.9.2
Actuator gain
KT
Later
26.1.9.3
Turbine gain
Kspd
Later
26.1.9.4
Governour gain
Kc
Later
26.1.9.5
Mechanical time constant
Tm
Later
26.1.9.6
Dead time
To
Later
26.1.9.7
Reset time
Tc
Later
26.1.9.8
Droop tome constant (steady state)
Tdrp
Later
26.1.9.9
Maximum turbine torque in MW
Pmax
Later
26.1.9.10 Minimum turbine torque in MW
Pmin
Later
yes/no
Later
26.2 POWER TRANSFORMERS

26.2.1 Unit Step-up Transformer
26.2.1.1

26.2.1.2
Main Design Data

Later
Manufacturer
Standard
IEC or ANSI
Type of cooling
ONAF/ONAN
Nominal rating (IEC)
MVA
350 for GTG,

235 for STG
Continuous rating at design site

ambient temperature and:
Item
Page: 205
Unit
Value/Description
ONAF cooling
MVA
350 for GTG,

235 for STG
ONAN cooling
MVA
210 for GTG,

140 for STG
Ynd1
Vector group
On-load
Type of tap changer
Later
Manufacturer of tap changer

Voltage adjustment
10
No-load voltage ratio at medium tap

changer position
kV
420/15.75 for GTG,

420/17.5 for STG
Impedance voltage referred to 75C

winding temperature and nominal
rating
14 for GTG,
17 for STG
No-load losses at nominal voltage

ratio an rated frequency
kW
195 for GTG,

130 for STG
Short circuit losses referred to 75C

winding temperature, nominal voltage
ratio, rated frequency and nominal
rating
kW
819 for GTG,

613 for STG
Max. temperature rises over the max.

ambient temperature of:
26.2.1.3
Oil
Later
Windings (average)
Later
Winding (hot spot; K = 1.3)
Later
Coupling capacitance between HV

and LV winding per phase
nF
Later
Zero sequence impedance XO/phase
Later
Transformer windings
Star connection with
oil/SF6 gas bushing
Type of winding HV side

26.2.2 Unit Auxiliary Transformer
26.2.2.1

26.2.2.2
Guarantee Data: see relevant tables
26.2.2.3
Manufacturer
yes/no
Later
Later
Page: 206
Item
26.2.2.4
No. of transformers
26.2.2.5
Code designation
26.2.2.6
Standard
Unit
3
Later
IEC or ANSI
ONAF/ONAN
26.2.2.7 Type of cooling

26.2.2.8
Nominal rating (IEC)
26.2.2.9
Continuous rating at design site ambient

temperature and:
Value/Description
50
ONAF-cooling
50
ONAN-cooling
30
Dyn11
26.2.2.10 Vector group
On-load
26.2.2.11 Type of tap changer
Later
26.2.2.12 Manufacturer of tap changer

26.2.2.13 Voltage adjustment
Later
15.75/11
26.2.2.14 No-load voltage ratio at medium tap

changer position
26.2.2.15 Impedance voltage referred to 75C
winding temperature and nominal rating
Later
26.2.2.16 No-load losses at nominal voltage ratio

and rated frequency
kW
Later
26.2.2.17 Short circuit losses referred to 75C

winding temperature, nominal voltage
ratio, rated frequency and nominal rating
kW
Later
Oil
Later
windings (average)
Later
winding (hot spot; K = 1.3)

max. hot spot Temperature: 98C
Later
Total length
mm
Later
Total width
mm
Later
Height up to tank cover
mm
Later
Overall height (with HV bushings)
mm
Later
26.2.2.18 Max. temperature rises over the max

ambient temperature of
26.2.2.19 Dimensions and Weights
Item
Page: 207
Unit
Value/Description
Weight of oil
Later
Total weight
Later
yes/no
Later
26.2.3 MV/ LV Auxiliary Transformers

26.2.3.1

26.2.3.2
Main Design Data
26.2.3.3
Manufacturer
26.2.3.4
No. of transformers
26.2.3.5
Standard
26.2.3.6 Type of cooling
Later
No.
6
IEC or ANSI
ONAN
ONAN
Dyn11
26.2.3.7 Vector group

26.2.3.8
Type of tap changer
No-load
No-load
26.2.3.9
Voltage adjustment
Later
Air
26.2.3.10 Cooling medium

kV
11/0.4
oil
Later
windings (average)
Later
winding (hot spot; K = 1.3)
Later
yes/no
Later
26.2.3.11 No-load voltage ratio at medium tap

changer position
26.2.3.12 Max. temperature rises over the max
ambient temperature of
26.3 BUSBAR SYSTEMS

26.3.1 Generator Busbar System
26.3.1.1

26.3.1.2
Manufacturer
26.3.1.3
Type
Later
Isolation phase busduct
IEC or ANSI
26.3.1.4 Standard
26.3.1.5 Highest voltage for equipment acc. to IEC
60038
kV
24
Page: 208
Item
Unit
Value/Description
Rated current at design ambient

temperature
14,000 for GTG,
26.3.1.7
Power frequency withstand voltage (rms)
kV
50
26.3.1.8
Dry lightning impulse withstand voltage

(1.2/50 peak)
kV
95
Main conductor
kA
100 for GTG, 60 for

STG
Tie branches
kA
100
26.3.1.6
9,000 for STG
26.3.1.9 Initial symmetrical short circuit current
26.3.1.10 Asymmetrical short circuit current (peak)

170 for GTG, 100 for
STG
Main conductor
170
Tie branches
26.3.1.11 Temperature rise at rated current
Conductor
Later
Enclosure
Later
26.3.1.12 Conductor material
Aluminum
26.3.1.13 Enclosure material
Aluminum
26.3.2 11 kV Busbar
26.3.2.1

26.3.2.2
Manufacturer
26.3.2.3
Type
26.3.2.4
Standard
yes/no
Later
Later
Non-segregated phase
busduct
IEC or ANSI
26.3.2.5 Highest voltage for equipment acc. to IEC

60038
kV
12
26.3.2.6
Rated current at design ambient

temperature
3150
26.3.2.7
Power frequency withstand voltage (rms)
kV
28
26.3.2.8
Dry lightning impulse withstand voltage

(1.2/50 peak)
kV
75
26.3.2.9
Initial symmetrical short circuit current

kA
40
Main conductor
Item
Tie branches
Page: 209
Unit
Value/Description
kA
40
26.3.2.10 Asymmetrical short circuit current (peak)

Main conductor
100
Tie branches
100
26.3.2.11 Temperature rise at rated current

Conductor
Later
Enclosure
Later
26.3.2.12 Conductor material
Later
26.3.2.13 Enclosure material
Later
26.4 MV SWITCHGEAR
26.4.1.1

26.4.1.2
Type
26.4.1.3
Manufacturer
26.4.1.4
Standards
yes/no
Later
Indoor use, metal
enclosed, self standing
Later
IEC or ANSI
26.4.1.5 Highest voltage for equipment
kV
12
26.4.1.6 Nominal system voltage
kV
11
26.4.1.7 Rated power frequency withstand voltage

(1 min)
kV
28
26.4.1.8
Rated lightning impulse withstand

voltage 1.2/ 50 mus value
kV
75
26.4.1.9
Rated short time withstand current for 3

sec. (at nominal system voltage)
kA
40
kA
100
26.4.1.10 Rated peak short circuit current

26.4.1.11 Insulation medium
Later
26.4.2 Circuit Breakers

26.4.2.1
Manufacturer
26.4.2.2
Type
Later
SF6 or Vacuum circuit
breaker
Page: 210
Item
Unit
Value/Description
26.4.2.3
Arc quenching medium
Later
26.4.2.4
Rated operating sequency
Later
26.4.2.5
Rated making current
kA
100
26.4.2.6 Rated symmetrical short circuit current
kA
40
26.4.2.7
kA
40
Rated short time current (3 sec.)
26.4.3 Earthing Switches

26.4.3.1
Manufacturer
Later
26.4.3.2
Type
Later
26.4.3.3
Rated short time current (3 sec.)
kA
40
yes/no
Later
26.5 LV POWER DISTRIBUTION SYSTEM

26.5.1.1

26.5.1.2
AC Main Board (Transformer fed)
26.5.1.3
Manufacturer
26.5.1.4
Type
Later
Metal enclosed
IEC or ANSI
26.5.1.5 Standard
26.5.1.6 Highest voltage for equipment (IEC)
Later
26.5.1.7 Busbar rating
3150
26.5.1.8 Symmetrical fault withstand current (1 sec.)
kA
50
26.5.1.9
kA
105
Asymmetrical fault withstand current

(peak)
Drawout type
26.5.1.10 Draw out technique

26.5.2 Circuit Breakers (Incomer / Coupler)
Air-break
26.5.2.1
Type
26.5.2.2
Rated current
3150
26.5.2.3
Breaking current
kA
50
26.5.2.4
Making current (peak)
kV
105
26.5.3 AC Switchboard/ MCC fed from Main Boards

26.5.3.1
Manufacturer
Later
Item
26.5.3.2
Type
26.5.3.3
Standard
26.5.3.4
Highest voltage for equipment (IEC)
Unit
Page: 211
Value/Description
Metal enclosed
IEC or ANSI
Later
Later
26.5.3.5 Busbar rating

26.5.3.6 Symmetrical fault withstand current (1 sec.)
kA
50
26.5.3.7
Asymmetrical fault withstand current

(peak)
kA
105
26.5.3.8
Draw-out technique
Drawout type
26.5.4 DC Switchboards
26.5.4.1
Manufacturer
26.5.4.2
Type
26.5.4.3
Standard
Later
Metal enclosed
IEC or ANSI
26.5.4.4 Rated voltage
DC220/110/24
26.5.4.5 Highest voltage for equipment (IEC)
Later
yes/no
Later
VA
Later
26.6.1.4 Rated DC current
Later
26.6.1.5
Current limitation
Later
26.6.1.6
Type of load voltage control
Parallel
No.
Later
Series
No.
Later
26.6 CHARGERS, BATTERIES AND

INVERTERS
26.6.1.1

26.6.1.2
220 V Rectifiers
26.6.1.3 Rated input at full load
26.6.2 220 V Batteries

26.6.2.1
26.6.2.2
No. of cells in:
Type of cells
26.6.2.3 Capacity referred to 1.8 V/ cell discharge

voltage:
Lead acid
Page: 212
Item
Unit
Value/Description
at 5 hours base
Ah
Later
at 3 hours base
Ah
Later
at 1 hour base
Ah
Later
VA
Later
26.6.3 24 V Rectifiers/Converters
26.6.3.1
Rated input at full load
26.6.3.2
Rated DC current
Later
26.6.3.3
Current limitation
Later
26.6.3.4
Type of load voltage control
Parallel
No.
Later
Series
No.
Later
26.6.4 24 V Batteries (if tendered)

26.6.4.1
26.6.4.2
No. of cells in:
Lead acid
Type of cells

voltage:
At 5 hours base
Ah
Later
At 3 hours base
Ah
Later
At 1 hour base
Ah
Later
Parallel
No.
Later
Series
No.
Later
26.6.5 110 V Batteries

26.6.5.1
26.6.5.2
No. of cells in:
Lead acid
Type of cells

voltage:
At 5 hours base
Ah
Later
At 3 hours base
Ah
Later
At 1 hour base
Ah
Later
26.7 CABLE SYSTEM
Item
Page: 213
Unit
Value/Description
yes/no
Yes
26.7.1 MV Cables
26.7.1.1

26.7.1.2
Main Design Data

Manufacturer
Dubai Cable or
Equivalent
Type of cable
CV/XLPE/AWA/PVC
IEC
Standards
8.5/15kV
Rated system voltage U0/U

26.7.1.3
KV
Conductors
Cu
Material
26.7.1.4
Max. continuous conductor

temperature
90
Max. short time conductor

temperature
250
Conductor Insulation
XLPE
Material of semi-conducting layer
XLPE
Cu
Material of screen
26.7.1.5
12
Outer Insulation
Material of outer jacket
PVC
Material of filling sheath
Later
Al
Material of armouring
26.7.2 LV Cables
26.7.2.1
Main Design Data

Manufacturer
Dubai Cable or
Equivalent
Type of cable
CV/XLPE/SWA/PVC
IEC
Standard
0.6/1kV
Rated system voltage U0/U

kV
0.38
Page: 214
Item
26.7.2.2
Unit
Conductors
Cu
Material
26.7.2.3
Value/Description
Max. continuous conductor

temperature
90
Max. short time conductor

temperature
250
Conductor Insulation
Material of conductor insulation
XLPE
Material of filling sheath
Later
Material of outer insulation
PVC
Please refer to Proposal

specification Item
2.26.8.
26.8 LIGHTING SYSTEMS
Ditto
26.8.1.1
Applied standards
Ditto
26.8.1.2
Fixtures
Ditto
26.8.1.3
Obstruction lighting
Ditto
26.8.1.4
Socket outlets
Ditto
26.8.1.5
Power socket outlets
Ditto
26.8.1.6
Portable lamps
Ditto
26.8.1.7
Sub-distributions
Ditto
26.9 EARTHING SYSTEM AND LIGHTNING

PROTECTION
IEEE 665
26.9.1.1
Earthing System
26.9.1.2
Disconnection facility with existing

system and overhead line available
26.9.1.3
Subsoil conductor material
Cu
26.9.1.4
Above ground conductor material
Cu
26.9.1.5
Earthing rods material
Yes/no
Later
SUS 304
Item
26.9.1.6
Applied standard for design
26.9.1.7
Max. admissible touch and step voltage
Unit
Value/Description
IEEE 80
270
NFPA 780
26.9.2 Lightning Protection

26.9.2.1
Page: 215
Cu
Down conductors material
26.10 ELECTRICAL CONTROL SYSTEM

26.10.1
Manufacturer
Later
26.10.2
Type
Later
26.10.3
Standard
IEC or ANSI
26.11 ELECTRICAL PROTECTION SYSTEMS

26.11.1
N.A.
400 kV GIS Protection (if tendered)
N.A.
26.11.1.2 System/ type
N.A.
26.11.1.3 Past service time in commercial

operation of the proposed type
N.A.
26.11.1.4 Total number of the offered relay in each

category in use
No.
N.A.
26.11.2
Generator-Transformer Unit
Protection
Later
Digital, multifunction
Later

category in use
26.11.3
No.
Later
MV - SWG Protection
Later
Later

Later

category in use
No.
Later
Page: 216
Item
Unit
Value/Description
26.12 CATHODIC CORROSION PROTECTION

SYSTEMS
26.12.1
Manufacturer
Later
26.12.2
System type
Later
26.12.3
Applied Standards
Later
Page: 217
27 I&C SYSTEMS
Item
Country of
Origine
Manufacturer
27.1 INSTRUMENTATION AND CONTROL

SCHEDULES
NAGANO KEIKI
27.1.1 Manufacturers of Field Instrumentation,

27.1.1.1
Pressure gauges
27.1.1.2
Pressure switches
27.1.1.3
Pressure transmitters
27.1.1.4
Flow indicators
27.1.1.5
Flow switches
27.1.1.6
Flow transmitters
27.1.1.7
Level indicators
27.1.1.8
Level switches
27.1.1.9
Level transmitters
NAGANO KEIKI
NAGANO KEIKI
YOKOGAWA
Later
Later
YOKOGAWA
SAKURA ENDLESS
NAKAKITA
SEISAKUSYO
YOKOGAWA
TOKYO KEIKI
27.1.1.10 Temperature indicators
TOKYO KEIKI
27.1.1.11 Temperature switches
OKAZAKI
27.1.1.12 Temperature sensors (TC)
OKAZAKI
27.1.1.13 Temperature sensors (RTD)
Later
27.1.1.14 Instrument air filter units
NAKAKITA/NIGATA
MASONEILAN
NAKAKITA/NIGATA
MASONEILAN
NAKAKITA/NIGATA
MASONEILAN
YOKOGAWA
27.1.1.15 Control valves

27.1.1.16 Control actuators
27.1.1.17 On/Off valve actuators
27.1.1.18 Local Controllers, if applicable
Item
Unit
Data
27.1.2 DCS Control System, General

27.1.2.1
DCS Manufacturer
27.1.2.2
DCS Type
27.1.2.3
Protection subsystem type
TOSHIBA
TOSMAP-DS
High speed triple
redundant controller
Page: 218
Item
27.1.2.4
MTBF value for the entire central system
27.1.2.5
Processing module microprocessor type
27.1.2.6
Max. possible number of process stations

on the bus
27.1.2.7
Number of considered system inputs,

analogue
27.1.2.8
Number of considered system inputs,

analogue binary
27.1.2.9
Max. possible/ offered number of curves
27.1.2.10 Autodiagnostic features, bus failure

27.1.2.11 Autodiagnostic features, Program error
27.1.2.12 Autodiagnostic features, Functional error
27.1.2.13 Autodiagnostic features, Improper card/
module inserted
27.1.2.14 Autodiagnostic features, Component
supervision for
1. Power supply
2. I/O signal abnormal
3.
27.1.2.15 Automatic programming on card exchange
27.1.2.16 Allowed supply voltage variations
27.1.2.17 Power consumption of a single average
process station
27.1.2.18 Heat dissipation of the above mentioned
station
27.1.2.19 Max. ambient temperature (continuous
operation)
27.1.2.20 Max. ambient temperature (for.....hours)
Unit
Data
Hours
20000
AM486DX5-133
(nos)
(nos)
C-NET: HMI16 + CNT20

(dual redundant)
Integrated Station LAN:
HMI 22
2,000
7,000
Y/N
Trend graph 100x8

X-Y plot 10x8
Y
Y/N
Y/N
Y/N
Y/N
Y
Y
Y
Y/N
%
W
Y
AC: 170-264V(for MMI)
DC: 24V(for Process
Control Station)
350
350
50
C/h
10 (for 24 hours)
27.1.3 Remote Bus (highway)

27.1.3.1
Cable kind/ type indoor
27.1.3.2
Cable kind/ type outdoor
Optical fibre cable

TK-G62_04-LAP-FR-xxM
Optical fibre cable
TK-G62_04-LAP-FR-xxM
Item
27.1.3.3
Baud rate
27.1.3.4
Number of messages/s
27.1.3.5
Max. number of participants
27.1.3.6
Bus communication type
27.1.3.7
Noise immunity class according to IEC

255-4 recommendations
Page: 219
Unit
Data
Baud
100Mbit /sec
(nos)
Max: 4000/sec/station
(nos)
C-NET: HMI16 + CNT20

(dual redundant)
Integrated Station LAN:
HMI 22
Ethernet, UDP/IP,
CSMA/CD
Class III
(nos)
16
(nos)
16
27.1.4 Binary Inputs

27.1.4.1
Maximum number of inputs per card
27.1.4.2
Used number of inputs per card
27.1.4.3
Overvoltage and noise immunity acc. to

IEC recommendation 255-4, class
27.1.4.4
External contacts voltage
27.1.4.5
Input circuits supervision, Wire break
27.1.4.6
Input circuits supervision, short-circuit
27.1.4.7
Input circuits supervision, Actuators

running time
27.1.4.8
Input circuits supervision, Signals

discrepancy
27.1.4.9
Time stamp at the I/O-s level
27.1.4.10 Time Resolution if binary inputs
Class II
V
48
Y/N
Y/N
Y/N
Y/N
Y/N
ms
(nos)
(nos)
bit
12
Y/N
Class III
Y/N
Y/N
Y/N
Y/N/(nos)
27.1.5 Analogue Inputs

27.1.5.1
Maximum number of analogue inputs per

card
27.1.5.2
Used number of analogue inputs per card
27.1.5.3
A/D resolution (only bits carrying process

information)
27.1.5.4
Noise immunity according to IEC 255-4

recommendations
27.1.5.5
Supervisory functions, wire break
27.1.5.6
Supervisory functions, short-circuit
27.1.5.7
Supervisory functions, signal validity
27.1.5.8
Supervisory functions, generation of
Page: 220
Item
Unit
signal limit values and number of

possible limit values per analogue signal
27.1.5.9
Real time stamping of signal limit values

on card
27.1.5.10 Time resolution of signal limit values
Data
(4)
Y/N
ms
50
27.1.6 Drive cards for On/Off drives and Motors

27.1.6.1
Maximum number of drive channels on

card1
(nos)
N.A.
27.1.6.2
Used number of drive channels on card
(nos)
N.A.
27.1.7 Drive cards for Analogue drives

27.1.7.1
Maximum number of drive channels on

card
(nos)
N.A.
27.1.7.2
Used number of drive channels on card
(nos)
N.A.
Y/N
Subject to
subcontractors
standardised design
Subject to
subcontractors
standardised design
Subject to
subcontractors
standardised design
Subject to
subcontractors
standardised design
Subject to
subcontractors
standardised design
27.1.8 Power drives

27.1.8.1
Silicon controlled semiconductor
27.1.8.2
With winding temp. supervision
27.1.8.3
Wire break supervision of temperature

monitoring
27.1.8.4
Permissible switching frequency
27.1.8.5
Braking pulse
Y/N
Y/N
Y/N
27.1.9 Protection System

27.1.9.1
Protection system standards fulfilled by

the system (International and/ or
national):
27.1.9.2
MTBF value
27.1.9.3
Number of redundant central processing

units
27.1.9.4
Special internal test routines or safety

functions, self-checking of fail-safety if the
protection system itself
27.1.9.5
On-line supervision for all channels
27.1.9.6
Automatic change of selection/voting
NFPA8502
Hours
3,670,000
3 (Asynchronous)
Y
Y
Y
Item
Unit
Page: 221
Data
criteria in case of one channel failed

27.1.10
Video Display Units

LCD
27.1.10.1 Operation principle

27.1.10.2 MTBF value
27.1.10.3 Screen diagonal
27.1.10.4 Image resolution
27.1.10.5 Image frequency
27.1.10.6 Number of colours
Hours
60000
Inch
18.1
pixel x pixel
1280x1024
Hz
81k/76
Nos
16,770,000
FP882
27.1.10.7 Indicating facility type

27.1.11
Large Screen Display

BARCO
Over View-mP50
27.1.11.2 Type
3 panesl poli-silicon LCD
hours
8000
inches
50
27.1.11.6 Number of screens for one large screen
(nos)
27.1.11.7 Large screen size
mxm
2x1.5
27.1.11.8 Image resolution
pixel x pixel
1024x768
27.1.11.9 Image frequency
Hz
HF:24~115k
VF:40~100
16,700,000
cd/m 2
800
27.1.11.4 Lifetime of projection source

27.1.11.5 Screen diagonal, each
27.1.11.10 Number of colours

27.1.11.11 Brightness
27.1.12
Log Printer
HP
8150N
27.1.12.2 Type
27.1.12.3 Noise
27.1.12.4 MTBF value (switched on/ printing)
27.1.12.5 Printing speed
27.1.13
dB(A)
hours/hours
59(printing)
41(standby)
8,000/6,000
char/s
32ppm
Protocol Printer
27.1.13.2 Type
HP
8150N
Page: 222
Item
27.1.13.3 Noise
Unit
Data
dB(A)
hours/hours
59(printing)
41(standby)
8,000/6,000
char/s
32ppm
27.1.13.6
27.1.14
Hardcopy colour printer

HP
8550N
27.1.14.2 Type
LBP

27.1.14.4 Noise
27.1.14.7 Buffer memory size
Hours/hours
57(printing)
52(standby)
8,000/6,000
Minutes/picture
6ppm
MB
64
DB(A)
27.2 COMMUNICATION AND CLOCK SYSTEM

SCHEDULES
27.2.1 Telephone System
ABB
Alcatel
Philips
Or Equivalent
27.2.1.1
Proposed manufacturer
27.2.1.2
Proposed number of internal subscribers
(nos)
100
27.2.1.3
Maximum possible number of internal

subscribers without extension
(nos)
30
27.2.1.4
Maximum possible number of internal

subscribers with modular extension of
the proposed PABX system
(nos)
200
27.2.1.5
Number of external trunk lines

(ETISALAD)
(nos)
10
27.2.1.6
Number of telephone sets for explosion

proof areas
(nos)
10
27.2.1.7
Manufacturer of telephone sets for

explosion proof areas
27.2.1.8
Number of telephone sets allocated

outdoor wall mounted with soundhood
ABB
Alcatel
Philips
Or Equivalent
(nos)
50
Item
27.2.1.9
Protection class of telephone sets

allocated outdoor wall mounted
Page: 223
Unit
Data
IP...
IP54
ABB
Alcatel
Philips
Or Equivalent
27.2.1.10 Manufacturer of telephone sets allocated

outdoor wall mounted
27.2.1.11 Number of telephone sets allocated for
indoor, industrial areas, wall mounted
with soundhood
(nos)
Included in 27.2.1.14
27.2.1.12 Protection class of telephone sets

allocated for indoor, industrial areas, wall
mounted
IP...
IP54
ABB
Alcatel
Philips
Or Equivalent

for indoor, industrial areas, wall mounted
indoor, wall mounted
(nos)
ABB
Alcatel
Philips
Or Equivalent

for indoor, wall mounted
indoor, office areas
85
(nos)

for indoor, office areas
27.2.1.18 Number of other telephone sets (please
define application)
(nos)
27.2.1.19 Back-up battery capacity
hours
100
ABB
Alcatel
Philips
Or Equivalent
5
(Control Telephone)
5
27.2.2 Loudspeaker System

ABB
Alcatel
Philips
Or Equivalent
27.2.2.1
Manufacturer of the Loudspeaker System
27.2.2.2
Capacity of loudspeakers, Type 1
27.2.2.3
10
27.2.2.4
20
27.2.2.5
Manufacturer of Pre-amplifiers
ABB
Alcatel
Philips
Or Equivalent
Page: 224
Item
27.2.2.6
Manufacturer of Power amplifiers
27.2.2.7
Number of Power amplifiers
27.2.2.8
27.2.2.9
Unit
Data
ABB
Alcatel
Philips
Or Equivalent
(nos)
Power output Power amplifiers each,

sinusoidal wave at the given distortion
factor
250
Frequency range of Power amplifiers
Hz to Hz
300-12500
27.2.2.10 Distortion factor Power amplifiers at 1000

Hz
27.2.2.11 Signal to noise ratio
dB
80
27.2.3 Clock System

DATUM
27.2.3.1
Manufacturer of the Master Clock

System
27.2.3.2
Accuracy of the Master Clock
sec/day
0.00864
27.2.3.3
Battery backup ride-over time
hours
13
27.2.3.4
Proposed manufacturer of analogue type

slave clocks
NA
SEIKO CLOCK
27.2.3.5
Proposed number of analogue type slave

clocks
(pcs)
40
27.2.3.6
Big size analogue type, diameter of dial
Mm
700
27.2.3.7
Normal size analogue type, diameter of

dial
Mm
310
27.2.3.8
Proposed manufacturer of digital type

slave clocks
27.2.3.9
Proposed number of digital type slave

clocks
DATUM
(pcs)
10
27.2.3.10 Digital type, size and figure size
Mm/mm
40Hx188Wx46D/20H
27.2.3.11 Date type, size and figure size
Mm/mm
40Hx188Wx46D/20H
27.3 TRAINING SIMULATOR

27.3.1 General
27.3.1.1
Manufacturer of the hardware
Hybrid simulator system

Toshiba
TRAX, Dell, 3Com,
Epson
Item
27.3.1.2
Operating Software
27.3.1.3
Software packages (Please list)
Unit
Page: 225
Data
MS Windows 2000
Pro Trax run time
executive (RTEXEC)
Fortran compiler
Trax I/O GEN
Toshiba DCS
translator
Toshiba master
controller translator
28 CIVIL WORKS
Not applicable
Page: 227

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CNE/015/2002

Part P1 Interfaces Working Doc.

INTERFACE POINT IDENTIFICATION CODE............................................................................ 1

ELECTRICAL INTERFACES ........................................................................................... 6

INSTRUMENTATION AND CONTROL INTERFACES................................................... 9

Part P1 Interfaces Working Doc.

INTERFACE POINT IDENTIFICATION CODE

System Number, as given in the table on the following page

Interface point number 3 between the system P7 (Steam

Part P1 Interfaces Working Doc.

L 400 kV Overhead Lines

Part P1 Interfaces Working Doc.

List of Mechanical Interfaces

P0/D11-1 Potable Water

Tie-in point on common potable water supply line

GTs Turbine Units and Auxiliaries including Bypass Stack

HRSGs and Auxiliaries

Gas Systems for GTs and Boilers

At pump station in Jebel Ali port

Part P1 Interfaces Working Doc.

At tie-in point on NG pipeline in the south-east corner of the

Steam Turbine Units and Auxiliaries

At MSF steam inlet valve, nearby pipe rack between P and

At MSF steam inlet valve, nearby pipe rack between P and

Condensate and Feedwater Systems

Closed Cooling Water System

Sea Water Supply

At CCW Cooler inlet flange

Sea Water Return

At CCW Cooler outlet flange

nearby CCW cooler / pumps, on ground level

nearby CCW cooler, on ground level

Black Start / Emergency Power Supply

On pipe rack between P and D area (E220), 1 per each

Instrument and Service Air

P11/D1-1 Service Air

On pipe rack between P and D area (E220), 1 per each

P11/D1-2 Instrument Air

On pipe rack between P and D area (E220), 1 per each

P11/S0-1 Service Air

At the east side of the GT Machine Hall (if required)

Steam / Water Sampling System

Steam / Water Circuit Chemistry / Dosing

Demineralised Water Plant

P15/D1-1 Distillate (in)

Connection at distillate header of the desalination plant to

Part P1 Interfaces Working Doc.

P15/D3-1 Supply of Caustic Soda

Connection flange at caustic soda bulk storage tank of the

P15/S0-1 Demineralised Water

Connection flange at the 400 kV S/S terminal washing

Waste Water Treatment Plant

P18/D4-1 Treated Waste Waters

at seawater outfall channel (if not drained into seepage

P18/D4-2 Cooling Sea Water

At auxiliary seawater header

Sewage Treatment Plant

P19/D4-1 Treated Sewage Water

At seawater outfall channel if not used for irrigation.

P19/D0-1 Sewage Waste Water

Tie-in point on common sewage water collection line on the

P19/S0-1 Sewage Waste Water

P20/D0-1 Chemical Waste Water