PVN/Long Phu – Song Hau Project Management Board Song Hau 1 (2x600MW) Power Plant

PECC2/PCC Request for Proposal

8.1. MAIN COOLING WATER (MCW) SYSTEM

8.1.1. General
The MCW system shall consist of the Equipment required to supply MCW to the
condensers, the Unit auxiliary cooling water (ACW) system, the closed cycle cooling
system and the chlorination plant. The Contractor shall take into account the hydraulic
loss in the optional scope of the MCW intake system for the design and supply of the
MCW system under the base scope. Total cooling water requirements for Song Hau 1
is about 60 m3/s, this total cooling water requirements have to be verified by the
contractor
The general scope of works is illustrated in the drawing ND-0712C.30.M.PA001Flow
Diagram of MCW System. The flow diagram of MCW system in the drawing ND-
0712C.30.M.PA001 is prepared for the purpose of indicating the general description of
Works.
The Contractor shall include in his scope of supply the following Equipment:-
a) MCW system including forebay, pump house, cooling water pumps, valves,
trash racks, trash-removal screens, crane for handling pump, screen washing
pump, access ladders and platforms in the MCW pump house;
b) Civil and structure;
c) Interconnecting pipeworks from pumphouse to the Units;
d) All services including fresh water, compressed air, fire fighting and electric
power etc for an unmanned arrangement of the MCW pumphouse.
e) Cathodic protection system (if any) for the MCW Equipment including the
associated MCW pipework ;
f) MCW discharge piping.
The Contractor shall design to have the cooling water supplied to the Units via two (2)
pressuried cooling water pipes. Each power unit shall be supplied cooling water by 2
pumps,
The intake chamber shall be adequately sized to give satisfactory flow condition at the
pump bellmouth. The main MCW pumps shall be of the wet pit, direct driven type,
complete with electric motor. There shall be 2 x 50% MCW pumps supplying water to
each Unit.
The MCW system shall ensure that there is no unacceptable surge developed in the
system following a pump trip or under system transient conditions. The MCW pumps
shall also be protected to prevent reverse rotation under these conditions.
Stop gates shall be provided upstream of the bar screen to enable each pump intake
channel to be isolated and dewatered for maintenance. Storage racks with hoists of
same number as stop gates supplied shall also be provided.
Similarly, provisions shall be made to allow the isolation of the MCW outlet culverts /
discharge so that they can be isolated for maintenance and inspection.
Submersible type dewatering pumps shall be provided for dewatering of screen
chamber, intake chamber, inlet and outfall culvert. Local power supplies shall be
supplied for each of pumping out areas for the dewatering pumps.
Appropriate number of access manholes shall be provided along the intake and outfall
culverts for inspection purposes.

Part 4 – Owner’s Technical Requirements – Book 4.1 – Chapter 8: Balance of Plant

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PVN/Long Phu – Song Hau Project Management Board Song Hau 1 (2x600MW) Power Plant
PECC2/PCC Request for Proposal

Cathodic protection shall be provided to protect all wetted parts against corrosion.
Cathodic protection shall also be applied to the protection of the MCW pipework as
well as the submerged intake and outfall structures. In addition, these submerged
structures shall also be protected by suitable chlorination dosing. The design of the
MCW system shall be designed to avoid the settlement of silt .Where necessary, the
design shall allow for measures to achieve the removal of silt by appropriate settlement
basin eg at inlet to the MCW pumphouse forebay. If such structure is needed, this shall
be deemed to be included in the base scope.
Cooling water shall be taken off the MCW system at a point upstream of the condenser
for use for the ACW system. The ACW cooling water after passing the Unit auxiliaries
shall be returned to the MCW system via a connection downstream of the condenser.
Isolation valves shall be provided upstream and downstream of ACW. Whenever a
direct river water cooling system is not considered appropriate for the cooling of
essential auxiliaries, eg due to the risks of contamination due to leakages, a second
cooling medium with demineralized water shall be used.
Connection to CW Pump Headers will be provided from the Raw Water Intake Pumps,
for CW system fill–up and for supplying auxiliary cooling water during plant
shutdown/start-up, when the main CW pumps of any unit are not running.
The scope of supply for the MCW system shall include, but not be limited, to the
following:
1) Four (4) sets of bar screens and accessories
2) Four (4) sets of travelling screens and accessories
3) Four (4) sets of screen wash pumps with motors, duplex filters, valves and
water jets
4) Stopgate enabling the isolation of two Units;
5) Four (4) 50% capacity Main Cooling water pumps with motors, and accessories
6) One set (1) of submersible pumps with motor drives for evacuation of river
water from intake chamber
7) All Main Cooling water pipework including:
a) All necessary valves, expansion joints, fittings, flanges
b) Manholes with fittings on the Main Cooling water pipe
c) Branches and blanks for anti-surge valves
8) Power operation of all valves and other items which are necessary for the
remote starting-up and shutting-down of the MCW system
9) Supports, access steelwork and platforms, including necessary walkways,
ladders and handrails required for convenient access for operation, inspection
and maintenance of the plant
10) All fixed and roller supports, foundation steel work, embedded steelwork
holding bolts and grouting materials
11) Painting and surface protection for components during and after manufacture
and at site after erection and testing
12) Local instruments, gauges and necessary test connections
13) Electrical Equipment
14) Controls and instrumentation
15) Anti-surge valves
16) Circulating water from chlorination plant to arrest biological growth and its
associated chlorine dosing and distribution systems
17) Cathodic protection system(where needed)
18) Hydraulic oil system
Part 4 – Owner’s Technical Requirements – Book 4.1 – Chapter 8: Balance of Plant
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PVN/Long Phu – Song Hau Project Management Board Song Hau 1 (2x600MW) Power Plant
PECC2/PCC Request for Proposal

19) MCW Pumphouse structure based on an enclosed building with the associated
cranes and lifting facilities
The general definition on the scope of supply for the MCW system is as indicated in
the drawing ND-0712C.30.M.PA001
8.1.2. Design Conditions for Main Cooling Water System
The MCW system shall be of once through type and is envisaged as follows.
Bar screens, traveling screens with motors and screen wash pumps with motors
installed outdoor shall be of weather proof structure.
Heated cooling water from condenser shall be discharged into the Hau River.
River water level at Site varies significantly depending on the seasons and is also
affected by the tides. The MCW system shall be designed suitable for normal full load
at LLWL at MCW intake and HWL at MCW outfall.
The system shall be designed to recover the maximum possible siphonic head, but the
MCW pumps shall be capable of priming the system without resort to vacuum or
priming devices. The Contractor shall select an optimum difference in level between
the top of the condenser water box and the top of the weir at cooling water seal pit
during the detailed engineering stage.
The pressure rating (the maximum working pressure) of the MCW pipework shall be
equivalent to the maximum pressure anticipated under surge conditions or 1.5 times
the pump shut off head, whichever is greater. Such pressure shall be sufficient to
sustain the system surge pressure in case of a pump trip or system transient with
suitable design margins.
Design pressure for the pipework shall be 10% excess of the maximum working
pressure. Hydrostatic pressure shall be 50% excess of the design pressure.
The MCW pumps shall be identical and shall be suitable for parallel operation.
Components of the MCW pumps shall be interchangeable. The head versus capacity
and shaft power versus capacity characteristics should match to ensure even load
sharing and trouble free operation through out the full load range. The pumps shall
operate satisfactorily without cavitation or deleterious effects or under vibration or
noise at all water levels from minimum to maximum.
A margin of 10 % on flow and 20 % on friction head shall be provided for the pumps.
The MCW pumps shall be directly driven by a constant speed squirrel cage induction
motor. Continuous motor rating (at 50 deg C ambient) for MCW pump shall be at least
ten percent (10%) above the maximum load demand of the driven Equipment in the
operating range (including run out condition of pump and shut off conditions in case
pumps are envisaged to be started with the discharge valve closed).
The thickness and the construction of the pipes / ducts including joints shall be able to
withstand the maximum pressure/ vacuum encountered during the transient conditions.
Pump design with single thrust bearing at motor top or separate thrust bearings at
pump and motor is acceptable. Thrust bearing shall be oil lubricated, centrally pivoted
tilting pad type capable of absorbing axial thrust in both direction of rotation.
The MCW pumps shall be of the vertical suspended, single stage, mixed flow bowl
type. Inlet to the pumps shall be formed in the pumphouse foundation. The pumps
shall be arranged so that entire pumps can be pulled out as a unit by disconnecting the
pump discharge pipes. Wear resistant coating shall be applied to high velocity areas
which are subject to erosion and corrosion.

Part 4 – Owner’s Technical Requirements – Book 4.1 – Chapter 8: Balance of Plant

Rev.4 – May, 2014 Page 11 of 311
PVN/Long Phu – Song Hau Project Management Board Song Hau 1 (2x600MW) Power Plant
PECC2/PCC Request for Proposal

Each MCW pump and motor drive shall be capable of starting against a closed
discharge valve and shall be capable of operating between zero flow and run out flow
without overloading the motor drive. The pumps shall be capable of running under
throttled discharge condition for the purpose of filling and priming the Main Cooling
water system and the condenser. Necessary speed switches to detect reverse rotation
shall be provided to prevent motor running. The indication and alarm in DCS shall be
provided for reverse rotation.
Electro hydraulically operated butterfly valves with its own actuator shall be provided
at the discharge of each pump. The butterfly valve for MCW system shall be designed
for 110% of pump shut off pressure.
8.1.3. Construction of Main Cooling Water Pumps and Accessories
The head piece shall be of fabricated steel construction. The pump casing, bellmouth,
rising main and flanged discharge bend shall be constructed from stainless steel.
Renewable liners of stainless steel shall be provided in the casing to allow the impeller
clearance to be maintained without replacing the whole casing.
The pump shaft shall be manufactured from stainless steel, with mixed flow impeller
securely keyed and locked. Journal sleeves shall be of stainless steel. Bearings shall be
of cutlass rubber and/or ceramics, and lubrication shall be by self water and service
water. Wearing rings shall be of stainless steel.
The drive motor shall be supported by the head piece made of fabricated steel with a
sufficient access to the coupling and upper pump seal for inspection and maintenance.
An intake chamber level indicator shall be provided. The level indicator of suitable
corrosion resistant materials shall be graduated in centimeters and shall have easily
readable division numbers engraved every ten centimeters.
A float type level switch to be installed near the level indicator and all cables and
accessories for monitoring the minimum water level compatible with the safe
operation of Main Cooling water pump shall also be furnished.
8.1.4. Main Cooling Water Piping, Expansion Joints and Valves
The piping shall include valves, manholes, expansion joints, air vents, foundation
bolts, supports, hold-down straps and other accessories needed for the complete
functioning of the system.
Bolted manholes shall be provided on the pipe at intervals of not more than 100 m.
Covers shall be designed and manufactured to seal and not to increase head losses.
Suitable reinforcing plates shall be provided around the manholes.
Carbon steel pipe shall be used in Main Cooling water system from intake to outfall,
GRP pipe can also be proposed if the advantages in compare with steel pipe can be
shown. Pipe support and stopper shall be provided for MCW system pipe. Settlement
monitoring poles shall be provided for those underground MCW pipework.
Carbon steel pipe shall be manufactured in full compliance with the American Water
Works Association (AWWA) Standard or equivalent standard.
A hydraulic butterfly valve and expansion joint shall be furnished at each MCW pump
discharge.
8.1.5. MCW Pump Discharge Valves
The Contractor shall provide for each MCW pump one rubber seated butterfly valve
with hydraulic actuator. Valve operating speed shall be selected to prevent the
occurrence of water hammer and to avoid damage to the system.

Part 4 – Owner’s Technical Requirements – Book 4.1 – Chapter 8: Balance of Plant

Rev.4 – May, 2014 Page 12 of 311