Tender 19sep12a

8/11/2019 Tender 19sep12a

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BROAD TECHNICAL SPECIFICATIONS

OF

BOILER TURBINE GENERATOR (BTG)

FOR

2X300 MW COAL BASED THERMAL POWER PROJECT

AT

BOTSWANA


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1.

INTENT OF SPECIFICATIONS:

This specifications in intended to cover supply and installation of 2X300 MW Boiler

island including ESP, Turbine Generator sets and respective auxiliaries associatedintegral and power cycle piping . Scope shall include design, engineering,

manufacture, procurement, inspection and testing at manufacturers works,

packing and shipment and delivery at site.

In addition the bidders scope shall also include erection/installation including

loading & unloading , storage and handling at site, site testing, commissioning,

trial run, performance and guarantee tests and other services including supply co-

ordination, engineering and project management related to equipments/systems,

liquidation/attending to punch points.

Bidder shall be responsible for provising all material, equipment and services,

required to complete the scope and fulfill the intent of ensuring efficiency,

operatibility, maintainability and reliability of the complete work.

2.

DESCRIPTION OF SITE:

Site Mmamabula, Botswana

Nearest Town Gaborone (180 km)Mahalapye (70 km)Francistown (250 km)

Nearest RailwayStation Mookane (25 km)Mahalapye (70 km)

Nearest Airport Gaborone (180 km)

Nearest Seaport Botswana doesnt have a seaportWalvis Bay (Namibia) 1600 kmMaputo (Mozambique) 1100 km

National Highway A1 connecting Gaborone to Francistown passing throughMahalapyeSite is off 23 km from A1 at the Tropic of Capricorn line

3.

CODES AND STANDARDS

3.1.

Except where otherwise specified, all items under Contractor's scope shall

comply with the appropriate Indian codes & standards or agreed

internationally accepted codes & standards as listed below, each

incorporating the latest revisions at the time of Contract.

3.2.

Where the Contractor proposes alternative codes or standards he shall

include in his bid one copy (in English) of each Standard to which materials


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offered shall comply. In such case, the adopted alternative standard shall be

equivalent or superior to the standards mentioned in the specification.

3.3.

The Plant shall conform to various statutory regulations prevailing in

Botswana such as Boiler Regulations, Electricity Rules, Explosives Act,

Factories Act, Environment (Protection) Act etc. Wherever required,

approval from statutory authorities for the Plant supplied under the

specification shall be the responsibility of the Contractor.

3.4. In the event of any conflict between the codes and standards referred

above, and the requirements of this specification, the requirements that are

in this specification shall govern.

3.5.

In case of any change of code, standards and regulations between the date

of award of Contract and the date the Contractor proceeds withmanufacturing, the Owner shall have the option to incorporate the changed

requirements. It shall be the responsibility of the Contractor to advise Owner

of the resulting effect.

3.6. List of Codes & Standards for Reference :

a) Boiler Regulations Codes & standards prevailing in Botswana (IBR).

b) Electricity, Explosives, factories Rules prevailing in Botswana.

c)

Pollution Control regulations of Botswana.d)

Any other statutory Codes/ Standards/ Regulations prevailing in

Botswana.

e)

Environment (Protection) Act, USA.

f)

International Standards Organization (ISO).

g)

International Electro-technical Commission (IEC).

h)

American Society of Mechanical Engineers (ASME).

i) American National Standards Institute (ANSI).

j) American Society for Testing and Materials (ASTM).

k) American Institute of Steel Construction (AISC).

l)

American Welding Society (AWS).

m)

National Fire Protection Association (NFPA), USA.

n)

National Electrical Manufacturer's Association (NEMA), USA.

o)

Japanese Electro-technical Committee (JEC).

p)

Institute of Electrical and Electronics Engineers (IEEE), USA.

q)

Federal Occupational Safety and Health Regulations (OSHA), USA.

r)

Instrument Society of America (ISA).

s)

National Electric Code (NEC), USA.

t)

Heat Exchanger Institute (HEI ), USA.


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u) Tubular Exchanger Manufacturer's Association (TEMA), USA.

v) Hydraulic Institute Standards (HIS), USA.

w) International Electro-Technical Commission Publications.

x)

Power Test Code for Steam Turbines (PTC), USA.

y)

Applicable German Standards (DIN).

z)

Applicable British Standards (BS).

aa)

Applicable Russian Standards (GOST)

bb)

Electric Power Research Institute (EPRI), USA.

cc)

Standards of Manufacturer's Standardization Society (MSS), USA.

dd) American Petroleum Institute (API).

ee) ICAO.

4.

SCOPE OF WORK:

Scope covers design, engineering, manufacturing, procurement, inspection &

testing at manufacturers works, supply, insurance, receipt at site, storage and

preservation at site, intra site transportation, construction, erection, trial run,

commissioning, performance guarantee testing, handing over to owner, along with

commissioning & recommended spares for two years operation, catalogues,

drawings, documents and services including lubricants, transformer oil,

consumables for the proposed 2X300 MW Thermal power plant.

Division of work shall be as per attached Annexure A.

Terminal points shall be as per attached Annexure B

Analysis of Coal to be utilized is as per attached Annexure - C

5. BRIEF TECHNICAL REQUIREMENTS:

STEAM GENERATOR & AUXILIARIES

Two nos steam generator of 300 MW capacity with an indicative boiler outlet

pressure 175 Kg/cmsteam temperature of SH and RH 540/540 Deg C to match

turbine inlet steam parameters including all related auxiliary equipments, control

& instrumentation. Steam generator shall be sub-critical type, natural circulation,

double pass/ tower type, single radiant furnace, dry bottom, balanced draft,pulverized coal fired with all auxiliaries, corner fire, ESP, integral piping,

elevators, coal bunkers and structures, SCAPH,etc.

Boiler maximum continuous rating (BMCR) shall correspond to at least 103% of

steam flow at turbine inlet under VWO condition plus continuous steam

requirement of auxiliary steam systems of the unit.

Design criteria:

a) Excess air at economizer outlet at TMCR load: 20% (minimum)


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b) Flue gas temperature at air-heater outlet at TMCR load: 125 Deg C

c)

Loss due to unburnt carbon in ash at all loads: 3%

Following minimum values of anticipated parameters with respect to ESPs shall be

considered in steam generator design:

i)

Air infiltration in ESP: 1% of ESP inlet gas flow

ii) Pressure drop in ESP: 20mm WC

iii)

Temperature drop in ESP: 2 Deg C

The design of steam generator shall be such that it does not call for any oil

support for flame stabilization beyond 40% BMCR load.

Steam generator shall be designed for continuous operation with all HP heaters out

of operation. Under above condition the super heater and reheater outlet steam

temperature shall be maintained at rated values within the whole control range of

steam generator load.

When unit trips on full load, HP-LP bypass system will come into operation.

Design life of the steam generator sets shall be 30 years minimum. However unit

shall also be capable of operation for two shifting cycle. The design duty for 30

years shall be as follows (as per IEC 45-1):

Very hot: 300

Hot start: 6000

Warm start: 1000

Cold start: 300

Design conditions:

Main steam line pressure drop, maximum: 7 to 8 bar

Super heater pressure drop, maximum: 15 bar

Pressure drop across economizer: 4 bar

Pressure drop through steam generator from economizer inlet to superheter

outlet: 20 bar

Reheater pressure drop maximum: 2 bar

Fans including drives and controls

Induced draft system including two nos ID fans, combustion air system including

two nos. FD fans and two nos PA fans with 2 X 60 % capacity.


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Air preheaters

Rotary regenerative trisector type.

Soot Blower system

Wall Blower, LRSB and associated complete system required for soot blowing

system

Coal feeding Equipment sizing: Steam generator shall be furnished with

pulverized and raw coal feeder to attain BMCR of steam generator. The pulverizes

shall be of sufficient capacity to attain BMCR when firing specified range of coal

and one pulverizer and feeder out of service.(N+1+1 mills).

Coal feeding system

Crushed coal from the crusher will be fed to raw coal bunkers/silos. The capacity

of series of bunkers/silos per unit would be to provide 12 hrs requirements at

maximum mill capacity of the unit.

Power cycle piping: piping with hangers & supports.

Ducting, damper and expansion joints:

Thermal insulation: All equipments/pipes/ ducts whose surface temperature is

higher than 60 Deg C shall be provided with thermal insulation along with

aluminum cladding for personnel protection and heat conservation.

PG test: as per ASME PTC-4

Electro Static Precipitators:

For collection of dust (fly ash), adequately sized outdoor type ESP and fabric bag

filter shall be installed on the cold end side of regenerative air preheater for each

unit. The flue gas shall be drawn from air pre heater outlet and guided through

adequately sized duct work.

The basic idea of the ESP+FF hybrid filter is to remove the large amount of dust

(80-90%) by the ESP first to reduce the dust concentration of flue gas, then collectthe residual particulate dust ( 10-20%) from the flue gas by the filter and ensure

dust emission standard.

The ESP+Filter will remove particulate from flue gas of the steam generators to

achieve guaranteed outlet emission of less than 50 mg/Nm.

Scope of supply for ESP shall include but not limited to followings:

a)

Casing and hoppers with required accessories such as heaters, vibrators, level

detectors, and their controls.


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b) Structural steel and access stairs, platforms and ladders.

c) Gas distribution system

d) Collecting electrodes

e)

Discharge electrodes

f)

Rapping system with microprocessor based control system

g)

Dust hoppers

h)

Casing

i) Opacity monitors

STEAM TURBINE AND AUXILIARY:

a)

Steam turbine shall be reaction type comprised of tandem compound, single

reheat, regenerative, condensing type, single/ multi cylinder type, with

separate HP, separate IP and separate LP casing OR combined HP-IP as per

standard design of manufacturer directly coupled with generator suitable for

indoor installation.

Turbine capability/systems

a)

Net power output at generator terminals at TMCR: 300 MW each

b)

VWO rating: 105 % of TMCR

c)

Limitation of variation from rated steam pressure/temp: as per IEC-45

d)

Number of extractions: 6 or more

e)

Make up : 0%

f)

Speed: 3000 RPM

g)

operating frequency range: 47.5Hz to 51.5 Hzh)

type of governing: Throttle

i)

type of governor: electronic

j)

turbine oil pumps: MOP (1X100% shaft driven), AOP(2X100% one AC+ one

DC), EOP(1X100%DC),JOP(2X100% -one AC+ one DC)

k)

control oil pumps: 2X100% AC

l)

oil purification equipment/ oil tank

m)turning gear: with hand barring facility

n) bearing cap vibration: ISO-10816

o)

shaft vibration: ISO-7919

p)

HP/LP Bypass system

q)

Integral piping with hangers & supports

r)

Drains & valves

s)

Noise level: 85 dBA at 1.5 Mtr from outline of Equipment

t)

Feed water HP /LP heaters/Dearator for 10 minutes capacity

u)

Power cycle pumps ( MDBFP,TDBFP, CEP)

v)

Butter fly valves

w)Air extraction system Vacuum pumps ( 3x50%)

x) RE Joints


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y) Condenser: Air cooled

z) emergency stop and control valves, reheat stop and control valve

aa)Turbine automation system (ATRS)

bb)

Turbine supervisory system

TURBOGENERATOR

300 MW Three phase, horizontal mounted, indoor installed, hydrogen cooled, two

pole, class F winding insulation with temperature rise limited to class B.

For design opf equipment/systems, ambient temp of 50 Deg C and relative humidity

of 95% shall be considered.

Equipment shall be suitable for rated frequency of 50 Hz with a variation of +3% & -

5%, terminal voltage of +/- 10% and 5% combined variation of voltage & frequency.

All the equipments shall confirm to latest edition of relevant International codes andstandards. Generator shall conform to IEC-34.

Rated parameters:

Power factor: 0.85(lag) to 0.95(lead)

Terminal voltage: 20 to 22KV

Frequency: 50 Hz

Speed: 3000 RPM

Short circuit ratio: not less than 0.5 (without negative tolerance)

System of cooling:

Stator winding: Hydrogen cooled

Rotor winding; directly hydrogen cooled

Systems: gas system/ seal oil system/stator water cooling system (if

applicable)/excitation System (brushless/static)

Documents

Tender 19sep12a