Tender Document For Construction of Ghorasal 300-450 MW ... - BPDB
Tender Document For Construction of Ghorasal 300-450 MW ... - BPDB
Tender Document For Construction of Ghorasal 300-450 MW ... - BPDB
TENDER DOCUMENT
FOR
DECEMBER '2011
Section. Page
TECHNICAL REQUIREMENTS
A Combined Cycle Power Plant of total 300-450 MW capacity at site conditions (350C,
1.013 mbar, 98% R.H.) is intended to be set up by Bangladesh Power Development Board
at Ghorasal, Palash, Narsingdi, Bangladesh. Approx. 9 acres of land is allocated for
implementation of this project. Natural Gas will be used as fuel of this Power Plant.
The Gas turbine(s) shall be equipped with the bypass stacks and diverter dampers to
allow continuous and reliable simple cycle operation.
The proposed Plant will be installed in the land as Shown in the site layout. The Project
will be implemented on turnkey basis.
The Power Station step-up transformers would be connected with the 230 kV Power Plant
Sub-Station through underground cable and other necessary electrical equipment as
shown in the single line diagram.
The project may be classified into the following broad areas. Details are
however given later in the scope of work.
4. Supply and Construction of all civil work for a power station complete in
all respect.
5. Supply and construction of entire Gas Fuel system for the plant, fire
protection system etc.
Scope of Work
2.1.1 General
2.2.1 General
2.6.1 One (1) unit of steam turbine of mixed flow and condensing unit,
and it shall be equipped with the following accessories.
2.15 Training
2.18 Tests
2.19 Commissioning
2.22 Transport
The Tenderers will have to Supply Main (230 KV & 15.75 KV) and Auxiliary
(6.6 KV & 0.415 KV) Equipment, Materials & Systems including Supply,
Installation, Testing, Commissioning of Equipment and Control system
(including pre-close check systems & inter-lock systems, Protection
system, Metering System etc. accordingly, based on 2:2:1 or 1:1:1
configuration CCPP. Tenderers shall also fill the Price Schedule of Vol. 1 of
3, Annexure-3 accordingly.
The work shall be carried out in accordance with the conditions of this
documents, and shall include but not necessarily be limited to the following
major items.
2.1.1 General
2.2.1 General
The unit of simple cycle heavy duty industrial type gas turbine suitable for
burning gaseous fuel including the following :-
2. Generator Package
a Outdoor enclosure.
b. Stator winding with class F insulation.
c. Cylindrical forged steel rotor with class F insulation.
d. Air-cooled system.
e. Lubrication system integral with gas turbine lubrication system.
f. Platinum RTD temperature detectors imbedded in the stator
windings.
g. Structural steel base.
h. Speed reduction gear. (if required)
i. Excitation system
j. Generator space heater (s)
3. Generator switchgear
a. Outdoor enclosure.
b. SF6 Generator circuit breaker for one GTG & STG
b. Potential transformers.
c. Current transformers.
d. Lightning arresters.
e. Neutral grounding transformers,
f. Connections to generator power leads and unit step up
transformers by phase segregated copper bus duct.
g. Lighting and heating equipment.
h. Ventilation system.
i. Connections to auxiliaries transformer.
j. 15.75 kV Generator breaker having adequate capacity to meet the
requirements (as per single line diagram)
4. Inlet Air System.
a. Filter compartment with:
Support structure.
Multi-stage (3 stage) filtration system, complete in all respects.
High efficiency media filtration.
Pressure measuring instrumentation.
Inlet ducting.
Access door.
Lighting.
Air inlet system special corrosion protection.
Air inlet system bypass door.
b. Inlet silencing.
c. Transition piece from inlet duct to inlet plenum.
d. Structural support.
Exhaust system shall be designed to enable the Combined Cycle Power Plant to
run as Simple Cycle mode and Combined Cycle mode as well.
a. Outdoor enclosure.
b. Turbine control panel.
c. Generator control panel and protection panel.
d. Motor control centre.
e. Heating and air conditioning system.
One (1)/ Two (2) identical unit(s) of heat recovery steam generators of dual pres-
sure steam cycle suitable to utilise exhaust gas from the gas turbine unit including
followings.
a. The steam drum and heat transfer sections which consist of the Economiser,
c. The stairs, platforms and ladders required for maintenance, inspection and op-
eration of the heat recovery steam generator.
d. The heat recovery steam generator circulating water system for the HP and LP
drums.
e. The steam generator valves and devices which consist of indications, switches,
transmitters and sampling nozzles. Motorised valves as required for remote or
automatic operation.
j. The steam generator control system to provide control capability for transient,
steady state and protective conditions.
m. Any other equipment/ material/ system required for HRSG complete in all re-
spect.
2.6.1 One (1) unit of steam turbine of mixed flow and condensing unit, and it
shall be equipped with the following accessories.
a. Inlet stop valve (s) with coarse and fine mesh steam strainer.
c. High pressure steam bypass valve with actuator and position feedback device.
d. Motorised drain valve for turbine casing, Gland steam, seal system and
above/below stop valve seats.
g. Turbine exhaust hood water spray system and motorised vacuum breaker
valve.
i. Hydraulic system with duplex pumps, coolers, filters and integral fluid condi-
tioning unit.
j. Over-speed governor with solenoid trip.
k. Lube oil system with tank, shaft driven main lube oil pump, AC auxiliary lube oil
pump, DC emergency pump, Jacking oil pumps, coolers, valves, oil condi-
tioner, vapour extractor, gauges, pressure and temperature control devices.
l. Closed circuit cooling water system, Aux. cooling water system with AC motor
and pump of adequate capacity.
m. Steam jet Ejectors in the air extraction system.
n. Turning-gear, motor operated with provision for automatic engaging and man-
ual cranking.
o. Insulation and lagging.
p. Foundation plates and bolts.
q. Piping
Piping is factory treated, prefabricated in shippable assemblies, ready for in-
stallation, (field welds by Contractor) as follows :
- Main steam line (s) connecting the emergency valve (s) and turbine
inlet (s).
- Steam seal system - all necessary piping connection the factory supplied
turbine-generator components.
- Oil system-all necessary oil feed return piping connecting the factory sup-
plied turbine-generator components.
r. Turbine special tools.
2.6.2 One (1) lot of mechanical equipment designed to be compatible with steam
system needs and consisting of the following components :
One (1) set of emergency diesel generating set (capacity 1000 KVA at 0.8 p.f.,
1500 rpm) complete with ancillary equipment having diesel storage capacity for 24
hours of continuous operation for supplying power to essential auxiliaries. EDG
shall be of automatic starting system [compressed air/ Battery] including quick start
& loading capability. The starting system shall be capable of carrying out at least
five (5) consecutive start without auxiliary power supply. In case of power failure in
0.4 kV bus, EDG will start and supply power to 0.4 kV emergency bus in auto
mode. EDG synchronizing facility with 0.4 kV live bus is also required.
EDG is required for the safe shutdown of the plant/ equipment under emergency
condition and in case of power failure for certain essential applications like battery
chargers, emergency lighting and all auxiliaries necessary for safe coasting down
of equipment and turning gear/ barring operation of the turbines.
7) One (1) lot of suspension/post insulator string sets, tension insulator string
sets and station post supporting insulator set with necessary hardware.
: HV winding LV winding
Rated insulation level 1050 kV (Peak) 75 kV (Peak)
1) Two (2) sets of unit auxiliary transformer (2 x 110% of total aux. power
requirement but each capacity not less than 25 MVA) and associated
equipment with the following features:
Type : Oil immerse, three phase and
two windings, outdoor power
transformer.
Rating : 25 MVA
Connection : DYn11
Rated insulation
level : HV Winding LV Winding
Lighting impulse
Withstand voltage
(1.2/50 micro sec) : 95 kV (Peak) 60 kV(Peak)
Power frequency
Withstand voltage
(For 1 mm). : 36 kV 22 kV
2) Four (4) sets of station transformer (4 x 55% of total 0.4 kV aux. power
requirement but each capacity not less than 2 MVA) and associated
equipment with the following features:
Rating : 2 MVA
Rated high voltage : 6.6 kV
Rated low voltage : 415 V
Connection : Dyn11
In addition to the unit local control and protection panels, the following panels shall
be provided in the central control room.
The design and construction of the Power house, Control building, Rest
house building, Dormitory building, EDG house, Store, Guard rooms, Water
reservoirs, Water Treatment plant, Fire fighting pump house, Cooling Tower
pump house, fencing, boundary wall etc. Extension of the existing Medical
Centre is within the scope of work. The design and construction of all major
foundations and buildings shall include piling.
2.15 Training
Drawings and other engineering data for the specified equipment and
materials are essential to the design and subsequent construction of the
entire generating unit.
The supervisor (s) must be able to fluently understand, speak, read, and
write the English language.
2.18 Tests
2.19 Commissioning
The Contractor shall provide One (1) Competent Operation Engineer who
will be in overall in charge of the Plant, one (1) Engineer for Electrical
Maintenance (Generator, Transformer, Substation, Switchgears etc.) &
I&C, one (1) Engineer Mechanical Maintenance (BOP), one (1) Engineer
Gas Turbine Maintenance and One (1) Engineers for Steam Turbine &
HRSG Maintenance during 24 months warranty period for smooth
maintenance and operation of the Plant. The Contractor has to provide all
the spares and service needed for maintenance requirement during the
warranty period and will engage required manpower in addition to the
above stated personnel.
During warranty period the above mentioned Engineers jointly with BPDB'S
Engineers/Staff shall have to perform the operation & daily maintenance of
the plant. For this purpose, quarterly progress report of BPDB Personnel
shall have to be submitted to the authority by the above mentioned
Engineers showing the progress of BPDB Personnel for safe & reliable
operation and maintenance of the plant independently.
2.21 First Inspection, CI, HGPI of Gas Turbine and overhauling of other
equipment
The Contractor shall provide necessary spares and expert service for
execution of first inspection, CI, HGPI & MI of the Gas Turbine Unit or any
other required maintenance of Steam Turbine, Generators, HRSG and
BOP during the Warranty period. During the warranty period the Contractor
have to conduct (providing all required spare parts and service) at least
1(One) CI & 1(One) HGPI for Gas Turbine and at least one inspection for
other equipment and any other maintenance work for force outage.
03 nos. of four wheel drive Jeep (3000 CC), 04 nos. of sedan car (1600
CC), 04 nos. of double cabin Pick up (2700 CC), 02 nos. of microbus (2400
CC), 10 nos. of motorcycle (100 CC), 01 no. of ambulance. Country of
origin of the transports will be Japan.
The Contractor shall submit a list & supply accordingly Essential spare
parts with OEM part No. (as per Vol. 2, Schedule-F) to be necessary for
maintenance of Gas Turbine Generating Unit, Steam Turbine Generating
unit, HRSG and other plant equipment inclusive of routine, scheduled as
well as emergency use that takes place in the course of operation of the
plant during warranty period (24 months) which are mandatory. It may be
mentioned that Tenderer must quote in Schedule-F in full quantity and also
additional items & quantity necessary as stated in Tender Document,
otherwise Tender shall be rejected. During the warranty period of 24
months the Contractor shall supply all necessary equipment/ equipment
parts, materials/consumables at his own cost in addition to items and
quantity listed in Schedule-F, Vol. 2 of 2 Part B Tender Documents. Spare
parts & consumables to be supplied for warranty period under the Contract
must be made available at site before start of testing.
The contractor shall provide all special tools including a boroscope set
required for maintenance of the unit and hand them over in good condition
to the BOARD. A list of all such tools shall be incorporated with tender.
Contractor shall not be permitted to use any equipment/ machinery/ tools,
which are to be supplied under the Contract.
Contractor shall supply one Simulator for Power Plant operation Training
with five (05) Work stations.
The Tenderer shall supply all relevant international standards (ISO, IEC,
ASTM, IEEE, ASME, NFPA etc.)
3.1 General
Gas Turbine Power Plant (Simple Cycle) with a continuous total net
generating capacity of 65% (+ 5% variation is allowed) of combined cycle
net output shall be accommodated in the location proposed.
The combined cycle power plant concept shall be based on using the ex-
haust heat from the gas turbines for heat recovery steam generator, which
supply steam to the steam turbine.
The major equipment of combined cycle plant shall include the one (1) or
two (2) identical simple cycle Gas turbine generating set, one (1) or two (2)
identical Heat Recovery Steam Generators, and one (1) Steam Turbine
Generating set, and a comparable array of auxiliaries. The Steam Turbine
Generating set shall be sized to accommodate steam from the heat recov-
ery steam generator(s) with exhaust heat collected from Gas turbine(s).
The plant arrangement shall be in multi-shaft type i.e. gas turbine drives its
own generator and exhausts into a heat recovery steam generator. The
steam output from the heat recovery steam generators shall be combined
in a header system (if 2:2:1 combination is proposed) and directed to a
steam turbine. Depending on the station operation mode desired, exhaust
gas diverter dampers shall be able to control flow to either the bypass stack
for simple cycle operation of the gas turbine generating set, or to the heat
recovery steam generator for combined cycle operation, as and when
needed as per system requirement. All of these components shall be se-
lected to provide low capital and operating costs for mid-range or base-load
application. The unfired heat recovery steam generator shall be pre-
assembled in modules to reduce field erection works. The turbine shall be
chosen so that the maximum plant efficiencies can be obtained.
The steam turbine generator shall be supplied for indoor installation in the
powerhouse. An overhead electrical crane shall be supplied for mainte-
nance of the steam turbine generator.
3.2 Guarantee
The net output and heat rate of the Unit shall be guaranteed by the
contractor at the following conditions:
The contractor shall guarantee the starting reliability of the Unit(s) including
all ancillary equipment. The guaranteed reliability shall be stated in the
Tender form together with the number of consecutive starts to which the
Unit(s) will be subjected to demonstrate this reliability (This is for a starting
reliability of 95 %, the Unit(s) shall be subjected to 20 consecutive starts of
which 19 shall be successful). The maximum speed rise after full load
rejection is to be guaranteed (see Tender)
The extent of supply shall include, but not be limited to, the equipment described
herein. All equipment comprising the gas turbine & steam turbine package shall be
pre-assembled in the factory.
(1) The total net base rated output of the power station at site conditions (35 0C, 1.013
bar, 98% relative humidity) shall be 300-450 MW.
No Tender which proposes less than 300 MW output at site conditions will not be
accepted. Excess output more than 450 MW at site conditions shall not be evalu-
ated.
The main steam system for the combined cycle unit coming from main
header fed from heat recovery steam generator(s).
Super heater outlet on heat recovery steam generator(s) shall be fitted with
a safety valve, non-return valve, by-pass valve and header shut-off valve.
The feeder shall also be fitted with motor-operated vents and drains which
shall be operated from central control room.
The main steam header shall be pitched for draining of condensate. As the
heat recovery steam generators are brought into service, the main steam
line must be drained form drain legs which are fitted with motor-operated
valves, and through the turbine above seat drain, which is fitted with a mo-
tor-operated valve and a steam trap assembly. The heat recovery steam
generator feeder temperatures shall be monitored by thermocouples and
pressure by pressure transmitters and pressure switches. Flow from each
In addition, super heater outlet shall be fitted with a steam sampling con-
nection as well as an acid cleaning connection, each feeder also shall have
manual free blow for maintenance purposes.
A motor operated relief valve shall be provided in the common main steam
header. A control switch for remote operation of this relief valve shall be
provided in the control room.
The main steam header shall deliver steam to the steam turbine stop valve,
bypass system, steam seal/gland regulator, and condenser ejector system.
Steam generator feed water shall be supplied with condensate from a sur-
face condenser, deaerated in the Deaerator. Suitable chemicals will be
added in the feed water cycle for oxygen scavenging and Ph control.
Deminarelized water will be used as make up to the plant.
The boiler feed water pump of steam turbine generating plant shall be
composed of Three (3) x 60% duty motor driven pumps.
Each boiler feed pump shall be equipped with a minimum flow re-circulation
system, consisting of a flow orifice, differential pressure transmitters and
control valves. Recirculation water shall be returned to the Deaerator.
Each feed water supply line to the respective heat recovery steam genera-
tor shall be fitted with a flow nozzle and its differential pressure transmitter
which alone with the feed water regulator form a part of the heat recovery
steam generator drum level controls. A motorised shut-off valve shall be
provided ahead of the feed water regulator as well as motorised bypass
valve.
In the main header, a pressure transmitter shall indicate header pressure
while a pressure switch shall be used to automatically initiate operation of a
standby pump.
The feed water shall be circulated in each heat recovery steam generator
Three (3) x 60% capacity condensate pumps shall take their suction from
the hot well. Condensate may also be used for the following secondary
use:
- Spray water for the condensate receiver and flash chamber.
- Vacuum pump seals.
- Turbine exhausts hood spray.
- Chemical injection units.
- Gland seal emergency spray.
- Auxiliary cooling water make-up
- Bypass steam de-superheater spray
- Condenser sparging de-superheater spray.
- Condenser ball cleaning (tube cleaning) system.
Pressure transmitters shall be used to provide condensate pump discharge
pressure indication. A pressure switch shall be used to switch to the standby
condensate pump when the operation pump or its motor has failed.
In order to ensure a minimum flow through the gland seal condenser, the con-
densate flow shall be measured by a flow nozzle and differential pressure
transmitter, which in turn controls the re-circulation flow to the condenser
through a control valve.
The condenser hot well level shall be controlled by split range level transmitters
located on the hot well. The control signals from these controllers shall be pro-
grammed so that condensate shall be dumped to the make-up water tank to
prevent high level in the hot well.
Condenser cooling water and cooling water for closed loop heat exchangers is
supplied by 3 x 60 % capacity circulating water pumps located in the pump
house adjacent to Cooling Tower. Auto Changeover system among the pumps
shall be provided.
The circulating water pumps shall take suction from Cooling Tower basin and
feed the cooling water to the condenser and cooling water to closed loop heat
exchangers.
The pumps shall be installed in the pit below minimum water level of cooling
tower basin. A circulating water pump house shall be provided.
Motor operated vent valves shall be provided at the top of condenser waterbox
to vent and shut the air automatically.
Minimum (2) x 100% water intake pumps shall be provided in the deep tube
well pump house to supply water to the chemical plant, a portion of which will
be used to produce demi water. Make up water to cooling tower basin and to
closed loop cooling water systems will be supplied from chemical plant after
required chemical treatment .
Design
The cooling tower shall be of the counter flow type. The cooling tower shall be ca-
pable of cooling the main cooling water flow to a cold water temperature required
to maintain condenser vacuum within allowable operating limits over the full range
of ambient and operating conditions and with the plant operating in full bypass
mode. The cooling tower design shall be based on providing 100% cooling capac-
ity with one cell isolated and inoperative.
The cooling towers shall be designed in accordance with the standards of the
Cooling Tower Institute (CTI). In terms of fire protection the cooling towers shall
comply with the requirements of NFP A 214. Air flow shall be by induced draft fans
operating at variable speed through electronic solid state speed controllers. The
Contractor shall allow in his design for any recirculation or interference which may
occur due to the proximity of buildings and as a result of wind conditions.
The cooling tower and all components shall be of non-combustible or fire retardant
materials to the extent practical. Plastic materials (PVC and CPVC) used in tower
construction shall be of special formulations to promote rigidity and shall be low in
plasticisers and highly resistant to ultraviolet exposure.
The cooling tower and access roads shall be designed and located to provide mo-
bile crane access from ground level for lifting gear reducers, blades, and motors of
every cell. A permanent hoisting crane shall be located on the fan deck to support
maintenance activities.
Fan stack height shall achieve optimum pressure recovery and good plume dis-
persion, but the height shall not be less than 2.4 metres. If required, the cooling
tower shall be equipped with a plume abatement system to minimise visible plume
as required by local or state regulations and permits.
Cycles of concentration shall be consistent with the make-up water quality and to
maintain cooling blowdown to within allowable wastewater discharge permit limits
and practical maximum limits of concentration of dissolved salts.
The cooling tower basin shall be constructed in reinforced concrete and have suffi-
cient volume to meet NFP A 850 requirements for provision of a minimum of two
hours fire water in the worst case fire situation.
Structure
The material for the cooling tower structure, top deck, access stairs, fan stacks and
cladding shall be FRP enhanced with ultra-violet ray blocking and fire retarding
properties. The cooling tower shall be divided into ~single cells, each capable of
being operated and taken out for maintenance independently, by full-width partition
walls.
All connectors, supports and hardware shall be of AISI 316 stainless steel (L
grades, if welded). Load bearing tower supports within the basin or around the pe-
rimeter shall be above water level. Structural framing shall be through bolted.
Glued and/or nailed joints shall not be used.
The fan deck shall be capable of supporting fan components, driving motor, gear-
box and shafting during overhaul. The Contractor shall ensure that the mobile
crane supplied as part of the Contract can safely lift these items from their perma-
nent position to ground level and vice versa.
The cooling tower shall also have a fixed lifting frame at one end of the upper desk
to lower and raise equipment to and from the ground.
Fill design shall allow for walking on during maintenance or alternatively provision
shall be made for installation of temporary platforms below and around fill areas.
Drift eliminators shall operate without vibration or flutter. Construction shall pro-
mote ease of maintenance, inspection and replacement. Drift eliminators shall be
multi-pass type to limit drift to a maximum guaranteed value 0.002% (should be
verified by a functional test) and designed to drain water back to the cold water ba-
sin. Eliminators shall be PVC, FRP or a suitable neoprene coated material. Cooling
tower drift shall meet permit limits and not impact plant equipment, substation, op-
erations, or offsite areas.
The water distribution system shall be capable of operating with water quantities
varying between 15% below and 15% above the design water flow per tower cell
or quadrant. The distribution of water to individual nozzles shall be such that the
flow to each nozzle does not deviate from the average flow per nozzle by ±5%.
The distribution system shall include valves for sectionalisation, permitting removal
of each individual tower cell or quadrant from service for inspection, cleaning, or
repair. Isolatable cells shall be designed to accommodate routine online cleaning
and maintenance activities.
The risers and distribution pipe work shall be manufactured from FRP and pro-
vided with adequate supports. Pipe work in each cell shall be identical and pro-
vided with flanges so that sections are interchangeable and can be removed for
maintenance.
Blade clamp material shall be stainless steel or cast iron with stainless steel bolts
and nuts.
The driveshaft tubes and flanges shall be of AISI 316 L stainless steel or carbon fi-
bre. Shafts shall be prevented from major displacement by retaining straps just
clear of the shafts.
Gear reducers shall have an oil level sight glass, fill line, vent line, drain line, low
level switch and grease fitting connections all located outside the fan cylinder for
convenient maintenance access. All lines shall be fabricated from AISI 316 L
stainless steel.
Motors shall have easily removable couplings, located outside the fan cylinder.
The drive tube shall be capable of being withdrawn through the fan cylinder for
maintenance.
The cooling tower vibration monitoring equipment shall be Bentley Nevada 1900-
Access
One end wall of the cooling tower shall be equipped with a stairway rising from the
level of the cold water basin curb to the fan deck. Landings shall be provided at
1,800 mm intervals. A fire escape ladder shall be provided at the other end of the
cooling tower.
Each cell shall have a lift-off access hatch in the fan deck floor and a ladder lead-
ing down to a landing at the drift eliminator level. Each landing shall have a lift-off
hatch for entry to the top of the fill and distribution level.
Fan stacks shall have easily removable external hatches of sufficient size to allow
removal of all mechanical equipment and components. One temporary access
catwalk to the centre of the fan stack shall be provided for use in each cell.
Make-up water shall be supplied from the condensate system to the cooling
water head tank.
The heat recovery steam generator system shall be provided with chemical
feed packages for the injection of amines and hydrazine into feedwater and
The air-removal for the steam surface condenser shall consist of two (2) full
capacity vacuum pumps and one full capacity steam jet air ejector and the
appropriate air removal piping system. Provision shall be kept for start-up
stage both vacuum pumps or steam jet air ejectors. When vacuum is estab-
lished, the vacuum pumps or steam jet air ejectors are operated in a pri-
mary back-up relationship from the control panel. The back-up vacuum
pump or steam jet air ejector will start up if the pressure switch at the con-
denser indicates that the vacuum has decayed to an alarm lever.
The water treatment system shall be designed preferably to use (if neces-
sary) HCl, NaOH for regeneration of demineralizers and Hcl, NaOH, FeSO4
etc. for dosing the claifier. This is however, may not be applicable to the
water treatment system using other advanced system of water treatment.
De-mineralized water plant shall have two (2) X100 % capacity trains, each
consists of activated carbon filter, cat ion exchanger, de-gasser tower, an-
ion exchanger and mixed bed ion exchange unit. Also chemical storage
The cation, anion and mixed bed ion exchangers shall be provided to re-
move ions from feed water and produce highly purified water.
One regeneration system for common use of two trains shall be provided.
Acid and caustic chemical dosing system shall consist of storage tank,
preparation tank, agitator, two pumps and associated equipment.
The produced DM water will flow to DM water storage tank. Two (2) 100%
capacity DM water transfer pumps taking suction from DM water storage
tank distribute the DM water to condensate tank, water wash skid and
closed cooling water make-up.
During the regeneration, chemical wastes are led to neutralization pit. Col-
lected wastes shall be neutralized by using the acid and caustic regenera-
tion facilities to meet the emission limits. The treated wastes are discharged
to storm water drain system.
Complete Bill of Materials (e.g. Raw water tank, demi water tank, semi-
demi water tank, filtered water storage tank, chemical storage tank, con-
densate tank etc. having adequate capacity) / type of equipment (e.g. clari-
fier, filter, roughing demineralizer, polishing demineralizer, condensate pol-
ishing system etc.) required for a particular water treatment plant shall have
to be provided by the Bidder according to the system of water treatment
plant proposed (depending on property of available ground water) for the
combined cycle plant. Raw water Tank capacity shall be for 24 hrs continu-
Chemical Laboratory
The laboratory installations and equipment shall be installed for routine
control of:
• service water
• water-steam-condensate water
• waste water and
in a Combined cycle Power plant.
The scope of supply comprises all necessary supplies and services even if no
special reference is made to these.
The instruments and equipment to be delivered shall be as up-to-date as
possible the laboratory shall be designed in accordance with general safety
stipulations.
Analysis
The scope of supply shall include all necessary equipment to analyze pa-
rameters as follows:
Service water analysis
• pH-value
• conductivity
• suspended solids
• chemical oxygen demand
• KMNO4 -demand
• Iron
• manganese
• total hardness
• alkalinity/acidity
• microbiological quality
• chlorine
Water-Steam-Condensate circuit
• oxygen(02)
• iron
• sodium
• silicate (SiO2)
• phosphate
Waste-water
• pH-value
• conductivity
Laboratory instruments
The laboratory equipment shall comprise all instruments and apparatus nec-
essary for the analytical investigations listed above including all necessary
accessories. Minimum requirements for instruments and apparatus are as
follows:
• UV/visible spectrophotometer. electrically operated for accurate routine
colorimetric analysis
• analytical balance. with digital display. fully automatic calibration and
multi-application key board. Weighing capacity 200 g. sensitivity 0.1 mg
• electronic top-loading balance. sensitivity 0.0 I g, max capacity 5000 g
• BOD analyser
• elementary analyser ",
• laboratory bench centrifuge for analysis
• portable pH-meter
• portable conductivity meter
• analysing equipment for measuring microbiological water quality
• muffle furnace microprocessor controlled rated temperature I 100°C.
• automatic heating and drying oven
• magnetic stirrer hotplates
• portable dissolved oxygen meter
• turbidity meter
• portable cooling boxes \
• electric rotator shakers
• electrically heated baths. lor use as watcr. oil or sand bath
• universal laboratory mill for grinding
• bunsen burners with all necessary equipment
• laboratory stirring apparatus
Potable water system to the plant area and other plant related area should
be included with the Tender.
The electrical system shall consist of apparatus required to operate the gas
turbine generating units, the heat recovery steam generators, steam turbine
generating set, associated equipment, and step-up transformer and 230 kv
switchgear equipment necessary to delivery power to the 230 kv national
grid system.
- 230 kv switchgear : 40 kA
- Generator switchgear : 100 kA for GT and 100 kA for ST
- 6.6 kv switchgear : 17.5kA
- 415 V switchgear : 25 kA
3.4.2 Generators
The gas turbine generators and steam turbine generator shall be of open
circuit air cooling type.
Each generator shall have a complete rotating rectifier type excitation sys-
tem or static excitation system mounted in a suitable enclosure including
rectifiers, static voltage regulator and required control functions. If rotating
rectifier type excitation system is not used and external static excitation is
used, separate excitation transformer shall have to be provided for each
generator.
The generators shall be connected to the low voltage windings of their step
- up transformers by 15.75 KV IPB (copper).
3.4.3 6.6 kV Switchgear
The 6.6 kV common switchgear will consist of metalclad circuit breakers
and fed through auxiliary transformers as shown on the drawing from gas
turbine generator circuit and as well as Steam turbine generator. The 6.6
kV switchgear shall supply auxiliaries and common auxiliary power. In addi-
tion of present requirement, two(2) nos. of spare 6.6 kV circuit breakers to
be installed for future requirement.
Electrical installation materials shall be chosen for power plant service in-
cluding lighting, lighting transformers, panel boards, switch's, outlets, re-
ceptacles, power and control cable, conduit, conduit elbows, bushings,
couplings, lockouts, cable trays, wire ways, pull boxes, floor ducts, junction
boxes, cable accessories, copper bar and ground rods connections, and
various devices for the safe operation of the system.
A main ground grid made up of copper conductor and an adequate number
of driven ground rods to give a low grounding resistance shall be provided.
The power and control, cable provided shall be constructed with insulation
and jacketing in accordance with the latest IEC standard.
3.5.1 General
3.5.2 Controls
The units shall be designed for water cooling of the condenser, lubrication
oil system, etc. The cooling system for generator shall be closed cycle cool-
ing water and air cooling system.
Vibration severity of the units shall not exceed 8.0 mm/sec. In normal op-
The Critical speed of the rotor assembly as a complete unit shall be at least
20% above or below the operating speed range of the units.
The Contractor shall submit a list & supply accordingly Essential spare
parts with OEM part No. and consumables to be necessary for mainte-
nance of Gas Turbine Generating Unit(s), Steam Turbine Generating unit,
HRSGs and other plant equipment inclusive of emergency use that takes
place in the course of operation of the plant (according to the manufactur-
ers recommendation and guide line) during warranty period (24 months)
which are mandatory. During the warranty period of 24 months, the Con-
tractor shall supply all necessary equipment/ equipment parts, materi-
als/consumables at his own cost whether it is listed or not in their list. Spare
parts & consumables to be supplied under the Contract must be made
available at site before start of testing
All spare parts shall be subject to the same specification, tests and condi-
tions as similar material supplied under the inter-changeable and suitable
for use in place of the corresponding parts supplied with the plant and must
be suitably marked and number for identification and prepared for storage
by greasing or painting to prevent deterioration.
All spare parts shall be delivered in cases or containers suitable for storing
such parts over a period of years without deterioration under the atmos-
pheric conditions existing in Bangladesh. The cases shall remain the prop-
erty of the Board.
Each case or container shall be marked with the appropriate contract de-
tails and a list of the parts contained therein with identification references
given of the outside of the enclosure.
The contractor shall provide all special tools including a boroscope set re-
quired for installation and maintenance of the units and hand them over in
good condition to the Board at the completion of the Project. A list of all
such tools shall be incorporated with tender.
Worn out tools or damaged tools shall be replaced with new one without
any cost.
4.1 General
4.2 Guarantee
4.3 Gas Turbine and Ancillary Equipment
4.1 General
4.2 Guarantee
The net output and heat rate of the Unit shall be guaranteed by the
contractor at the following conditions:
0 0
a. Ambient temperature : 95 F (35 C)
b. Site elevation : less than 100 ft(msl)
c. Relative humidity : 98%
d. Barometric pressure : 1.013 bar
e. Generation voltage : 15750 V
f. Power factor : 0.8 lagging
g. Frequency : 50 Hz
The gas turbine (Simple Cycle) generating unit shall be of well proven
design and the offered model of gas turbine generating unit (offered model
shall be within the evolution of frame) shall and have satisfactory operating
experience outside manufacturer's country for at least 2 (two) years.
Tenderer shall have to submit separate certificate in this respect, otherwise
Tender shall be rejected.
The extent of supply shall include, but not be limited to, the equipment
described herein. All equipment comprising the gas turbine package shall
be pre-assembled in the factory.
The gas turbine generating unit shall be of the simple cycle heavy-duty
industrial packaged type suitable for outdoor installation and operation
under the site conditions as specified in Art. 4.2 & Schedule B of Volume 2
of 2 Part B.
The radial amplitude of vibration of any rotating shaft under steady state
conditions at normal operating speed shall not exceed the value specified
in API Standard 616 when measured at the shaft local to the bearing. The
critical speed shall be beyond ±20 % of the operating speed of the engine.
The gas turbine unit shall be designed to burn natural gas as specified.
The unit shall be capable of frequent starts and stops without damage to
the hot gas path components and shall be able to run for base load.
The gas turbine(s) shall have motor driven starting equipment capable of
sustaining the complete starting cycle. The starting motor shall be capable
of carrying out at least Five (5) consecutive starting without any harmful
effect. Tender can also propose SFC starting. For SFC starting system
each GT unit shall have individual SFC with SFC transformer. If 2:2:1
configuration is proposed, necessary arrangement is required so that any
GT unit can be started with any one SFC.
Necessary oil piping and appurtenances shall be included. Turning gear oil
piping system shall be a part of the turbine lubrication system and shall be
complete with all necessary pressure switches or other interlocks to prevent
turning gear operation if lubricating oil pressure drops below than pre-set
valve. Suitable housing and safety guard shall be provided for all moving
parts of the turning gear. Turning gear operation shall be indicated on the
remote control panels. The turning gear shall have automatic engaging and
disengaging mechanisms. Additional arrangement for hand turning shall be
provided for use in case the automatic turning system fails to operate.
The turbine shall be equipped with good quality and suitable load gear
equipment of proper rating if required to match the generator speed for 50
Hz generation. Load gear shall be totally enclosed and be equipped with
forced lubricating device to the gear.
The turbine shall also be equipped with suitable accessories driven gear
unit.
The compressor wet washing system (On & Off line) shall basically
comprise of wash water tank with accessories, detergent hopper,
ii) Detergent hopper to hold the detergent for every wash cycle.
2 Calcium 10 ppm
3 pH 7.5 to 8.0
The Tenderer shall design, manufacture and supply all the components
(Viz. water tank, piping, valves, strainer, drains, manifolds, injection nozzles
etc.) of the above mentioned compressor wet washing system of suitable
grade of material to handle the above wash water without any deterioration.
The Tenderer shall clearly specify the proposed grade of materials of the
above components. The Tenderer shall provide complete system.
The gas turbine unit shall be provided with a complete governing system
which shall be capable of maintaining a required constant speed under
conditions of load variations, control the turbine load, combustion gas
temperatures and prevent turbine over-speed.
The speed governing system shall be provided with speed changing device
capable of local and remote control. Provision shall be made to shutdown
the turbine under emergency by local and remote control. The speed
regulation shall be adjustable (from no load to full load) between plus and
minus 5 %. The rated speed at no load condition shall be adjustable
within ±0.5 % for easy synchronising. The governing system for the unit
shall also be provided with automatic over-speed trip devices adjustable up
to 110 % of the rated speed, and a load limiter.
The governing system shall be suitable for parallel operation with a large
power system and also for completely isolated and independent operation.
In addition to the automatic speed governing system, a separate
emergency over-speed trip mechanism and over combustion gas
temperature trip system shall be furnished on the unit. These systems shall
operate to shut the emergency fuel trip valves.
The unit shall not trip with voltage fluctuation of ±10% and frequencies
variation ±4%.
Over-speed occurring under any conditions shall not have any harmful
influence on the turbine generating unit or on its auxiliaries. The governor
shall have adjustable (±2%.) droop setting.
The lubrication system of the unit shall be equipped with the main oil pump,
auxiliary motor driven oil pumps, delivery pipes, return pipes, reservoir,
strainer, oil cooler, pressure gauges and thermometers, and all necessary
oil piping for the system.
The unit shall be equipped with a gear driven main oil pump, a full capacity
motor driven auxiliary oil pump and an emergency DC motor driven oil
pump. The emergency DC motor driven oil pump shall have sufficient
capacity to prevent damage the turbine generator during an emergency
shutdown. Each oil pump shall be equipped with a section strainer.
Pressure switches shall be provided as required to permit automatic
sequential starting of the auxiliary oil pump, and emergency DC oil pump in
case of oil pressure drop. Auxiliary contacts required for indication shall
also be furnished on pumps and pressure switches.
Each oil reservoir shall be furnished complete with, vapour extractor, level
indicator, high and low level alarm switches, strainer, drain valves, overflow
pipe, manhole, valves, and piping.
The system shall include oil pressure and temperature alarm, and trip
mechanism, each bearing shall be provided with thermocouple cell and a
thermometer in pocket of oil drain.
Complete oil coolers each for 100% capacity shall be provided. One of two
oil coolers shall normally be in service, change over from one oil cooler to
the other during operation shall be possible. It shall also be possible to use
both oil coolers at same time. The oil coolers shall be of either air cooling
type or water cooling type. The oil coolers shall be provided with blowers or
water pumps, depending upon the type of cooling.
The unit shall be provided with gas fuel system. The natural gas system
shall have the necessary pressure regulating valves, piping, shut off valves,
metering device, pressure gauges, and other indicating instruments
including flow meter with integration. The gas fuel system shall be provided
with necessary protective equipment for proper control and safe operation
of the gas turbine generating unit.
The Tenderer shall supply 1 filter unit for Gas Turbine complete in all
respects including necessary supporting structures, holding frames,
fasteners, pressure switches, gauges etc. whichever are necessary. The
Tenderer shall also submit necessary design documents and drawings for
this filtration system.
Each air inlet system shall be provided with silencer if required capable of
keeping the sound pressure level of 45 dB when measured at a distance of
100 meter from the plant operating at full load as per ISO standard.
Gas turbine unit shall be equipped with an exhaust duct and a suitable by
pass stack (not less than 50 m) with hydraulic diverter damper for
prolonged continuous simple cycle operation. The exhaust system shall
have a silencer to reduce the sound level of 65 dB when measured at a
distance of 100 meter from the plant when operating at full load.
The duct shall be supplied complete with all necessary expansion joints
thermal and acoustic insulation, manholes, drains, supports, bolting and
jointing. It shall be arranged in such a way that normal maintenance can he
carried out on any component without dismantling the duct.
The Emission level of exhaust is less than 30 ppm for NOx.
The gas turbine unit shall be equipped with an instrument air supply system
which includes instrument air compressor, air reservoir, oil separator, air
drier etc. and complete in all respect.
The noise level at 1 (one) meter distance will not be more than 85 dB and
less than 65 dB at 100 meters.
The entire gas turbine generating unit including all auxiliary compartment
shall be automatically protected from fire with complete fire protection
system complete with C02 gas system, fire detectors, pipeworks, control
and safety device. Actuation of the fire protection system shall be indicated
at the control compartment and by a visual and an audible alarm to warn
any personnel in the compartments.
The casings of all the rotary parts on the main unit shall be spilt horizontally
for easy dismantling and inspection. Lugs for lifting the upper casing shall
be provided at points which will lift the casing half well balanced. Complete
lifting gear together with lifting drawing and instruction shall be furnished.
5.1 General
5.1 General
The heat recovery steam generator unit shall be of outdoor, forced circulation or
natural circulation and water tube type arranged for using exhaust gas from the
gas turbine unit.
The steam generator shall be of welded construction throughout. The entire steam
generator (exclusive of minor boiler component parts) shall be either suspended
from a steel framework located above the unit proper or bottom supported. Sup-
ports at intermediate levels shall not be used.
a. The steam drum and heat transfer sections which consist of the economiser,
evaporator and super heater tube bundles of the steam generator.
b. The support structure system for the steam generator and ducting.
c. The stairs, platforms and ladders required for maintenance, inspection and
operation of the heat recovery steam generator.
d. The steam generator circulating water system for the evaporator and drum
circuits.
j. The steam generator control system to provide control capability for tran-
sient, steady state and protective conditions.
The steam conditions shall be determined by the Tenderer and be clearly indicated
in the "GUARANTEE SCHEDULE" and " TENDERER'S DATA SHEET" (Part B,
Vol. 2).
The steam generator shall be capable of meeting the output efficiently for ex-
tended periods with normal on-load cleaning only and without having to be shut
down for overhaul of off-load cleaning of the gas pathes and heating surfaces.
The tenderer shall submit calculations showing how the MCR of the steam genera-
tor is derived.
All pressure parts of the steam generating unit shall be designed to withstand the
design pressure to be stated in "TENDERER'S DATA SHEET" and shall conform
to the requirements of relevant standards.
Steam generator feed water shall be supplied by condensate from a surface con-
denser, desecrated in the condenser or a desecrating feed water heater. Suitable
chemicals will be added in the feed water cycle for oxygen scavenging and pH
control. Demineralized water will be used as make up to the plant cycle.
The tenderer shall state the rates of loading which the steam generator will be ca-
pable of achieving while maintaining the superheated steam temperature within the
limits stated above. Control may be effected by either spray type or surface type
desuperheater.
Steam temperature curves below the control point shall be as flat as possible and
shall be provided by the Tenderer.
The control equipment shall automatically maintain the superheat steam tempera-
ture within the control range as specified in this Clause. Manual control of super-
heat steam temperature shall be possible over the full range of steam generator
output.
Provision shall be made to facilitate acid of the pressure parts. Vents and drains
shall be of ample size and suitable connections shall be provided for feeding acid
flushing headers after the wash.
The Contractor shall assume full responsibility for ensuring that the acid cleaning is
to be carried out effectively and in a manner to prevent damage any part of the
All necessary equipment, for this process, external to the boiler such as tanks,
pumps and piping, shall be provided by the Contractor. All necessary chemicals for
the process shall be recommended and provided by the Contractor.
Following acid cleaning the steam generator and associated steam legs will be
steam purged. The Tenderer shall state his recommended operating procedure for
the various phase for steam purging and the disturbance factors to be expected in
each phase.
The Contractor shall provide details of connections for temporary steam purge
pipework and valves, which shall be provided by the Contractor and which include
suitable blanks for the protection of the turb0-generator.
Each assemble shall be designed and fabricated to the ASME Code Section I and
will be subjected to a witnessed shop hydrostatic test at a minimum pressure of 1.5
times the design pressure of the system. The final hydrostatic test of the erected
and assembled components shall be performed by the Contractor.
The steam generator shall be of the forced circulation type. It shall be the function
of the circulation water pump to maintain a positive water flow through the evapo-
ration section of the steam generator at all operating conditions.
The super heater section shall be positioned to absorb the heat from the high tem-
perature gases. The super heater, composed of rows of tubes in multiple passes,
connecting the inlet and outlet headers shall be specifically designed to meet the
performance requirements of steam flow and superheat temperature. Steam flow
through the super heater shall be counter flow to the exhaust gas flow for maxi-
mum heat transfer.
A multiple row two-pass evaporator provides for unrestrained tube expansion dur-
ing temperature swings through the sue of free-floating return bends (U-bend type
construction) at one end of the evaporation.
The economiser tube circuits shall be arranged to provide counter flow heat trans-
fer between the water and the exhaust gas flow. Free expansion of the tubing shall
be allowed for by the use of a suspension type arrangement with the headers fixed
in position. Economiser heat transfer surfaces shall be selected to prevent exces-
sive economiser steaming which may lead to vapour locking of some of the
economiser tube circuits.
All tubes shall be of seamless steel, conforming to the specified code require-
ments. Tubes shall be treated to be free of all mill scale. After cleaning, tube ends
shall be protected with non-metallic caps, outside swabbed with oil or sprayed with
a suitable rust preventative. Tube connections at headers shall be so arranged as
to permit full strength welding of all joints.
The arrangement of tubes shall be such as to follow for easy withdrawal and re-
placement with minimum distance of the remaining tubes and for this purpose, and
in order to facilitate erection, the tubes may be site welded.
Water walls shall confirm to specified code requirements. All drums and headers
shall have tube stubs strength-welded thereto in the manufacturer's works in ac-
cordance with the relevant current standards. The tube stubs shall be butt welded
to the tubes on site. Water wall headers shall be provided with suitable handhold
openings designed for seal welding for cleaning. Should any water wall header ex-
tend outside the setting, it shall be insulated by approved means with provision for
movement and sealing.
The steam generator drum shall be of fusion welded construction, fabricated from
steel plate and shall be tested with X-ray and stress relieved in annealing furnace.
The interiors shall be cleaned by shot blasting for removal of mill scale and foreign
matters. The drum headers shall be tested hydrostatically at the manufacturer's
work in accordance with the relevant code.
The steam drum shall be equipped with necessary internals so that the total dis-
solved solids in steam leaving the drum will not exceed 0.1 ppm.
The drum shall be fitted with a manhole door at each end designed to open in-
wards. The drum shall be provided with all nozzles. Connections and openings re-
quired for operation, testing and maintenance. The number, location and size of all
connections shall be subject to the approval of the Engineer. Particular attention
shall be paid to the design of the down comer nozzles, in order to avoid thermal
stressing of the nozzle welds the drum shall be self draining into the down comers.
If siphon tubes are provided they shall be of adequate number and size to com-
pletely drain the drum.
The chemical feed pipe shall be strategically place in relation to the feed water
pipe so there will be complete mixing of the chemicals and feed water before the
mixture leaves the steam drum and passes through the evaporator section.
Chemical injection may be either intermittent or continuous, as required.
The continuous blow-down pipe shall be located just below the surface of the wa-
ter. Its function shall be to reduce the drum water concentrated near the upper sur-
face of the drum water.
The intermittent blow-down through shall be located at the bottom of the drum and
shall be used to remove the sludge and scale that has settled there. It can also be
used to reduce excessive water concentration and, in case of emergency, high
drum water level. Drum water condensation may be reduced by this method, how-
ever, the controlled continuous blow-down shall be determined by the operating
personnel. The intermittent blow-down valves shall be used to drain the steam
drum for maintenance and repairs.
Two water level gauges, one at each end of the boiler drum, shall be provided with
each gauge including an approved form of lighting fitting suitable for use on 110
volts AC. Both gauges shall be of an approved bicolour type and both gauges shall
provide a direct indication of the water level in the form when viewed at boiler drum
level. The gauges shall be fitted with drain and self closing check valves, together
with valves for shutting of and blowing through. Each gauge glass fitting shall be
forged steel or other approved material designed so that it can be removed from
the drum as a complete unit. The gauge glass shall be easily replaced without re-
moving the gauge from the drum.
Two water level transmitters, one at each end of the drum for remote level indica-
tion and control purposes, shall be provided by the contractor.
A system to allow the water level in the drum to be seen from a convenient point
shall be provided by the contractor.
The steam water mixture shall leave the evaporator through short pipe connections
and enter a distribution baffle tray area of the drum, where the return mixture is
The vane-type separation element shall force the steam to pass through a number
of closely spaced vertical baffles. The baffles shall be shaped to provide constant
obstruction to the steam flow. Liquid particles which are still entrained in the steam
will impinge on the baffle surface due to centrifugal force, the moisture thus accu-
mulated will flow downward to drainage pockets by gravity through the drain pipes
which extend well below the minimum water level in the steam drum.
A steam sapling nozzle shall be installed at the inlet and out let to the super-
heater. Steam sampling especially between the drum and super-heater inlet, is a
very important and useful tool, it will not only indicate any malfunction of drum
equipment, i.e. water columns, purifiers, continuous blow down, etc. but will also
indicate faulty boiler water treatment. The sample readings must be taken system-
atically if they are to be meaningful.
5.2.3 Super-heater
The super-heater shall be designed and positioned in the steam unit with special
reference to the high steam temperature at the superheater outlets. Means shall
be provided to ensure balanced conditions at he superheater outlets under any
condition of service.
All interconnecting piping between the various sections of the superheater shall be
welded.
Provision shall be made on the super heater outlet for the fitting of temporary test
pressure gauges including permanently installed valves, piping and mounting
plates to enable the gauges to be conveniently red for setting safety valves.
The design of the superheater shall be such that any individual tube element can
readily be removed and replaced. The superheater shall be of the self draining
type.
Provision shall be made in the unit casing for the insertion of permanent thermo-
couples for obtaining the temperature of the gases before the superheater sections
when bringing the unit up to load or when picking up load under emergency condi-
tions.
5.2.4 Economiser
The economiser shall preferably be of the continuous tube type located in the
boiler casing. Economiser headers shall be provided with welded connections for
inlet, outlet, drains and vents.
The outlet connections from the economiser shall be directed to the steam genera-
tor drum without any intermediate valves. The distribution of the feed-water in the
drum shall be uniform over the full length of the drum. The connections to the drum
and distribution of the feed-water shall be such that the connections and the drum
are unaffected by variations in the temperature of the water and the danger of cor-
rosion fatigue cracking is avoided.
The contractor shall furnish all insulation materials and casing as required for all
equipment included in the scope of this specification.
The casing shall be sufficiently tight at full steam generator rating and recom-
mended internal pressure, so that leakage is reduced to a negligible amount. The
Tenderer shall give details in his Tender of the methods he proposed to ensure
minimum leakage.
The casing shall be lagged until a pressure test of approved method has been
successfully completed and full allowance shall be made in the construction pro-
gramme for this test.
The exterior surfaces of casing and other insulation shall have a surface tempera-
ture not over 700 C with ambient temperature of 500 C and air velocity of 15m/min.
The outer steel casing shall not be less than 4.5 mm thick, stiffened and rein-
forced. Stiffeners and backstays shall be rounded at corners. The design of the en-
tire casing system shall be submitted to the Engineer for approval.
The insulation of all casings, flues, ducts, pipes and valves shall be such as to re-
duce the heat loss to a minimum and adequate means shall be provided to ensure
satisfactory foxing of the insulation.
All heat insulation material of approved type shall be asbestos free and chemically
The Tenderer shall in this Tender thickness of each layer of heat insulating mate-
rial to be applied to the various parts of the unit.
The contractor shall ensure that the final Finnish of all material prior to painting
has a first class smooth surface.
Unless otherwise approved the heat insulation for all casings, flues and ducts shall
as its main constituent, magnesia or glass fibre and shall consist in the main of
preformed slabs. Particulars of the insulation shall be stated in the Tender.
All pipework lagging shall be provided with sufficient expansion joints of approved
design to prevent any cracking of the completed lagging.
The Contractor shall furnish the following fittings, valves and mountings.
Pressure and temperature ratings of all item shall be suitable for intended service.
An approved number of safety valves of approve design and capacity shall be fur-
nished as required by the relevant Boiler Code or ASME. In addition electrically
assisted valves and associated gate shut off valves shall be furnished at the sup-
perheater outlets.
The safety valves shall be set to blow in a predetermined sequence staring with
the valves at the superheater outlet. In determining the capacity of the safety
valves due allowance shall be made for the back pressure which will occur in the
safety vale escape pipes and silencers where appropriate. The location of the
safety valves shall be selected so that there will be no detrimental unbalancing of
steam flow caused by their co-operation. Where in order to achieve this condition,
the valves are required to be mounted on steam piping then the piping to which
these valves are connected shall be provided under this contract.
The safety valves shall be designed to ensure clean and certain opening at the set
pressure and rapid and certain closing at the reseating pressure with neither sim-
mering nor the necessity to reduce boiler pressure below the reseating pressure to
firmly seat the valve.
Irrespective of the type of safety valve used each valve shall open within + 1.0 bar
of its set pressure of its set pressure and shall have a blow-down which can be ad-
justed independently of the set pressure to any desired value.
In the design and manufacture of the safety valves every care shall be taken to
ensure repeatability of the safety valve's operation and the practicable minimum of
maintenance to prevent leakage of steam past the seat. It shall also be designed
The safety valve installation shall be complete with all necessary stand pipes, con-
nections, piping, supports and other items necessary for their satisfactory opera-
tion. These safety valves may have welded inlet connections.
An approval system of safety valve escape pipes with expansion joints, anchors
and supports shall be provided to exhaust above the steam generator. The loca-
tion and arrangements of the outlets of these pipes shall be such that when the
safety valves are operating there will be no danger personnel who may be in the
vicinity of the outlets.
An approved number and type of stop and check valves at the inlets to the steam
generator shall be furnished as required by arranged of piping..
One 100% duty feedwater regulators and one 25% duty start up feed regulator of
approved design shall be provided. The type shall be such as to maintain a con-
stant water in the drum during start up and varying load conditions and feedwater
pressures. For 100% duty feedwater regulator, the Contractor shall provide one
motorised valve with motorised by pass valve at the inlet. For the 25% duty feed-
water regulator, the Contractor shall provide one motorised valve at the inlet and
one isolation valve at the outlet.
Separate alarms of external type for high drum water level, low drum water level
and low drum water level trip shall be provided and arranged with contacts which
can be used to initiate alarms. Provision shall be made for one high water level trip
alarm if necessary. The connections to the steam generator of these external
alarms and tripping facility shall be fitted with full bore valve capable of being
locked in the open and closed positions. A separate set of tapping points shall be
provided for these alarms.
The alarm system to be initiated by the level alarm shall be supplied and installed
by the Contractor.
A blow-down and drain piping system shall be provided complete with a drainage
receiver designed to cater for all blow-downs and drains from the plant. The re-
ceiver shall be provided with drains, drain valves, outlet piping and vent piping.
The vent piping shall exhaust all vented steam to a safe location above the top of
the steam generator. It shall be of corrosion resistant material or treated in an ap-
proved manner so that there will be no deterioration particularly in the outside ap-
The outlet piping for normally draining the water from the receiver shall be in the
form of an inverted U and shall discharge into a pipe below ground level. The inlet
of this outlet piping shall be continuously submerged. The top of the U-bend shall
be connected to the vent piping through a small bore line which shall act as a si-
phon breaker.
Blow-down connections shall be provided and the location of the connections shall
be to the approval of the Engineer , being selected so as to enable the quality of
the steam generator water to be corrected as rapidly as possible and to enable
steam generator level to be quickly lowered without affecting adversely the normal
circulation within the steam generator.
A main isolating valve followed by a main blow-down valve shall be provided for
each blowdown connection and a by pass consisting of an orifice between two iso-
lating valves shall be provided around the blowdown valves. All valves shall be
suitable for safety operating at full steam generator pressure.
Drain valves and piping to the drainage receiver shall be provided at all points of
the steam generator where it is necessary to remove sludge and similar accumula-
tions and to drain the water walls, steam generator and economiser (if necessary.)
Drain valves and a separate piping system to the drainage receiver shall be pro-
vided to drain the superheater headers.
An approved number of saturated steam supply valves, main steam outlet valve
shall be furnished.
The contractor shall provide all instrument and connections as required for sound
operations of the steam generating unit.
The Contractor shall furnish all necessary items or structures for the support of the
steam generator unit and associated equipment this shall include, but not be lim-
ited to, the supply of the following :-
(a) All columns, beams and bracing necessary to support the steam generator unit.
The steel supporting structure shall be mounted on foundations and apart from
the neighbouring building columns, beams or bracing members.
(b) All supporting structures required for auxiliary equipment whether supported by
(c) All platforms and walkways with the appurtenant chequered plate or grating toe
plates and railing, ladders and stairways to insure safe accessibility to all parts
of the steam generator and related equipment.
(d) A sufficient quantity of erection bolts and proper welding rod for site assembly.
(e) All special supporting hangers, struts, braces, frames, etc. between other
building frame and any steam generator equipment component parts located out-
side the steam generator equipment component parts located outside the steam
generator perimeter.
The above steel shall include all built-up girders, beams and other rolled sections,
connections, hangers, stiffeners, buckstays and plates as required to properly
support the equipment. Stiffeners and buckstays shall be rounded at corners and
meeting points.
The Contractor shall furnish to the Engineer all loading, design calculations and
detail drawings of the steel framing adjacent to the steam generator, the main sus-
pension steel framing at the top of the drum all other supports, steel work for ap-
proval by Engineer.
Weights of water and other normal loads imposed during operation, construction,
maintenance and testing shall be included in the design loads, Seismic reactions,
and expansion limits shall also be indicated on the drawings.
All structural steel furnished shall be in accordance with relevant standards and
subject to approval.
All structural steel furnished shall be designed fabricated and detailed in accor-
dance with the relevant Standards. Any deviation therefrom shall be submitted for
approval.
5.2.9 Pipework
It is important that all piping arranged to afford easy access for operation and
maintenance. Particular attention shall be given to the arrangement of miscellane-
ous electrical conduits and piping furnished by the Contractor. The Contractor shall
co-operate with the Engineer to ensure a well co-ordinated arrangement.
The joints which are necessary shall be in approved positions and shall be welded
butt joints unless otherwise approved. At terminal point the joint shall be of the sea
welded or bolted non welded flanged type as provided below.
Except where otherwise approved, joints shall be electric butt welded. All details of
fabrication shall be to approval.
Prior to and during the whole of the welding operating of a butt welded joint the
After welding is completed, all electrical butt welded joints for carbon steel pipes
shall be stress relieved by an approved method.
The whole details of construction of seal welded and non welded flanges to the
pipes, shall be subject to the approval of the Engineer.
All flanges used for bolted joints shall be cutter barred or faced at the back so that
units, washers and bolts heads may be down satisfactorily.
All blank flanges for pipes included in this Clause shall be steel.
All high pressure steam pipes, bends and fittings shall comply with ISO Standard
where applicable.
Where welding is used for the attachment of branch pipes the method shall be
subject to approval. In order to compensate for the metal cut away from the main
pipes suitable reinforcement shall, where required by the Engineer, be provided
around the opening which is formed to receive the branch pipe. The method of
welding for the attachment of the reinforcement to the main pipe and to the branch
pipe shall be subject to approval.
All steam mains shall be erected with an approved fall in the direction of flow so
that condensed steam will flow towards the positions on the mains where the
drainage points are situated.
All high pressure feed pipes shall be designed for a maximum working pressure
and temperature and shall comply with relevant ISO standard where applicable.
Where welding is used for the attachment of branch pipes the method shall be
subject to approval. In order to compensate for the metal cut away from the main
pipes. Suitable reinforcement shall, where required by the Engineer, be provided
around the opening which is formed to receive the branch pipe. The method of
welding for the attachment of the reinforcement shall be approved by the Engineer.
Sampling valves of arrived design shall be provided in approved positions for tak-
ing samples of feedwater.
5.2.10 Valves
All valves shall be of approved design and manufacture and those of similar make
size and type shall be interchangeable with one another unless otherwise ap-
proved.
All control valves shall have manually operated inlet and outlet isolating valves with
a bypass valve arrangement.
All valves shall be fitted with outside screws unless otherwise specified or ap-
proved.
All valves shall be closed by rotating the handwheels in clockwise direction when
loading at the face farthest away from the body of the valve. The valve spindle
shall also be rotated in a clockwise direction the close the valve when viewed from
the outer end of the spindle and in cases where the handwheel is not directly at-
tached to the valve spindle, suitable gearing shall be introduced to reconcile the
above condition. The face of each handwheel shall be clearly marked with the
words 'open' and 'closed' with arrows adjacent to indicate the direction of rotation
to which each refers.
Each handwheel shall also be fitted with a circular nameplate indicating the service
for Shiite the valve is intended. The nameplates shall be of stainless steel with en-
graved letters filled with black enamel. Valves for emergency operation shall have
the lettering in with red enamel. Where required by the Engineer valve spindles
shall be lengthened so that the handwheel is at a height of approximately 1 meter
above the level of the floor or platform which the valve is to be operated.
Where extension spindles are fitted all thrust when opening or closing the valves
shall be taken directly on the valve body and all valve pedestals shall be mounted
direct on the floor girders and not on the floor plating. Any floor steel work trimmers
necessary for supporting the pedestals shall be provided by the Contractor.
The spindles of all valves for use outside the power station building shall have
weatherproof protection covers of approved contraction.
All valves shall be fitted with indictors so that it may readily be seen whether they
are open or close and in the case of those valves fitted with extended spindles, in-
dicators shall be fitted both to the extended spindle and the valve spindle.
Valves shall not be fitted in an inverted position unless other wise approved. Eye-
bolts shall be provided where necessary to facilitate handling heave valves or parts
of valves.
The Tender shall submit alternative offers for the first isolator of all high pressure
valves, one of which shall be with gland packing and the other shall be of gland-
less type.
The design of the high pressure valves shall be given special attention with regard
to the selection and thickness of material so that they will be suitable for high pres-
sures and temperatures and full details of the design shall be submitted for ap-
proval as early as possible. Approved means shall be provided to prevent and by
accumulation of pressure between the discs of any high pressure steam of feed
parallel slide valve. Preferable in the case of valves with bypass, the integrate
space of the main valve shall be connected to the integrate space of the bypass
valve
The stop which limits the travel of the valve in the "open" and "close" positions
shall be arranged exterior to the valve body and no packing under pressure device
shall be fitted.
All valves used for low pressure water, exhaust, low pressure steam, air and oil
services shall be of approved manufacturer.
All valves specified to be motor operated shall be fitted both with hand and motor
operating gear. They shall be of approved design and complete in all respects in-
cluding the motor and the necessary controls for automatically stepping the motor
when the valve gate has reached the "full open" of "full close" position. The motor
shall be placed in such a position relative to the valve that there is no possibilities
of steam or water leakage from the valve joints or glands blowing on to the motor
or control equipment.
The operation of opening or closing the valve shall be controlled by means of three
push buttons labelled respectively "open" "close" and "stop" or by means of an ap-
proved type of hand control lever. The control shall be so arranged that the motor
can be stopped with the valve in any position and can then be restarted in either
direction. The push buttons or hand control lever shall be mounted together in an
approved position on or adjacent to the valve, in such a position that valve indica-
tor is readily visible to the operator.
An interlock shall be provided such that when the valve is being operated manu-
ally, the electrical supply to the control circuit of the motorising valve is isolated.
An motor operated valves and their associated control equipment shall be suitable
for operation by a three phase three wire 415 volt 50 Hz supply.
Control of the steam generators and associated auxiliary plant will be carried out
on a direct wire remote control basis from the central control room.
All controls essential to the normal run up, shut down and operational running of
the unit shall be capable of being carried out completely from the control panels in
the central control room.
Sensors for temperature, pressure, electrical quantities, switch and valve positions
etc. shall be provided to give indications transducers shall be electrical.
The indications and other relevant information may also be scanned by data log-
ging equipment supplied as part of the central control room equipment which will
print out readings and provide alarm indication.
All equipment, valves and controls for which provision has been made for remote
operation shall be provide with facilities for local operation.
The Contractor shall furnish all motors, limit switches and torque switches neces-
sary for proper operation of the valves which he supplies, Limit switches and
torque switches shall be heavy- duty type, independently adjustable for both direc-
tions of travel.
It is intended that all designed measurements will be separately displayed and re-
corded in such a manner that for each measurement, the indicator can operate in-
dependently of the recorder and vice versa.
All connections between fixed cables and measuring devices should be robust,
protected by suitable insulation and electrical screening and placed so as not to be
damaged during transit, normal operation or during dismantling of the plant for
over hauls.
Electronic measuring systems shall employ all solid state components and be suit-
able protected against damage from voltage or current surges, The systems shall
also possess adequate common and series mode noise rejection characteristics,
such that accuracy of indication and recording is not affected by voltage or current
surges, or by the general noise level existing at he location of the system.
Instruments supplied for outdoor units shall be weather proofed and suitable for
adverse outdoor conditions.
It is essential that all deposits on the heating surfaces must be removed down to
bare metal throughout by the off load cleaning device. Irrespective of whether dry
cleaning or wet methods be employed. Irrespective of whether dry cleaning or wet
methods be employed, special care shall be taken to avoid damage and corrosion
to the heating surfaces.
The extent of supply shall include, but not be limited to the equipment described
herein.
Steam turbine shall be of proven design and of the single line impulse, impulse re-
action or reaction type, throttle or nozzle controlled, designed for high efficiency
operation and suitable for coupling to and running in conjunction with the con-
denser supplied under this Contract. The steam turbine shall be of sliding pressure
type with hot and cold start provisions.
Steam will be supplied to the turbine stop valve at steam conditions specified in the
heat recovery steam generator section of this Specification.
The unit shall be designed to operate safely at 47.5 to 52.5 Hz. The Contractor
shall state limitations, if any, as to frequency, load, or duration for this mode or op-
eration.
The turbine shall be equipped with emergency/stop valves, control valves, with ac-
tuators integrated with the turbine control system.
These valves shall be capable of being tripped by hand at the turbine floor level
and by remote operation from a push button in the central control room. They shall
be automatically closed in the event of failure of the lubrication oil supply.
Provision shall be made on each valve to give remote indication of the valve posi-
tion over the full range of travel.
The steam chests shall be constructed of approved material and shall be so sup-
ported to avoid distortion of the turbine cylinders.
Permanent steam strainers shall be provided to prevent the entry into the machine
of any foreign material which could damage blading or control valve seats, it shall
be arranged to permit easy inspection and cleaning.
Temporary steam strainers, having passages of a smaller size than those in the
permanent strainers shall be supplied and fitted so as to prevent any damage to
the turbine blading during the initial commissioning period.
Temporary pressure gauges shall also be provided during the initial period of run-
ning so that pressure after the temporary steam strainers can be measured.
The Tenderer shall state what provision they have made for on load testing of the
governing valves.
The design of all valves and their control gear shall be such that utmost reliability
of operation and easy servicing can be achieved.
The Tenderer shall state the precautions taken to avoid seizure of any stop or con-
trol valve spindle under all operating conditions. Full details of the materials pro-
posed for the valves, seats, spindles and guides to ensure safe operation shall
also be given in the Tender. Full details of the experience with these materials,
particularly in respect to maximum operation temperatures shall also be given in
the tender.
6.2.2 Supervisory Equipment
Turbine supervisory instruments shall be included to provide a series of measure-
ments from which the mechanical performance of the turbo generator unit may be
assessed under start up and loading conditions and during "on-load" operation.
Provision shall be made in the design of the rotors, casings, bearing pedestals and
valves, etc., for the supervisory measuring devices to be provided under this Con-
tract. The Tender shall include full details of the supervisory instruments offered
which shall be subject to the approval of the Engineer.
Operation of the event marker will simultaneously operate a chart speed change
mechanism. Such that the chart speed in increased to a value which will allow a
period of not greater than 5 minutes to be resolved on the time scale of the chart.
Transducers shall be mounted in positions which are readily accessible for pur-
pose of routine maintenance, calibration and replacement with the unit on load,
Where the designed measurement precludes ready access, then a second local
absolute indication for comparison purpose shall be provided.
All transducers, measuring devices or assemblies and their connecting leads shall
be capable of withstanding their environment. They shall be mounted enclosed or
encapsulated to prevent ingress of steam, moisture, oil etc.
All connections between fixed cables and measuring devices shall be robust, pro-
tected by suitable insulation and electrical screening and placed so as not to be
damaged during transit, normal operation or during dismantling of the plant for
overhauls.
Each measurement shall have its associated alarm, the level of which shall be ca-
pable of being set at any point over the operating range of the measuring instru-
ment.
Operating of the alarm shall not sensible modify or in any way change the accu-
racy of the measuring system..
Electronic measuring system shall employ all solid state components and be suit-
able protected against damage from voltage or current surges. The systems shall
also possess adequate common and series mode noise rejection characteristics,
such that accuracy of indication and recording is not affected by voltage or current
surges, or by the general noise level existing at the location of the systems.
The lubricating oil level in the main storage tank shall be supervised by two level
switches which will be used to initiate alarms when the oil is in order of 100 mm
and 150 mm below the normal working level.
The bottom of the tank shall be designed to give a fall to the drainage point which
shall be fitted with a drain valve locked in the closed position.
A visual indicator, independent of the alarm float, shall be provided. The indicator
shall be marked to show the running and shut down oil levels and variations above
and below normal working level shall be indicated in litres and this indicating shall
be at operating floor level, or clearly visible from operating floor level.
Special attention is drawn to the provision of vapour extraction equipment for main
oil tank and the arrangements proposed shall be stated in the Tender. The Ten-
derer shall give particulars of the treatment proposal to avoid acid attack on the
tank interior, pedestals, oil wells etc.
While oil is being pumped through the coolers, the oil pressure shall exceed the
cooler water pressure.
Full flow filters having sufficient fineness of mesh openings to protect the plant
from damage shall be provided in the bearing governor and power oil supply lines.
The Contractor shall provide information regarding running hours between oil
changes, both for the initial commissioning period and for normal operating condi-
tions.
A turbine oil make-up or measuring system shall be provided for initial filling,
evacuation and make-up of the main oil tank. The system shall comprise of an
adequately sized storage tank, a suitable type of tank for pump, measuring device
and pipework and valves.
All steel piping in the lubricating oil system shall be picked and adequately pro-
tected for ocean shipment. Piping with hangers for the lubricating system shall be
furnished complete, including oil piping to and from oil cooler, and shall be ar-
ranged for maximum protection against turbine oil fires, The pipe shall be com-
pletely welded throughout, except where flanges are furnished for maintenance.
Backing rings are to be used in locations where it is not possible to remove weld
slag from pipe bore. As far as possible the piping shall be located below the level
of the turbine room operating floor. Piping shall be laid out in straight runs with
bends and joints in the piping organised in a neat and orderly manner to give a
good appearance.
All glands shall be suitable for starting under high vacuum. The design of the
glands shall preferable be such that they can be examined and replaced if neces-
sary without lifting the top halves of the cylinder casings.
Arrangements shall be made for automatic and manual control of the gland steam
and to prevent leakage steam blowing from the glands into the turbine house un-
der all loading conditions. The gland steam regulator shall operate satisfactorily
under all turbine loads and shall be arranged for automatic control with remote and
local facilities.
A full description of the gland sealing arrangements including the gland steam
condenser and exhaust fans shall be given in the Tender together with a diagram-
matic arrangement of the system.
Individual gland systems shall be fitted with means for periodically measuring the
gland flow as check on gland conditions. These facilities may take form of a per-
manent orifice with appropriate tapping points for measurements.
The turning gear shall be equipped with a zero rotor speed indicator for showing
the turbine rotor speed as the rotor approaches rest. The speed sensor shall pro-
vide a signal to an indicator or alarm to be mounted in the central control room and
shall also initiate the automatic engagement of the turning gear when the shaft has
dropped below turning gear speed but before coming to rest. An additional indica-
tion shall also be given in the control room to indicate the rotor in resting condition.
The turning gear circuit shall be provided with pressure actuated switch to prevent
the turning gear motor from staring before adequate bearing and jacking oil pres-
sure have been established by the oil pumps.
Hand turning facilities shall be provided together with the necessary turning tools.
The governor shall be equipment with a speed change by means of which the
speed power output of the turbine may be changed to suit varying system operat-
ing conditions. Means shall be provided for speed changed adjustment made by
hand at the turbine as well as by remote control from the central control room.
Provision shall be made to shutdown the turbine under emergency by local and
remote control. The speed regulation shall be adjustable between + 5% . Speed
droop adjustment shall be provided. The governing system shall also be provided
with automatic over speed trip devices adjustable up to 110% of normal speed,
and a maximum load limiter.
The E-H governor shall include speed control, load control, stress control and vari-
able speed droop facilities.
The speed control system shall govern the turbine from zero speed to rated speed
automatically by means of the speed setter which sets the pre-determined speed
and the speed rate setter which sets the rate of changing speed.
The governing system shall be suitable for parallel operation with a large power
system and also for completely isolated and independent operation.
The load control system shall be control the loading of the turbine by the load set-
ter which sets the target load and the load rate setter which sets the rate of change
load. The load control system shall also be able to adjust the power output by re-
sponse to power system frequency change.
The stress controller system shall monitor and control the thermal stress of the tur-
bine rotor. The system shall determine the loading rate under rolling and loading
conditions respectively so the stressed do not exceed the predetermined limits.
The turbine shall be equipment with a load limit device arranged for manual setting
at the turbine and remotely from the control room limiting the opening of the gover-
nor-controlled valves to any valve within the full range of valve travel, which the
turbine is in operation. Provision for remote indication shall be furnished.
The Tender shall contain a statement of the permissible maximum value of the
steady state speed variation, the maximum momentary speed variation, and the
time within which a steady speed is at trained, when the maximum guaranteed
output is completely thrown on or off.
The Tenderer shall submit complete descriptive information's about the governing
system they propose to provide.
The turbine shall be equipped with a device which will limit the steam flow to the
machine when the main steam pressure reaches a predetermined low point, and
will continue to decrease the steam flow in proportion to further reduction in pres-
sures. A simple means shall be provided for overriding the unloading gear when
operating the turbine with low steam pressure during start up. This device shall
have provision for remote control and indication.
In addition a separate device shall be included on the main turbine which shall, in
the event of a further reduction in pressure, trip close the turbine steam valves.
The Tender clearly indicate the unloading procedure and the related steam flow to
steam pressure.
The gear shall be provided with an alarm initiating device, and means for on-load
testing both the unloading and the trip functions of the gear.
The gear shall be so arranged that the load is not automatically restored.
The turbine shall be equipment with an undefended safety device in the form of an
emergency overspeed governor. This shall be mounted on the turbine shaft and
shall be arranged to actuate, at a predetermined speed a tripping device which will
trip close the turbine steam valves. Means shall be provided for adjusting the
speed setting of this governor. The emergency overspeed governor shall auto-
matically recover and make possible resetting the valves at approximately one
percent above rated speed of 3000 rpm; Means shall be provided for on-load test-
ing the operation of the emergency overspeed governor.
A local emergency trip plunger shall be provide on the turbine pedestal. The
plunger shall trip close the turbine steam valves in a similar manner to the opera-
tion of the overspeed tripping device.
Provision shall be made for an emergency trip button in the central control room.
A low lubricating oil pressure trip device shall be provided to trip close the turbine
steam valves on extreme low pressure in the lubricating oil system. Allow oil pres-
sure switch for alarm purpose shall also be furnished.
The turbine shall be equipment with device which will limit the steam flow to the
machine when the condenser vacuum reaches a predetermined low point, and will
continue to decrease the steam flow in proportion to further reduction in vacuum.
In addition an entirely separate device shall be provided on the main turbine which
shall, in the e vent of a further fall in vacuum, trip close the turbine steam valves.
The gear shall be provided with an alarm initiating device, and means for on load
testing both the unloading and the trip functions of the devices.
The gear shall be so arranged that the load is not automatically restored.
The tenderer shall clearly indicate the unloading procedure and the related steam
flow to condenser vacuum.
A temperature detecting device shall be located in the exhaust of the turbine and
be arranged for alarm initiation in the event of high exhaust steam temperature.
Adequate provision shall be made to prevent turbine shaft current flowing between
shaft and base through bearing and journals. This shall be in the form of one or
more earthling devices between the stationary and rotating turbine parts.
All nozzles, blades and buckets in the steam path shall be of hard corrosion and
erosion resisting material suitable for the conditions encountered. All blading shall
be readily renewable Clearances shall be such as to avoid danger of rubbing un-
der the operating conditions.
Particulars of the method proposed for protecting the blades at the low pressure
end of the machine from erosion by water shall be clearly stated in the tender.
6.2.10 Rotor
The rotor shall be of suitable material accurately machined to size and propor-
tioned so that critical speeds are remote from the operating speed. Vibration sever-
ity measured in any direction at the journals of a shaft shall not exceed 10 mm /
sec when operated under any load at 3000 rpm.
The turbine rotor shall be forged in one piece. The procedure proposed for inspec-
tion of the rotor in order to ensure its soundness and homogeneity shall be state in
the Tender together with particulars of the thermal treatment proposed in order to
minimise the possibility of distortion occurring in service.
The rotor, when completed, shall be dynamically balanced and tested to an over-
speed of 15 percent for 5 minutes unless otherwise agreed.
The type of thrust block and whether axial adjustment is possible or not shall be
stated in the Tender.
The turbine rotor shall be coupled together by rigid forged couplings of approved
design.
The design and construction of the turbine casing shall be such that growth or dis-
tortion of any part such as to affect the efficiency and reliability of the plant shall
not occur as a result of operating conditions to which the plant may be subjected.
Those parts of the casings which may be subject to steam at a temperature of
more than 10000C under any conditions of load, shall be constructed of steel and
be heat treated before rough machining. The thermal treatment proposed in order
to minimise the possibility of distortion occurring in service shall be stated in the
Tender.
The turbine casing shall be divided on the horizontal centre line and suitable lifting
gear and slings shall be provided for raising and lowering the upper sections of
turbine casing and turbine rotor clear of the blending. Guide rod necessary for pre-
venting damage to the blending shall be provided. No studs will be allowed in cas-
ings or in pipe connections to casings unless approved.
All cylinder flange bolts or studs or other bolts or studs subject to high temperature
shall be of approved design and of creep resisting steel.
To ensure that bolts and studs are tightened up uniformly and correctly when mak-
ing the flange joints which are subject to high pressure and temperature, arrange-
ments shall be made for stretching the bolts and studs to the required tension ei-
ther by electric heating or hydraulic means. One set of the necessary apparatus
shall be supplied by the Contractor and shall remain the property of the Board.
The design of the main turbine shall provide for the inclusion of relief diaphragms
in the low pressure casings. The design of the diaphragms shall be such the
clamping rings shall effectively support the diaphragm to percent fatigue cracking.
Diaphragms shall be easily replaceable preferable without the use of special tools.
The diaphragms shall be mounted in with water. Adequate provisions shall be
made for convenient and safe access to the diaphragms but the diaphragms shall
be so located or protected to prevent inadvertent damage.
- The thermal stress at the most vulnerable points of the turbine chests and
cylinders may be determined and appropriate limits placed on the rate of
acceleration or loading.
The Tender shall comment on the requirements and on the number of thermocou-
ples to be supplied.
6.2.12 Bearings
All bearings shall be of the forced-feed lubricated type Bearings shall be of split
design so that the upper half is readily removable and the lower half can be re-
moved and replaced without lifting the shaft. Means shall be provided to indicated
excessive axial movement due to failure of a thrust bearing. Arrangements shall be
made for visible indication of the oil flow from each bearing pedestal. A dial ther-
mometer equipped with adjustable contact making device shall be provided at
each bearing to monitor the temperature of oil leaving each bearing and to give
high temperature alarm.
All clean drains from steam chests, loop pipes turbine cylinders and any point
downstream of the emergency stop valves shall be returned to the atmospheric
flash box or drain tank.
Where traps are required they shall be fitted in accessible positions and provided
with by-pass arrangement. A valve shall be fitted on the line side of each trap at
the junction of the drain pipe and the part of the plant to be drained.
The Tenderer shall put forward in his proposal a recommended scheme for auto-
matic traps with the appropriate instrumentation.
Steam turbine generator shall be equipped with one stationary oil purification and
water separation plant connected to the main oil tank of the unit, comprises with oil
centrifuge machines, filters, oil storage tank and transfer pump.
The oil centrifuge shall preferably be installed in the turbine oil room and shall
permit a continuous purification and clarification of at least 5% per hour of the total
oil quantity.
The plant shall be complete with integrated inlet and discharge pumps, each with a
by pass for flow adjustment, pre-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 control
room in case of any fault.
6.3.1 Condenser
A surface type condenser set shall be provided for operation with steam turbo
generator. The condenser shall consist of single shell having water box and
hotwell.
The source of condenser circulating water shall be from Cooling tower basin only.
The plant in operation shall be able to meet the following specific performance re-
quirements.
(1) The condenser temperature at all loads shall be equal to the corresponding back
pressure in the condenser at that load.
The condenser shall be complete with all gauges, switches, and other necessary
fittings.
The condenser tube shall be material suitable for the specified water of cooling
tower. The tubes shall be adequately stayed by supporting plates to prevent vibra-
tion and to permit self draining of the tubes, the contractor shall provide means to
cater for differential expansion between the tubes and the shell.
The hotwell outlet to the condensate pump suction shall be arranged to avoid dead
strange in the hotwell.
Design of the water box shall ensure an even distribution of flow to all tubes.
The condenser end covers shall be provided with an ample number of side hinged
manhole doors to enable access to be gained to the whole surface of the tube
plates without removal of the end covers. The manhole doors shall be secured by
the guide release or captive nut and bolt arrangements.
The Contractor shall supply three (3)x 60% capacity multistage, free suction cen-
trifugal condensate pump, each complete with mounting flange, inner assemble,
driving motor coupling and standard accessories for each turbine unit. The capac-
ity of each condensate pump shall be 60% of the condensate flow at maximum
output. The pumps shall be identical and all parts interchangeable.
The pumps shall have continuously rising head capacity characteristics. The dis-
charge pressure shall be selected so that the pumps will meet the pump the design
flow pressure drop requirements.
All parts subject to wear shall be fitted with renewable liners, and all bearings shall
be automatically lubricated.
The pump gland and suction valve shall be suitable sealed to avoid the ingress of
oxygen into the condensate. An emptying connection complete with drain piping
shall be provided on the feed piping between the extraction pump discharge valve
and the ejectors if supplied. A suitable strainer shall be provide to prevent any for-
eign matter being discharged from the extraction pumps to the feed system during
the initial commissioning period.
Air extraction system shall be one of the following two types or combination those:
(1) Vacuum Pumps
Two duplicate condenser steam side mechanical vacuum pumps including motor
and auxiliaries shall be provided for normal operation of the plant to remove air
leakage into the condenser to maintain condenser vacuum. Pumps will be applied
singly to maintain vacuum in both condenser shells under normal operation condi-
tions. Vacuum pumps will be applied in parallel to evacuate are from the con-
denser shells for start-up. The time allowed for raising vacuum shall be determined
by the hot start up time specified by the Tender.
Vacuum pumps shall be rotary, positive displacement liquid sealed type. Pump
shall be complete integrated units with motor-drives, couplings, interconnecting
The Contractor shall provide one full capacity steam jet air ejectors complete with
condensing unit for air extraction. These ejectors shall be combined with inter
and/or after coolers designed to operate a pressure sufficiently below the normal
pressure at the steam generator pressure. All necessary fittings and local instru-
ments shall be included. In additional the time allowed for raising vacuum shall be
determined by the hot start up time specified by the Tenderer.
An automatic venting system of proper design shall be provided for the condenser
system.
A suitable drain tank shall be provided for receiving drain water from the ejectors if
provided, and other equipment. The tank shall be fitted with a protected gauge
glass, a thermometer pocket, and a float-operated valve, the float being so ar-
ranged that when the accumulating of water in the tank reaches a predetermined
limit the excess water is passed through the valve to the condenser. A section of
the tank cover shall be hinged for cleaning purposes.
The Contractor shall furnish a high head, horizontal tray, pressure type de-aerator,
if required, with internal direct contact vent condenser and a separate horizontal
storage tank section for turbine unit. The unit shall be complete with, but not limited
to, trays, baffles, spray valves, internal distribution piping for introducing of steam
drains and condensate. The de-aerating section shall be supported on the storage
tank section.
The feedwater delivered at all loads up to and including the maximum effluent flow
shall no exceed an oxygen content of 0.01 ppm measured at the deaerator outlet.
However, during the first hour of start up, a higher oxygen content can be toler-
ated, but in any case, a maximum value of 0.1 ppm shall not be exceeded.
The Tenderer shall state in his proposals to minimise dissolved oxygen at start-up.
The pump glands and suction valves shall be suitable sealed to avoid ingress of
oxygen into the condensate.
The joints which are necessary shall be in approved positions and shall be welded
butt joints unless otherwise approved. At terminal points the joints shall be of the
seal welded or bolted non-welded flanged type as provided below.
Exceed where otherwise approved, joints shall be electric with welded.
The whole details of constructing of seal welded and non-welded flanges to the
pipes, shall be subject to the approval of the Engineer.
All flanges used for bolted joint shall be cutter barred or faced at the back so that
nut, washers and bolt heads may be down satisfactorily.
All blank flanged for pipes included in this clause shall be of steel.
All piping shall be colour coded properly as approved by the Engineer.
All high pressure steam pipes, bends and fittings shall be designed for the maxi-
mum steam generator super heater safety valve blow off pressure and tempera-
ture.
To enable regular creep measurements to be made under service conditions the
Contractor shall provide non-corrosible gauging points at suitable positions on the
high temperature steam pipework together with gauging apparatus. Arrangement
shall be made with the Engineer for the initial measurements to be taken prior to
the pipework going into service.
Where welding is used for the attachment of branch pipes the method shall be
Where necessary drain pockets of ample size and of approved construction shall
be fitted.
All high pressure feed pipes shall be designed for maximum working pressure and
temperature of the feed system and shall comply will ISO standards were applica-
ble.
Where welding is used for the attachment of branch pipes the method shall be
subject to approval. In order to compensate for the metal cut away from the main
pipes, suitable reinforcement shall, where required by the Engineer, be provided
around the opening which is formed to receive the branch pipe. The method of
welding for the attachment of the reinforcement to the main pipe and to the branch
pipe shall be approved by the Engineer.
All release valves shall be provided and arranged in suitable positions for opera-
tion.
6.4.4 Low Pressure Piping
All medium and low pressure piping for condensate drain, bleed steam, vent, va-
pour and other services shall be provided. It shall be of hot-finished seamless steel
tubes manufactured and tested in accordance with the current issue of ISO stan-
dards.
Flanging shall be in accordance with the appropriate table given in ISO and
flanges shall be cutter-barred or faced at the back so that nuts, washers and bolt
heads bed down satisfactorily.
All nuts and bolts shall be of best quality bright steel, and shall be machined on the
shank and under the head and nut.
6.4.5 Drain Piping
All drain pipes on the inlet side of drain valves shall be designed for the same
pressure and temperature as the valve, pipe or vessel which they drain and shall
be subject to the specification and tests relevant thereto.
Drains shall be provided at suitable points on the steam ranges where water may
collect during the period of warming up of the plant. Automatic drain traps shall be
provided on the water range where appropriate.
The discharge from all drain points shall be arranged with an approved continuous
fall towards the drain vessels.
Drain valve hand wheels shall be extended for operation where required by the
Engineer.
Motorised drain valves essential for automatic start-up and control purpose shall
be provided to Engineer's approval.
6.4.6 Valves
All valves shall be of approved design and manufacturer and those of similar
make, size and type shall be interchangeable with one another unless otherwise
approved.
All control valves shall have manually operated inlet and outlet isolating valves with
a bypass arrangement unless otherwise stated.
All valves shall be fitted with outside screw unless otherwise specified or approved.
All valves shall be closed by rotating the handwheels in clockwise direction when
looking at the face of the handwheel . The face of the handwheel shall regarded as
the face farthest away from the body to the valve. The valve spindle shall also be
rotated in a clockwise direction to close the valve when be viewed form the outer
end of the spindle and in cases where the handwheel is not directly attached the
valve spindle, suitable gearing shall be introduced to reconcile the above condition.
The face of each handwheel shall be clearly marked with the words "open and
close" with arrows adjacent to indicate the direction of rotation to which each re-
fers.
Each handwheel shall also be fitted with a circular name-plate indicating the ser-
vice for which the valve is intended. The name-plates shall be of stainless steel
with engraved letters filled with black enamel. Valves for emergency operation
shall have the lettering filled in with red enamel where required by the Engineer,
valve spindles shall be lengthened so that the handwheel is at a height of ap-
proximately 1 meter above is to be operated.
Where extension spineless are fitted thrust when opening or closing the valves
shall be taken directly on the valve body and all valve pedestal shall be mounted
direct on the floor girders and not on the floor plating. Any floor steelwork trimmers
necessary for supporting the pedestals shall be provided by the Contractor.
All valves shall be fitted with indictors so that it may readily be seen whether they
are open or close and in the case of those valves fitted with extended spindles, in-
dicators shall be fitted.
The valves in the circulating water system and in other water services connected
thereto shall be subject to the corrosive action of water and care shall be taken in
the choice of materials to be used in the construction of those parts of the valves
which shall be in contact with this water, the valve bodies being constructed of
special cast iron or rubber lined to resist corrosion.
All valves specified to be motor operated shall be fitted both with hand and motor
operating gear. They shall be of approved design and complete in all respects in-
cluding the motor and the necessary controls for automatically stopping the motor
when the valve gate has reached the "full open" or "full close" position. The motor
shall be placed in such a position relative to the valve that there is no possibility of
leaked or water from the valve joints or glands blowing on to the motor or control
equipment.
The operation of opening or closing the valve shall be controlled by means of three
push buttons labelled respectively "open", "close" and "stop" or by means of an
approved type of hand control lever. The control shall be so arranged that the mo-
tor can be stopped with the valve in any position and can then be restarted in ei-
ther direction. The push buttons or hand control lever shall be mounted together in
an approved position on or adjacent to the valve, in such a position that the valve
indicator is readily visible to the operator.
An interlock shall be provided such that when the valve is being operated manu-
ally, the electrical apply to the control circuit of the motorised valves is isolated
supply and indications for the status of control shall be shown in the central control
room.
The Tenderer shall give a full list in "TENDERER'S DATA" valves fitted with ex-
tended spindles, indicators shall be fitted both to the extended spindle.
Valves shall not fitted in an inverted position unless other wise approved. Eyebolts
shall be provided where necessary to facilitate handling heavy valves or parts of
valves.
6.4.8 High Pressure Valves
All valves intended for high pressure steam, feed water, or any other services sub-
ject to high pressure or temperature shall be of approved manufacturer and shall
have cast or forged steel bodies with, wherever possible bolted on covers and
glands and the materials of the internal parts shall be subject to approval.
The design of the high pressure valves shall be given special attention with regard
to the selection and thickness of material so that they will be suitable for high pres-
sure and temperatures and full details of the design shall be submitted for approval
as early as possible. Approved means shall be provided to prevent any accumula-
tion of pressure between the discs of any high pressure steam or feed parallel
slide valve. Preferable in the case of valves with by-passed, the integrate space to
the by-pass valve.
The Contractor shall provide all lagging and cladding for the turbo-generator unit
and heat recovery steam generators.
All exposed portions of the plant which operate at temperature above 80 0C shall
All unlagged surfaces shall have smooth finish. Any surplus welded seams shall be
removed by grinding.
7.1 Generator
7.1.1 General Requirement
7.1.2 Generator(s)Rating
7.1.3 Voltage and Short Circuit Ratio
7.1.4 Temperature Rise
7.1.5 Insulation
7.1.6 Stator
7.1.7 Generator Leads
7.1.8 Bearings
7.1.9 Rotor
7.1.10 Temperature detectors
7.1.11 Insulation against shaft current
7.1.12 Accessories
7.2.1 Exciter
7.2.2 Automatic voltage regulator
7.1 Generator
The MVAR leading capability shall not be less than 30 % of the MVA rating
of the generator at 0.8 leading power factor. The generator in conjunction
with its exciters shall be designed to operate stably at all loads up to the
maximum continuous rating.
The generator shall be capable of supplying the rated output at rated speed
and at rated power factor with a voltage variation between 90% and 110%
of the rated voltage.
The temperature rise of the generator under the base and peak rating
operations at any ambient condition shall not exceed the values given
below:
at Base at Peak
/MCR
a. Stator winding by resistance 950C 1000C
temperature detectors method
7.1.5 Insulation
The insulation of the armature and field windings of the generator shall
satisfactorily withstand high voltage tests as specified in IEC standard.
Insulation of the armature windings, field windings, and collectors shall be
class F.
7.1.6 Stator
Protective covers and air shields shall be made of steel plates, welded,
stiffened with suitable angles and channels, and formed in segments for
case of handling. The segments shall be bolted together and to the stator
frame.
The windings, terminals, and leads shall be fully insulated throughout and
The general construction of the stator and bracing of the winding overhand
shall provide adequate cooling surface and the avoid the hot stops. The
stator coils shall be either semi or completely pre-formed and shall be
made up before insertion to the slots.
The neutral and output ends of each phase windings shall be brought out to
the generator terminal cubicle.
7.1.8 Bearing
Bearings shall be pressure lubricated by pressured oil from the gas turbine
lubricating oil system, and oil drain pipes shall be equipped with pockets for
thermometer and suitable sight flow opening for observing bearing oil flow.
Separate lubricating oil system for condenser' operation shall also be
provided, if required.
7.1.9 Rotor
The rotor slot insulation shall be mainly of epoxy resin or other approved
material and particular attention shall be given to the insulating and
securing of coil to coil and slip ring connections, if any, and to avoid
vibration and the possible failure to either the connector or its insulation.
More than nine (9) resistance type detectors shall be provided for
monitoring of generator stator winding temperatures. The detectors shall be
built into the generator, fully protected from the cooling air, suitable
distributed around the circumstances, and embedded in the slots in
positions normally having the highest temperature in accordance with
7.1.12 Accessories
d. Alarm contacts
e. Space heater
7.2.1 Exciter
The excitation system shall match the generator rating and shall maintain
the voltage of the unit within a tolerance of plus and minus 0.5% of rated
voltage regulation. The exciter shall have capacity to supply not less than
110% of the field current required by the generator at rated output, power
factor, frequency and voltage.
The rated voltage of the exciter shall be 110% of the machine excitation
voltage at the rated output of the machine.
The ceiling voltage of the exciter shall not be less than 140% of the
matching excitation voltage. Insulation of stator and rotor winding of the
exciter shall be class F. A field breaker and discharge resistance shall be
provided or alternatively special provisions must be taken to either
7.3.1 General
The generator circuit breaker, isolators, earthing switches, CT, PT, surge
capacitors, surge absorber shall be provided, and these shall be
accommodated in metal clad switchgear cubicle arranged for local and
remote control. Secondary wiring including cable termination facilities shall
be provided.
1) The switchgear shall be of the metal clad type and shall comply with the
standards given below and with the relevant requirements stated in this
specification.
2) The switchgear busbar and associated connections shall have the insulation
levels as given below:
Withstand voltage
Lighting (impulse) : 75 KV (peak)
(11.2/50micro sec.)
4) The current rating of the main bus bars shall not be less than rated current
of the related generator and rating of the associated connections shall be
determined by the Contractor.
(5) The short time three phase fault level rating for one second of the
switchgear shall be of 100 kA(rms) for GT and 100 KA (rms) for ST . The
Contractor shall check the system fault current level.
(1) The switchgear shall consist of rigid welded steel cubicles and shall house
generator circuit breaker, bus bars, current transformers, voltage
transformers, neutral grounding transformer, surge absorbing equipment
etc, The generator circuit breaker and the voltage transformers shall be
withdrawable type. All doors shall be padlockable and readily removable
when necessary.
(2) The bus bar and its connections shall be of copper and all joint surfaces
shall be silver plated.
(3) All bus bar connections shall be by bolted type. Flexible joints shall be
provided wherever for thermal expansion will occur.
- a circuit breaker from being inserted into the fixed position unless
the secondary isolating contacts are fitted.
- a circuit breaker from being inserted into the fixed position unless
the secondary isolation contacts are fitted.
7) A common earth bus bar shall be provided in the switchgear. The bus bar
shall consist of one copper
Generator unit Circuit Breaker shall be of SF6 gas and other Circuit
Breaker(s) shall be of SF6 gas or vacuum type.
The circuit breaker shall comply with the requirements of IEC 56 and the
relevant requirements of these Specifications.
Circuit breaker rated current / voltage will be as per rated current / voltage
of the Generators. CT/ PT ratio will be as per requirement
All circuit breakers of same rating & shall be identical in arrangement and
shall be interchangeable and floor mounted.
The voltage transformers shall be of the horizontally with draw-out type and
shall be located on top parts of each unit switchgear. Padlocking facilities
shall be provided for both the services and isolated positions. The fixed
isolating contacts shall be covered by a positively driven pad-lockable
shutter when the voltage transformer is withdrawn.
The ratio, rating, polarity and accuracy classes of voltage transformers shall
conform to IEC 186 or IEC 60044-2.The current limiting fuses shall be
provided on high tension circuit of the voltage transformer.
The surge arresters and capacitors for surge protection of the generator
shall be provided.
The common switchgear shall be fully metal clad arrangement for local and
remote operation, and shall comprise the following cubicles:
- Incoming circuit breaker cubicle for the unit auxiliary transformer.
- Outgoing circuit breaker cubicle to station transformers.
- Voltage transformer cubicle.
- Outgoing circuit breaker cubicles to starting motor/ SFC transformer,
Excitation transformer, GBC, other 6.6 kV loads etc.
The circuit breaker shall be of SF6 gas or vacuum type.
The circuit breaker shall comply with the requirements of IEC 56 and the
relevant requirements of this Specifications.
All circuit breakers shall be of same rating and identical in arrangement and
shall be interchangeable.
Withstand voltage
Lighting (impulse) : 60 KV (peak)
(11.2/50micro sec.)
4) The current rating of the main bas bars shall not less than the rating of the
unit auxiliary transformer and rating of the associated connections shall be
determined by the Contractor.
(5) The short time three phase fault level rating for one second of the switch
gear shall be of 40KA (rms).
The circuit breaker shall comply with the requirements of IEC 56 and with
the relevant requirements of this specification.
Only fully type tested circuit breakers complying with IEC 56 will be
considered, and a statement as to the availability of certificates of all such
type tests including impulse tests on identical or similar circuit breakers
shall be submitted with Tender.
Specification:
Circuit breaker :One (1)
1250 A, 50 KA (rms)
Transformers
8.1 General
8.1.1 Requirements for Characteristics
8.1.2 Requirements for Construction-
8.5 Accessories
8.1 GENERAL
The maximum continuous rating of the transformer shall meet at any taps
with the output of the Generator, which is connected with the transformer in
series as shown in the attached single line diagram ( Vol. 2 of 3). The
maximum continuous rating of the transformer (Three phase and Vector
Group = Ynd1) shall be 120% (one hundred and twenty per cent) of the cor-
responding MVA (pf=0.8) of the Guaranteed Net Generator output at Site
condition of 350 C, 1.013 bar and 98% RH.
The self cooled capacity shall not be less than 75 % of forced air cooled
capacity
Three phase, oil immersed type, self air-cooled (ONAN) for stepping down
the voltage from 15.75 kV to 6.6 KV with off circuit tap changer. The
capacity of each auxiliary transformer shall 110% of total auxiliary load for
both GT & ST and common station service..
Three phase, oil immersed type, self air cooled (ONAN) for stepping down
the voltage from 6.6 kV to 415 V with on load tap changer. The capacity of
each station transformer shall enable to supply 55% of total 415 V auxiliary
load for both GT & ST and common station service.
(1) Efficiency
The transformers shall be of highest efficiency that the Contractor can
attain.
(2) Temperature Rise
The temperature rise of the windings shall not exceed 550C when
measured by he resistance method, after circulating the rated current at
rated frequency in the windings under test.
The temperature rise of top insulation oil shall not exceed 55 0C when
measured by a thermometer in an oil filled thermometer pocket on the
cover or in the outlet pipe to the cooler, and the method of the test of
temperature rise will be decided in accordance with IEC 76-2 .
a. 230 KV CIRCUIT
- lightning impulse withstand test voltage : 1050 KV (peak)
(1.2/ 50 micro sec.)
The no load excitation current under the rated voltage and frequency shall
be as small as possible.
(7) Noise
e. The sealed joint part of the tank shall be designed to prevent oil and
gas leakage and shall be water light even after long term use, and
careful attention shall be paid to fastening methods of packing of
bushing, bursting tube, cooling radiator, connecting pipes and other
g. All generated gas and oil flow under fault conditions shall be
concentrated to the Buchholz or similar type relay so as to ensure
the relay action.
- Buchholz relay and Pressure Relieve Device (PRD) similar type for
alarm and trip
- High temperature alarm and trip (winding and oil)
A Buchholz relay or oil pressure relay shall be fitted on between the
conservator and the tank. A dial type thermometer with hand resetting
maximum indicator shall be provided. A Pressure Relief Device (PRD) with
operation indicator shall be provided.
The gas relay should be provided with double float (one operated by
volume of gas flow and other operated by mass gas flow). It should have
following provision:
(7) Wiring:
All wiring mounted on the transformer shall be drawn through conduit pipes
or adequate protective tubes to the control cabinet which shall be properly
located on the transformer.
The transformer shall be of three phase, oil immersed, self cooled / forced
air cooled (ONAN/ONAF) by cooling fans, outdoor use type. Ratio of delta
star connection shall be 15.75 KV to 230 KV on full load condition.
The on load tap changer (MR, Germany/ ABB, Sweden) shall be provided
on the high tension winding, and their ratio shall be as follows:
The maximum continuous rating of the transformer shall met at any taps a
total output of the generator which is connected with the transformer in
series as shown in the attached single line diagram (Annexure -6).
The self cooled capacity shall not be less than 75 % of forced air cooled
capacity.
Impedance voltage (+ve Seq.) shall be within the range of 15% to 18% on
the forced air cooled rating on the rated tapping (15.75 /230 KV ) and shall
be guaranteed by the Contractor.
The full insulation shall be applied on both 230 KV (phase & neutral) and
15.75 KV windings and neutral point of 230 KV windings shall be solidly
The on load tap changer with motor drive unit (MDU) made by “MR,
Germany/ ABB, Sweden” shall be provided on 230 KV side of winding and
shall be designed to meet the requirement of IEC 76. Provisions shall be
made for padlocking in any tap position.
1) Use : Protection
2) Ratings
Rated primary current : As required
Rated secondary current :5A
Accuracy class : 5 P20
Rated burden :15 VA
The transformers shall be of three (3) phase, oil immersed, self air cooled
(ONAN) type. Nominal no load ratio of delta star connection shall be 6.6
KV to 0.415 KV.
8.3.2 OUTPUT
Each Station transformer shall enable to supply 55% of total 415V auxiliary
power for the gas turbine generating unit(s), steam turbine generating unit
and common station service.
The impedance voltage shall not less than 5 %, but not more than 7.5 %
on the rated tapping (6.6KV/ 415V) and shall be guaranteed by the
Contractor.
The off load tap changer shall be provided on 6.6 kV winding and shall be
designed to meet the requirements of IEC 76 . as follows.
Central tap : 6.6kV
Step voltage : 1.25%
All the mechanical operating parts of the gear shall be self lubricated with
transformer oil, no special lubrication being necessary. The tap changer
shall be operated electrically by means of manual push buttons mounted
on the central control panel. The tap changer compartment oil shall be
isolated from main transformer tank oil, and the compartment shall be
provided with proper protection facilities and accessories.
The cable boxes shall be provided on both high tension and low tension
terminals to terminate high and low voltage power cables. Proper cable
supports and cable cleats shall also be provided.
The unit auxiliary transformers shall be of three (3) phase, oil immersed
type. Nominal no load ratio of delta star connection shall be 15.75/6.6 KV
(ONAN).
8.4.2 Output
The impedance voltage shall not less than 5%, but not more than 7.5% on
the rated tapping (15.75/ 6.6 KV) and shall be guaranteed by the
Contractor.
8.5 ACCESSORIES
a. Name plate
b. Valves for oil filtering and sampling
c. Air vent valve
d. Manhole and hand-hole including blind covers
e Ladder fixed to the transformer tank for inspection of the upper part
of The transformer.
f. Hanging hook
g. Grounding terminals
h. Anchor device
i. Oil preservation system including oil conservator
j. Oil level gauge
k. Dial type thermometer with hand resetting maximum indicator
l. Breather with silica-gel
m. Other necessary accessories
n. Connecting conductors including flexible connectors among the
single phase transformer to compose three phase bank.
(Step-up transformer only)
0. Rail track in the transformer yard.
9.4.1 Insulators
9.4.2 Fitting
9.4.3 Standard Conductor for Over Head Line
9.1 GENERAL
(1) Type
Three (3) pole, porcelain type, high speed, outdoor, trip free in any
position, hydraulic & spring operated SF6 gas puffer, single flow type
complete with hydraulic pump, tank, piping, conduit, wiring, and all other
necessary accessories.
(2) Use
(3) Ratings
c. In case of phase open trouble, all phases of the circuit breaker shall
be opened by a protection circuit.
d. The arcing contact shall be of an arc proof metal and the main
contact shall be covered with silver electroplated.
e. Five (5) pairs of “a-b “spare contacts shall be equipped with the
auxiliary switches.
f. The tripping current of the trip coil shall not be more than 2 A per
phase.
j. The weather and dust proof type control box shall be furnished with the
circuit breakers. The control box shall be equipped with all necessary
parts to operate the circuit breaker, such as control solenoids, operating
switch of remote and local control, auxiliary switch, terminal blocks,
protective devices, indicating lamp sockets, and other accessories. An
anti condensation electric heater with thermostatic switch shall be
provided inside the control box.
s. The Contractor shall furnish all control cables, pipes or ducts and
fittings between each phase and control box.
t. The indicating lamp signals which display " on (red) “ and " off (
a. Name plate
b. Position indicating lamps (red and green) or flags.
c. Operation counter.
d. Grounding terminals
e. Gas, and hydraulic pressure gauge
f. Safety valves, if any
g. Pressure drop protecting device
h. Manual operation device.
i. Auxiliary switch
j. Control box with locking device
k. Steel supporting structure with anchor bolts and nuts
l. Operating mechanism.
m. Special tools for checking and testing
n. Power outlet, single phase, 230 V, 10 A in control box
0. Conduit pipes(Steel/GI)
p. Communication facilities between switchgear and control room
q. Other necessary accessories, if any
(1) Type
For buses
Outdoor, three (3) pole, single throw, group operated, horizontal break,
rotating insulator, remote controlled motor operated type.
(2) Ratings
(5) Accessories
Nameplate.
Control box with locking device.
Grounding terminal.
Auxiliary switches.
Steel supporting structure with anchor bolts and nuts.
Manual operation handle.
Motor operating mechanism with manual operation inter-lock.
Conduit pipes(Steel/ GI).
Other necessary accessories, if any
(1) Type
Outdoor, single phase, oil immersed with level indicator or gauge, N2 gas
sealed Electromagnetic type voltage transformer.
(2) Use
For metering and protection
- Primary :230 kV 3 kV
- Secondary : 110 V 3 kV
- Tertiary : 110 V/3
d. Rated burden
- Secondary :200 VA
- Tertiary :25 VA
(1) Type
Outdoor, single phase, oil immersed with level indicator or gauge, N2 gas
sealed porcelain clad type, quadruplicate cores.
(2) Use
For metering and protection
(3) Ratings
a. Rated current
- Primary :3000 A
- Secondary : 5-5-5-5 A
j. The junction box with terminals shall be provided for the secondary circuit
connections.
m. Unless otherwise specified, the characteristics and others shall comply with
IEC 185 .
(5) Dielectric Test Voltages
a. Power frequency withstand voltage :460 kV for one minute
on primary windings.
b. Lighting impulse withstand voltage
Full wave (1.2/ 50 micro sec.) :1050 kVPEAK
(6) Accessories
The following accessories shall be provided for each current transformer.
Nameplates.
Grounding terminals.
Lifting lugs.
Steel supporting structure with anchor bolts and nuts.
Junction boxes.
Conduit pipes (Steel/GI).
Other necessary accessories, if any
(1) Type
Outdoor, single phase, self standing, Metal-Oxide type with surge operating
counter.
(2) Use
For protection of 230 kV outdoor switchyard equipment and transformer
windings.
(3) Electric system to be protected
Three (3) phase, three (3) wire, neutral point solidly grounded system.
(4) Ratings and Performances
a. Rated voltage : 186 kV
b. Rated frequency : 50 Hz
c. Nominal discharge current : 10 KA
d. Type of duty : Heavy, Long duration
discharge
e. Pressure relief class :C
f. Lighting impulse insulation level : 1050KVpeak
(1.2 / 50 micro sec.)
g. Maximum residual voltage : 400 KV
h. Power frequency spark-over voltage : 170 KV
a. The series gaps shall be so designed that for practical purposes the
various characteristics will not alter under the change of weather
conditions.
b. The various parts of the lightning arrester shall be of complete moisture
proof construction so that the characteristics shall not be impaired under
long term use. Sealed parts shall be so designed to prevent to ingress of
moisture or water under long term use.
c. The operation counter shall be equipped on the lightning arrester in each
phase and consist of a sure current recording and measuring device, such
as a magnetic link surge crest ammeter, and counter for the number of
discharges of the lightning arrester. It shall be located at the position
convenient for inspection.
d. Creepage distance of bushing shall not be less than 25 mm/ kV of phase
to phase voltage. The glazing colour shall be of brown.
e. Unless otherwise specified, tile characteristics and others shall comply with
IEC 99-1.
(8) Accessories
a. Nameplates.
b. Grounding conductor to grounding terminal.
c. Operating counter.
d. Grounding terminal.
e. Steel supporting structure with anchor bolts and nuts.
f. Other necessary accessories, if any.
9.3.1 TYPE
Wind loads shall be calculated with wind speed of 45 m / sec, but the wind
loads on unit projected area shall not be less than the followings:
The Contractor shall calculate the maximum and minimum stresses at any
combination of loading conditions. The design of each type of steel
structure shall be made by the same manner of analysis. The design
stresses of individual components shall be largest value of maximum
stresses in the respective loading conditions.
The safety factors shall not be less than two (2) under the normal working
conditions.
(1) Workmanship
Workmanship shall be first class throughout. All pieces shall be straight,
true to detailed drawings and free from lamination, flaws and other defects.
All clippings, back nuts, grindings, bends, holes, etc. shall be true to
detailed drawings and free of burrs.
(2) Galvanising
The steel structure shall be completely galvanised (Hot-Deep), except for
part which shall be embedded in concrete foundation. All ferrous materials
shall be galvanised to meet the requirements of IEC.
(3) Materials of Steel Structure
All materials shall be hot rolled structural steel and/or high strength
structural steel.
(4) Marking
All products shall be marked with systematic numbers and / or colours for
convenience of assembly.
(5) Future Extension of Structure
In designing the steel structure, consideration shall be given in the design
criteria to permit easy extension of steel structure in the future and same
loading conditions shall be taken into account in accordance with the
Specifications.
(6) Bolts and Nuts
All the members shall be connected by bolts and nuts. The diameter of the
connection bolts and step bolts shall not be less than 16 mm.
The Contractor shall submit to the Engineer for approval design sheets and
drawings including calculation of Loads, selection of constitution and
members, selection of connecting bolts and calculation of reaction load
against base concrete.
9.3.5 ACCESSORIES
9.4.1 INSULATORS
o. The suspension insulators shall he of ball and socket type and shall
conform to the requirement of IEC 120.
p. The insulator unit shall be standard 254 mm porcelain disc type or fog type
254 mm porcelain disc type, and have a spacing of 146 mm between
discs.
q. Total creepage distance of the insulator assemblies shall not be less than
3300 mm.
9.4.2 FITTING
The suspension and tension clamps for bus works and outgoing feeders,
All metal shall be free from rust, burrs, sharp edges, lumps and dross and
shall be smooth so that interconnecting parts will fit properly and the parts
may be assembled and disassembled easily. Hardware shall have ultimate
strengths exceeding three (3) times tension load of bus work and overhead
ground wire.
The hard down aluminium stranded conductor of 850 mm2 shall be used for
230 kV bus bars and for outgoing feeder circuit. The conductors shall
comply with the requirements of IEC.
- Conductor number.
- Kind and cross sectional area of conductor.
- Conductor length
- Spool weight
- Name of manufacturer or abbreviation
- Date of production
- Position of beginning of conductor
- Direction of rotation of spool
- Indicator showing the remaining length of conductor
10.1.1 CONSTRUCTION
As shown in the Auxiliary One Line Diagram, the auxiliary Power system
shall consist of the following equipment, but not be limited to:
- 6.6 kV Switchgear
- 415 V Switchgear and Motor Control Centres
Note: High speed Bus Transfer (HSBT) system to be incorporated with 6.6 kV
bus incomer breakers. With the failure of 6.6 kV bus incomer breaker, bus
interconnector is to be closed without making any disturbance to 6.6 kV
loads.
10.1.1 CONSTRUCTION
(3) Compartment
Circuit breaker chamber and bus chamber shall be isolated by grounded
steel plates, and bus conductors shall be installed.
Control cables shall be led from terminal blocks through front bottom of
front bottom of cubicle.
As shown in the Auxiliary One Line Diagram, 415 V switchgears and motor
control centres shall be supplied to control all electric motor driven
auxiliaries and supply power to the other electric load of the generating
plant. If control centres or distribution panels not described in this
Specification be needed, they shall be supplied with each facility. In
addition of the requirement, 10 nos of spare 415V circuit breaker are to be
installed for future use.
The switchgears and motor control centres are classified into the following:
- Type
Indoor, steel sheet formed cubicle, single bus draw-out type.
- Rating
Rated voltage :415 V
Rated frequency :50 Hz
Rated normal current
Incoming and bus tie circuit :2,500 A
Feeder circuit :600 A
Rated short circuit current :40 KA(rms)
e. Cable Connection
Power cables and control cables will be led from the terminals
through rear bottom of cubicle.
f. Control Power
The switchgear
- Type
Indoor, steel sheet formed, self standing dual face type motor
control centre.
- Rating
Rated voltage : 415 V
Rated voltage : 50 Hz
c. Compartment
Grounded metal plate shall be provided to separate between the
unit and C B. section and bus bar section conductors shall be
insulated.
d. Draw-out system
Control centre unit and incoming circuit breaker shall be drawn out
horizontally by hand and main circuits shall be disconnected from
bus bar.
g. Cable connection
Power cables and control cables will be led from the terminals
through front bottom of cubicle.
h. Busbars
Bus bars shall be copper bars with insulating cover.
11.9.2 Control
The unit shall have its own local unit control room which is completely
independent of the control room for the other unit.
- Normal start-stop
- Emergency stop switch
- Base- peak load selection
- Manual load control
- Manual voltage control
- Synchroscope switch
- Synchroscope, synchronising lights, and incoming and running
voltmeters
- Status lights to indicate: Standby, starting, on-line, Emergency
shutdown, etc.
- Speed indicators
- Frequency meters
- Fired time indicator in both base load operation and peak load
operation
- Three start counters:
- Generator ammeter
- Generator voltmeter
- Bus voltmeter
- Generator watt meter
- Generator voltmeter
- Bus voltmeter
- Generator watt meter
- Generator var meter ( zero centre)
- Generator watthour meter with indicating lamp for voltmeter
- Generator varhour meter
- Watt and Var
- Test switch
- Recording of following parameters:
Air temperature
Lube oil temperature
Bearing temperature
Critical Turbine gas temperatures
Bearing vibration
- Automatic synchroniser
- Speed matching
- Voltage matching
- Voltage acceptance
- Synchronising check or synchro- acceptor
The contractor shall furnish all control equipment, meters, relays or similar
devices not specifically listed but those are required for the sound operation
of the unit.
r. Generator differential x x
S. Generator over-current x
u. Loss of excitation x
x. Generator ground:
1st stage x
2nd stage x x
The operation shall bring the unit automatically through all the stages of
start up and synchronise the generator to the system, and taking the load.
Active load raise or lower control shall be connected to the governor speed
control circuit.
Reactive load and voltage raise or lower control shall be connected to the
generator AVR system.
Tile following control shall be provided, but not be limited to, on the remote
unit control.
The following remote indications shall be provided, but not be limited to, on
the remote unit control:
a. Ready to start
b. Auxiliaries running
c. Normal start sequence in progress
d. Start sequence completed
e. Shutdown sequence in progress
f. Generator breaker open / close
g. Flame indication
Ii. Temperature control indication
i. Mode selection indication base / peak
k. All trip cause.
The following parameters shall be provided, but not be limited to, on the
remote unit control.
11.5 DELETED
The DCS shall include 230 KV system switchgear equipment for controlling,
indication and protection but not to be limited to, in the central control room.
(1) The DCS shall include the following but not be limited to:
The control panel shall be equipped with the following items of protection,
but not be limited to:
One necessary auxiliary relays, test terminal blocks, lockout relays, etc.
shall also be provided.
The quantities shown above are for reference only. Actual figures
shall be based on the bidder's study and proposed CCPP
configuration.
One (1) lot Control switch for 15.75 KV circuit breaker for incoming
One (1) lot Control switch for spare 15.75 KV circuit breaker
One (1) lot 15.75 KV bus voltmeter selector switch
One (1) lot Incoming circuit ammeter 3 Nos.
One (1) lot 15.75 KV bus voltmeter (0-15.75 KV)
One (1) lot Incoming ammeter (0-9000 A), 3 Nos.
One (1) lot Spare breaker watt meter
One (1) lot Spare breaker Var meter
One (1) lot Spare breaker watt-hour meter with indicating lamp for
voltage failure
One (1) lot Mimic bus
One (1) lot Annunciation
One (1) lot Test terminal blocks
In the case of 6.6 KV starting motor (s) control switch for starting motor (s)
and one (1) ammeter with selector switch for each motor shall also be
provided on this panel.
The 15.75 KV, 6.6 KV, 0.4 KV systems shall be available & indicated in
Required no. of 6.6 KV and 415 V bus tie circuit breaker control switch
Required no. of 6.6 KV and 415 V feeder circuit breaker control switch
11.9.2 MEASUREMENTS
Measurements shall be taken for plant operation and control, and for heat
balance and equipment's performance & efficiency calculations including
supply of software on on-line plant monitoring and optimisation to interface
with DCS system.
Welded wells for temperature element shall be the same material as the
associated piping systems. All screwing wells shall be stainless steel.
Flowmeters shall, with the exception of the area meter, operate on the
relationship which exists between differential pressure and fluid velocity.
Flowmeters shall have liner outputs. Accuracy for fuel gas flow meter shall
be within 2.0% at rate of flow higher than 80%.
Flow metering of gas shall be temperature and / or pressure compensated.
For flow metering of oil, positive displacement meters or area meters shall
be used.
(1) Transmitters
Indicating transmitters shall be provided for control loops as required.
Transmitters shall be substantially unaffected by changes in temperature
and in process static pressure over a range from zero to twice the normal
operating pressure. Transmitter shall feature accessible zero. and span
adjustment.
a. Control Valves
Control valves rated at 2,00 kN/ sq.m (300 lbs ASA) and below shall
be flanged and higher rating shall be welded. Valves shall with
stand shock loads imposed by the processor. control valve
actuators shall be sized to overcome packing friction and dynamic
stem forces. Unbalanced force shall be kept to a minimum level
consistent with efficient operation in service.
b. Damper Actuators
All solenoids shall have class F insulation or higher class and solenoid
enclosure shall be of weatherproof construction.
11.11.1 General
A fully integrated unitary DCS has to be supplied for monitoring, control, display,
alarm and recording of selected physical and electrical parameters associated with
all relevant plant areas. All monitoring and control interactions shall be done via
VDU, keyboard and Mouse/Track ball. No conventional control desk equipment shall
be required in the central control room (CCR).
The structure of the DCS shall be clearly separated in sequence (binary) control ( unit
control, function group control, drive control and analog control, master controllers, analog
drive controllers) .The control system shall be also structured hierarchically, according to
process areas, into clearly defined groups. The controls must be completely shared in
Hardware and Software. Interconnections between the controllers shall be done via
a redundant data bus. All signals shall be available on redundant data bus.
The DCS must be reliable and unique, covering all automation functions of the
power plant, which are:
In co-ordinating the design of the control systems for this contract, the contractor shall ac-
count for the following requirement. The operational functions of control, and supervision
of the combined cycle power plant, its auxiliaries, the 230 KV substation, 15.75 KV,6.6 KV
and 415 V station and unit switchboards, and diesel generator shall be carried out re-
motely from the Central Control Room (CCR).
The scope shall include provision of control and supervisory facilities for the systems; 230
KV substation, 15.75 KV, 6.6 KV and 415 V station and unit switchboards, and Emergency
Diesel Generator.
The co-ordination necessary to achieve this objective shall be achieved by the pro-
vision of a single integrated control system, encompassing the entire contract
scope. It shall be microprocessor based and use state of the art Distributed Control
System (DCS) technology.
The Contractor shall perform all the engineering necessary to provide the operators in the
CCR with a consistent standardised man-machine interface solely by means of the single
approved DCS for all the plant in this contract.
In certain cases the Contractor may propose that a plant supplier is also the provider of its
associated control system because it forms an integral part of the proprietary package.
It is to be noted that, heterogeneous solution for the proposed control system of the
Steam Turbine and HRSG shall not be accepted.
The PPCS and the choice of DCS shall be subject to the approval of the Employer.
• Operational availability
• Configuration flexibility
• Ease of maintenance
• System design shall be adapted to the power generation application
• Vendor support for the projected plant lifetime
The specifications shall apply to all systems and components for protection, safety, per-
missive, interlocks, auto-sequencing, regulating control, supervisory control, data acquisi-
tion, maintenance, configuration, and interfacing to others.
General
¾ Function groups, analogue control loops, drives control loops shall be con-
trolled by fully redundant POS from the main control desk.
¾ No electronic module shall be installed locally. All analogue and binary signals
shall be cabled to the electronic rooms. Where the conversion into BUS signals
takes place.
¾ The design of the control system shall be distributed and decentralised such
avoiding that one failure leads to a tripping of more than the directly related ap-
paratus.
¾ The transmission capacity of the BUS system must permit to handle the maxi-
mum amount of data arising during major process disturbances. Data buffers
between the control stations and the BUS transmission system are not allowed.
¾ Any failure within the electronic digital control system shall not affect the opera-
tion of the plant or any major part of it.
¾ Redundancies in the process (e.g. feed water pumps, condensate pumps, etc)
shall be followed in the design of the controls. That means, that the processing
has to be realised in separate modules.
It is a requirement that the DCS proposed for this project meet the following requirements.
(a) The manufacturer shall be of international repute.
(b) The control system shall have been developed for power generation plant
control, incorporating proven hardware and firmware for such applications.
(c) The control system shall have a demonstrable development history.
(d) The manufacturer shall operate a design policy incorporating compatibility
between versions/generations of equipment.
(e) The version of system proposed shall be the manufacturer's latest
current design (State of the art) and shall be identified.
(f) Engineering support facilities for Bangladesh are in place.
(g) The control system must have a satisfactory reference list illustrating
power generation applications.
(h) The manufacturer is required to give his undertaking to provide support, in
terms of spares provision / compatible solution, maintenance and engineer-
ing for a period of 15 years from the taking over date for the station. The
manufacturer shall explain the history of his customer support policy by out-
lining the duration of support provided for previous generations of control
system.
The Tenderer shall submit sufficient information in response to each of the above
items to enable the Engineer to complete his assessment.
The timely completion of the Contract and the satisfactory operation of the plant will de-
pend upon the successful engineering and implementation of the integrated control sys-
tem whose duty is to co-ordinate all the normal plant operations.
(a) The engineering of the DCS shall be the responsibility of a single management
unit. It is recognised that the identity of this unit will be dependent upon the composition of
the consortium undertaking this project. It is accepted that this management unit may be,
for example, in the DCS Vendor's company, or in the turnkey managing company.
(b) The DCS design unit must have demonstrable know-how and experience in the
particular field of power generation project engineering.
The Tenderer shall submit sufficient information in response to each of the above items to
enable the Client to complete his assessment. The proposed "DCS design management
unit " shall be clearly identified in the Tender.
If the Tenderer proposes a choice of design entity which fails to meet the stipulated re-
quirements then the Tender may be rejected unless the proposal is amended to the Engi-
neer's approval.
The Contractor shall prepare, for drawing approval, a document entitled "Control & Opera-
tion Review of Proposed CCR Facilities". This report shall be accompanied by the first is-
sue of CCR general arrangement drawings.
The above review shall cover the following aspects and their impact on control room facili-
ties design.
The CCR facilities shall incorporate a consistent design throughout for VDU and keyboard/
Mouse positioning, Monitors, Mimic copiers / Colour Printers.
The human-machine interface (HMI) in the CCR shall be based mainly upon operator
workstations each comprising a VDU, functional keyboard and mouse. These shall all be
sourced from the same vendor and operate by means of a common firmware system
(namely that, of the approved DCS) yielding a common format for display, graphics and
An operator's station shall comprise an ergonomically profiled desk on which are mounted
several VDUs and keyboards / Mouse grouped together in a manner which accounts for
the above-mentioned requirements. The design shall take note of the fact that, although a
high degree of automation is to be achieved, operators in the CCR will on a periodic basis
be instructed to perform plant start up and shut down procedures without the assistance of
auto-sequence control. Hence the presence of additional operator(s) at the station is to be
allowed for.
The Contractor shall explain the impact of VDU failure upon the control and supervisory
facilities provided by each console.
In order to demonstrate avoidance of high luminance images in VDU screens, the Con-
tractor shall submit for approval his design proposals (and calculations). These shall show
how the design of the luminaries (luminance limit angle), tilt angle of screen, screen
height, radius of curvature of screen and other factors are integrated to prevent the ap-
pearance of reflections of luminaries in the screens.
The Computers, Monitors and other facilities in the CCR and adjacent areas shall be laid
out to meet the needs of shift management, control room operators and maintenance
staff. The requirement for storage of documentation shall be accounted including 0&
M manuals, printouts, reports and magnetic media.
The Contractor shall develop his proposal, tailored for the requirements of this project and
for the design characteristics of his equipment. The Contractor shall be required to justify
his control room layout, which shall be subject to approval.
All normal operations, relating to the combined cycle power plant shall be carried out re-
motely by staff situated in the CCR. This room will be continuously manned.
In designing the CCR and its operational facilities, the Contractor shall take into account of
the following points.
(a) The CCR shall be the communications focal point enabling all operations to be su-
pervised from here, including normal operations, abnormal operations, emergency
operations and also electrical controls.
(b) It is a requirement that all normal plant operations, including shutdown and any
start up not preceded by maintenance outage, are achieved remotely and solely by
operators in the CCR. During such operations there shall be no need for plant at-
tendants to intervene locally at the plant itself.
(c) Ease of communication between the CCR engineers and the unit operators is a
requirement.
(d) By means of DCS visual display unit (VDU) facilities, the engineer (supervisor) and
manager shall be able to monitor the status of the plant and be able to exercise
historical data retrieval, analysis, review and report production.
Associated with the above, situated in the Control Building, or as appropriate shall be pro-
vided:
This is to be referred to as the Unit Control. The scope of supervision, control and op-
eration performed from the Unit Control shall include the Gas Turbines, the HRSG, the
Steam Turbines, Generators, and all associated auxiliaries.
(c) Operators' workstation (4) each including high resolution colour VDUs (2)
- Workstation computer
(e) Sub-panels integrated into the control on which are mounted (hardwired)
• Responding to alarms and incidents and taking the appropriate corrective actions
• HRSG start up
Permissive interlocks shall be provided to ensure that plant cannot be endangered by in-
correct operation of inter-related items such as pumps and valves; this shall apply whether
the command was initiated by the CCR operator or by the auto-sequence system.
11.11.7.2
(a) Emergency trip push buttons (fitted with lift up cover flap to prevent inadvertent
operation) for Gas Turbine trip, HRSG trip, steam Turbine trip, and generator trip.
(b) Emergency stop pushbuttons (key lock re-settable) shall be provided locally for
each major plant drive (uni-directional).
It is a requirement that the plant can be operated, at the manager's discretion, under the
various regimes of automation set out below. The necessary controls, instrumentation and
sensors must be provided to achieve all the regimes described, i.e., automation levels.
This automation shall be co-ordinated and implemented by the DCS, utilising where
appropriate subsidiary automation (to the same standard) of Proprietary Package Control
Systems.
Automation Level I
The auto sequencing of the drive level items associated with a subgroup applies at this
level of automation. Also activated is the auto sequencing together of all the subgroups
forming a group. Under this level of automation, the necessary interactive operator guid-
Automation Level 2
This is the highest level of automation, and in terms of plant start up and shutdown, it cor-
responds to "Block co-ordination" control/ Unit control described later.
Accordingly families of group controls, which have a functional relationship between them,
shall have their operations co-ordinated by additional auto-sequencing logic. This shall
incorporate operator guidance interactive displays, including advice on the next step the
operator should take when each "Level 2 sequence" has been successfully completed.
The operational objectives that shall be met by the implementation of level 2 Automation
are as follows:
(a) To ensure that the Block start-up and shut-down manoeuvres are of predictable
duration to facilitate load dispatching and grid system operations;
(b) To achieve minimum run-up and loading times for the Units and Block, compatible
with the plant constraints;
(d) To reduce the number of decisions that need to be taken routinely by unit opera-
tors.
The following sections include a description of the controls, which comprise the various
automation levels:
All drives which need to be put into operation in order to proceed through a unit cold or
warm, hot start-up shall be remotely controllable by the unit operator in the Central Control
Room, i.e. stop/start of motors (pumps, fans), open/shut/inching of isolating valves, damp-
ers and open/shut of solenoid valves. It is not acceptable to resort to intervention by roving
attendants local to plant items and local to motor control centres as a means of achieving
start-up. Plant items trips, start permissive and run permissive, shall also be implemented
for drive level controls.
This includes the auto-sequencing of, for example, valves or dampers associated with the
discharge or suction of each individual pump or fan. Also in this category are auto-start of
standby or make-up drives, and closed loop modulating control functions. Such sub-group
controls shall be implemented for every plant system whose operational status needs to
be changed during unit start-up or shutdown.
This is defined as the on-line co-ordination of all the plant groups associated with the start-
up and shut-down of each of the Gas Turbine, HRSG units in conjunction with the Steam
Turbine Generator. In establishing the design requirements, it shall be noted that the fol-
lowing manoeuvres have to be achieved by the block co-ordination scheme:
(b) Block start-up following various duration of shut-down; this shall take into account
of the initial conditions of the Gas Turbines, HRSG's, and Steam Turbine
(c) Re-start of block, Gas Turbine, HRSG, or Steam Turbine following a trip;
(d) Block normal shutdown (heat retention to facilitate subsequent warm start)
(e) Block shutdown (to facilitate earliest possible maintenance access to either boiler
or Turbine).
(a) Preparation of all drive, auxiliaries, motor operated valves, control settings and
auto-control status's required to satisfy the Gas Turbine "ready list"
(c) Auto synchronisation of each Gas Turbine generator and load ramp to pre-set load
(d) Preparation of all drives, auxiliaries, motor operated valves, Hydraulic operated
diverter dampers, drain valves, control settings and auto-control status's required
to satisfy the HRSG "ready list"
(f) Preparation of all drives, auxiliaries, motor operated valves, drain valves, control
settings and auto-control status's required to satisfy the Steam Turbine "ready list"
(h) Auto synchronisation of Steam Turbine generator and load ramp to pre-set load
The Contractor's design shall take away from the operator much of the routine work-load
but require his attention and decision-making at the key stages of start-up.
Extensive operator guidance shall be included. Each of the above automatic sequences
shall incorporate displays to show the operator the succession of the steps and the criteria
to be met for each step. This shall be a dynamically updated display indicating actual pro-
gress, the meeting of criteria and achievement of steps within the sequence. In the event
that a criterion is not met, this shall be indicated and guidance on obviating the problem
shall be displayed.
It is a requirement of the design that the Power Station's Operational Management is able
to take the decision to enforce the limitation of automation to, say, Level Zero. This is to
ensure that all operators benefit from continued experience of the details of plant supervi-
sion and control and do not become unfamiliar with the requirements.
The system shall be designed such that, whether automation is being utilised or whether
the operator is making his own decisions at drive level or sub-group level, the plant is al-
ways secured against mal-operation by means of the permissive protection (interlock) sys-
tem.
The HP and LP steam pressure controls shall be designed to achieve the necessary tran-
sition between bypass controls and steam Turbine admission controls, from starting to full
load operation.
When the governor valves are fully open they no longer act as pressure regulators; when
this has occurred, the steam pressure is solely the result of the steam generation rate of
the HRSG's in operation.
The steam Turbine's stress controller is to intervene and initiate governor valve action in
the event that an operational gradient limit is exceeded.
The steam Turbine operates with the governor control valves in the fully open positions for
the upper 50% of the load range.
When pressure control is not performed by the bypass valves, the bypass system tracks
the actual pressure with an offset to inhibit bypass opening for small pressure fluctuations.
A block load control (BLC) / Unit control system shall be provided for the control and su-
pervision of MW generation. This shall incorporate a target load set point that can be ac-
cessed by the CCR operator.
For 2:2:1 configuration: All operating Gas Turbines are in combined cycle and included in
BLC. The measured steam Turbine generation is subtracted from the required block load
and the resultant is shared equally among the Gas Turbines, so that the Gas Turbines op-
erate at the same load.
For 1:1:1 configuration: Operating Gas Turbine is in combined cycle and included in BLC.
The measured steam Turbine generation is subtracted from the required block load and
the resultant is the load output of the Gas Turbine Generator.
All operating Gas Turbines are included in the BLC. The required block load is shared
equally, which make use of normal plant measurements to compute data, enabling trends
in performance to be assessed. This is not intended to provide absolute efficiency figures;
the objective shall be to provide information to the operations staff to allow deterioration of
plant to be identified. Separate performance assessments shall be provided online for the
following but not be limited to:
Algorithms shall be included in the DCS which make use of normal plant measurements to
enable the cumulative effects of operation upon remaining plant life to be determined, as
an online function.
In order to meet the needs of automation, the modulating controls shall incorporate exten-
sive logic control functions including the automatic initiation of:
• freezing of set-points
• ramping of set-points
The modulating controls fall into two categories and shall be itemised in the Tender; these
are:
(a) those whose set-points follow the power generation required from the block.
(i) Description
The operator shall gain access to the command and supervisory facilities by means of the
VDUs and keyboards, Mouse forming part of the DCS, and which provide the interface to
all plant systems. The CCR shall include in its design the facilities needed to enable the
operators and supervisors to carry out their duties under the various operational regimes
described in the earlier sections of this specification.
• Performance calculations
The DCS and its incorporated VDUs shall provide the sole means by which the CCR op-
erator commands and supervises power station and switchyard plant.
The displays shall be selected by use of the functional keyboard and cursor or else by
track-ball or mouse. Additionally the operator must be able to quickly step from one dis-
play to another related display by means of soft-keys or equivalent facility depending upon
the proprietary range of equipment.
When the operator needs to carry out a command operation, the procedure shall typically
be as follows. By use of the keyboard/ Mouse he is to call up a mimic graphical display.
He shall then identify the particular valve and call up a display showing its "auto-manual
fascia"; this is to correspond to an actual array of auto/manual, raise/lower keys on the
keyboard by which the operator commands a change in the valve's status. These shall
preferably be performed by Faceplates.
A similar procedure shall apply for the commanding of motor stop/start, switchgear
open/close and auto-sequence start/stop.
For the proposed DCS, the Tenderer shall provide a description of the particular operator
actions necessary for the above commands.
The Tender shall include for the configuration of sufficient numbers of displays to meet the
requirements of the Contract. This shall include at least the following designated numbers
of active mimic displays.
The Tender shall state the numbers of other displays proposed to be configured, identify-
ing them and subdividing them into categories of displays (trends, alarms, reports etc.)
Interface equipment shall be provided to facilitate communications with the Load Dispatch
Centre (LDC).
The station's block operator shall, by use of the BCC, have means of authorising the re-
mote control centre to raise/lower the demanded or target power generation on selected
operating units or blocks. The limitations to power generation and rates of change (pre-set
by the unit operator) shall apply, and this data shall be transmitted to the remote control
centre. In turn the remote centre's load dispatcher shall be equipped to transmit the unit or
block power generation target for the completion of the next time interval to the UCC,
enabling the station's electrical control supervisors and unit operators to make the appro-
priate preparations.
In a similar manner, the remote grid control centre shall have access to the control of unit
voltage and power factor.
Means shall be provided for the local operation of modulating control valves, motorised
isolation valves and for the testing of motor drive switchgear from their respective motor
control centres. It is not the intention to facilitate the local control of plant as a "normal op-
eration" basis. The arrangement described is intended to allow testing only, because the
action of selecting "local" status on the contractor panel (or breaker panel or control valve
or motorised valve) will bypass incoming control signals including permissive interlocks.
The Contractor shall provide in his Operation and Maintenance Instructions clear refer-
ence to the need for management safeguards (in the case of local operations) requiring a
permit-to-test procedure.
The local/remote status of each plant item, for example motorised isolation valve, shall be
transmitted to the BCC, thus advising the unit operator of the condition (availability) of the
plant item concerned.
It is an essential requirement of this Contract that the design and engineering responsibil-
ity for all the plant control systems be vested by the Contractor with a single entity (i.e.
management group).The Contractor shall demonstrate his recognition of the fundamental
The Tenderer shall demonstrate in his proposal how he will meet this requirement. In the
design of the DCS, the following needs shall be met:
- (b) Standardisation in the design of interfaces between the DCS and every cate
gory of plant item. This shall lead to:
The control system proposed as the means of achieving total integration of the control
functions, shall be a state of the art micro-processor based Distributed Control System
(DCS). The DCS vendor shall be selected and the system shall be supplied and config-
ured to comply with the following requirements.
(a) All the functions of - operational control, plant supervision, data acquisition, se-
quence of event recording, accumulation of historical data and archiving, presenta-
tion of processed and formatted information to the operator, and supervision of the
DCS itself - shall be implemented by one system.
(b) The above functions shall be implemented by means of solely one DCS system
which shall encompass these plant areas; combined cycle power plant and auxilia-
ries, station common services plant and auxiliaries,
(c) Open system architecture shall be employed. The Contractor shall identify the ex-
tent to which his proposed DCS achieves multi-vendor inter-operability. The Con-
(d) The proposed DCS shall inter-operate with industrial standard software packages
including report-making, database, spreadsheet, statistical analysis and graphical
functions.
(e) The DCS system's design basis shall incorporate a stated migration policy, by
which newer technologies can be inter-operated transparently with existing tech-
nologies.
(f) The DCS shall be self-documenting. This includes the requirement that, subse-
quent to any design changes, the revised configuration is readily available on-
screen and in the form of documentation suitable for retaining for "as-built" records
in hard copy form, incorporating diagrammatic information supported by text anno-
tation.
(g) The data management shall be object based and relational. Any data to be put into
the system shall only need to be entered once. Any user of the system, subject to
authorisation, must have access to all current data wherever it resides in the sys-
tem.
(h) Tools and facilities shall be supplied as part of the Contract to enable design and
configuration work to be carried out on the contract system by the use of a Per-
sonal Computer. The scope shall include the provision to the Engineer of such a
facility early in the Contract to enable the Engineer to review the design submis-
sions as they are submitted.
(I) An engineering workstation shall be provided for the use of the Engineer during
construction and commissioning. This facility shall, via the DCS communications
link, enable the Engineer to monitor progress with construction and commissioning
of the control systems. This facility shall be limited to monitoring only.
(j) The proposed DCS shall in all respects exhibit well developed characteristics of
being user-friendly, easy to maintain and readily re-configurable.
Operational availability of the entire control system is of prime importance. Each of the
various links and modules of which the system is comprised especially Safety related
equipment, Boiler protections, Turbine protections, Feed pump protections shall be engi-
neered in Triple redundant forms.
The Contractor shall issue for approval a formal document entitled "System Reliability and
Availability Report", in which
(b) The impact of failure of each link or module of the system is tabulated.
This report shall systematically embrace all controls; it is not merely to be limited to the
DCS. It shall therefore take into account the PPCSs and the arrangement of Communica-
tions between them and the DCS.
Analog value storage of the Process operator station for process control
shall be extendable to an 8 day history preferably. Both associated cyclic
buffers shall operate with the following time references and storage times
¾ 24 h for values with storage cycle time 1s
¾ 8 days for values with storage cycle time 16s
The bar charts (profile displays) shall display a group of process values
with the same scale and engineering units. The display shall be used for
stress monitoring of the boiler or turbine.
Alarm Display
Both the standard and the user configurable displays (e.g. mimic displays),
plus all process, control system and machine disturbances, shall be sig-
nalled to the operating staff on the process operator station. For the stan-
dard display, an alarm hierarchy shall be built up becoming progressively
finer when proceeding from signalling in the plant overview down to the
group display. The loop display should provides a further degree of detail
for disturbances in the control system. The plant overview shall provide the
operating staff with generalised knowledge for each area and for different
alarm priorities as :
¾ Priority 1 (alarm)
¾ Priority 2 (warnings)
¾ Priority S (control system faults).
An extensive range of standard tools shall be provided for alarm function in the
user-configurable displays :
Sequence of Events
A characteristic feature of this display shall be the indication of alarm and other
messages for total or partial sequence of event messages in correct chrono-
Storage should take place as a history within the Process Operator Station, at the
storage rate of n x 50.000 messages in cyclic FIFO buffers (n depends on configu-
ration of the system). The history messages are to be combined into units capable
of being archived. These shall also be transferred to an external archive (manual
and automatic initiation). Process control and evaluation tasks should take place
according to different criteria. Different presets capable of defining in relevant task
specific message selection defined, exist both for displays and reports, The se-
quence of event display shall fully be integrated into the Process Operator Station
selection philosophy, i. e. cross selections from one message line to other relevant
display types. Acknowledgement shall also be effective for all display types, plant
segment wide The system should be of fully colour compatible with all other dis-
plays for all types of display selection, the most recent messages should be initially
displayed. In this condition (display of the most recent messages), new incoming
messages shall always be added at the bottom end of the almost entire monitor
page. If the monitor page is already full on the arrival of an new message, the
messages on the monitor shall automatically be moved upwards by message, the
messages on the monitor shall automatically moves upwards by ten messages. In
addition to the usual paging options jumping to the beginning or end of the list
shall also possible. Reporting should be possible consecutively or on call accord-
ing to current selection. In principle, the report layout shall correspond to that of the
display.
Reports :
The operational reports primarily shall contain calculation values that refer
to certain periods of time.
Initiation shall take place automatically at the end of the report or also manually as
required.
Standard weather stations with all required facilities have to build so that
ambient condition can be monitored and recorded for the purpose of
capacity test
12.1 General
12.2 Cable Types
12.3 Raceway
12.3.1 Raceway
12.3.2 Raceway Fittings and Supports
12.1 GENERAL
(1) Scope
The Contractor shall design, supply, install, terminate and commission all
the cables for the plant.
(3) Armouring
All cables except 230 KV power cables, control and instrument cables shall
be provided with galvanised steel wire or steel tape armour and PVC cover
sheath.
(2) Insulation
The insulation material shall be extruded cross linked polyethylene of low
dielectric loss, high dielectric strength, low thermal resistivity and long term
stability. It shall be free from contamination by oil, chemical and moisture.
The extrusion process shall ensure that the insulation is homogenous and
The single core 15.75 kV XLPE Copper conductor power cable and other
necessary items for the completion of the cable system.
The single or triplex core 6.6 kV XLPE copper conductor power cable and
other necessary items for the completion of the cable system.
(2) Insulation
The insulation material shall be extruded cross-linked polyethylene of low
dielectric loss, high dielectric strength, low thermal resistivity and long term
stability. It shall be free from contamination by oil, chemical, and moisture.
The extrusion process shall ensure that the insulation is homogeneous and
free from voids and impurities, and it shall be dry method.
(3) Terminations
The end terminating materials shall be supplied for the termination of 6.6
kV cables.
The cables shall be rated 600 volts for installation in cable trays, conduits
and cable ducts.
All auxiliary power cable with a nominal conductor area of 60 sq. mm and
above shall be stranded annealed copper conductor, XLPE insulated with
galvanised steel wire or steel tape armour and PVC sheathed. All other
auxiliary power cables shall be stranded annealed copper conductor, PVC
insulated with galvanised steel wire or steel tap armour and PVC sheathed.
All auxiliary power cables shall be designed, fabricated and tested in
accordance with the latest IEC Standard.
The cables shall have copper conductor and shall be selected with due
consideration to load requirements of each feeder and short circuit current
capacity of the cable in order to prevent premature insulation failure. The
conductor insulation shall be numbered or colour coded.
For motor circuit, the cables shall have a current carrying capacity of at
least equal to 115% of the full load current rating of the motor after
application of the appropriate de-rating factors.
Cable supports shall be provided for the cables and shall be at least one
cable support bracket per vertical section for interconnection between
adjacent sections. The minimum size of power cable shall be of 10 sq.mm.
In general, control and instrument cables shall be rated 600 volt and shall
have copper conductor with either PVC overall jacket, unless specified
otherwise. All control and instrument cables shall be designed, fabricated,
and tested in accordance with the latest JIS or IEC Standards.
All control cables, with the exception of equipment internal wiring and panel
wiring, shall be installed in conduits, cable ducts or cable trays.
(2) Insulation
The insulation material shall be extruded cross linked polyethylene of low
dielectric loss, high dielectric strength, low thermal resistivity and long term
stability. It shall be free from contamination by oil, chemical and moisture.
The extrusion process shall ensure that the insulation is homogenous and
The single core 230 kV XLPE Copper conductor power cable and other
necessary items for the completion of the cable system.
(3) Terminations
The end terminating materials shall be supplied for the termination of 230
KV cables.
(4) Laying
Under-Ground Cable from 230 KV side of Unit Transformer to 230 KV Sub-
station Bay shall be provided with RCC slab on three sides.
12.3 RACEWAY
12.3.1 RACEWAY
Raceway shall be provided for all cables, and these shall be rigid conduit
metal through type cable trays.
Concrete lined cable trenches shall be provided within the power station. All
such trenches shall be provided with covers to form a flush finish with the
finished floor level. Cables shall be secured by non-corrodable cleats
supporting steelwork, or on trays. Wooden cleats shall not be used. Cables
shall not be clipped or cleated directly to masonry. All cable supporting
steelwork racks cleats trays and fixings in trenches or elsewhere shall be
supplied under this contract.
Cables tray shall be of the first grade perforated galvanised steel with
folded side members and supported on steel work or masonry is required.
Segregation of the various services shall be achieved by use of separate
trays for each voltage grade of cable used. The design of the cable tray
system shall make due allowance for the future installation of at least 10
percent spare cables and also for the installation of cables supplied by
others.
All cables in vertical runs shall be supported to ensure that no strain due to
the weight of the cable is taken by any terminating box. Each cable when
erected shall have permanently attached to it at each end, non-corrodable
metal markers showing the cable identification number, voltage, rating, size
and make up.
Single core cables shall be laid up in close trefoil 3-phase groups and
erected in separate non-magnetic clamps to the approval of the Engineer.
12.5 GROUNDING
The Contractor shall provide all grounding cable, equipment, and materials
required for a complete installation including the direct buried ground mat
for the power station,. This shall include, but not be limited to, all facilities
for grounding of panel boards, control panels, transformers, switches,
lighting poles, lighting standards, and all electrical equipment enclosures.
Two point grounding for each equipment, panel board and steel structure
shall be provided.
Hard drawn copper stranded wire in accordance with latest IEC Hard
Drawn Copper wire for electrical purposes”.
Nominal cross sectional area: 200-sq. mm.
14.1 General
14.2 Distribution Boards
14.3 Cables
14.4 Lighting and Small Power
14.5 Emergency Lighting
14.6 Miscellaneous Materials
14.1 GENERAL
The Contractor shall design, manufacture, deliver and install power station
lighting and small power supply complete with all the accessories at the site
as specified hereinafter.
(2) Details
The DC supply/ UPS supply required for emergency lighting services shall
be obtained from the batteries supplied under the Section 13. Under normal
AC failure conditions emergency lighting to be installed shall be
automatically switched on.
The distribution boards and all component parts shall be manufactured and
tested in accordance with the latest IEC standard. Distribution boards shall
have dust proof sheet steel, galvanised, weatherproof cases. The metal
casing is to be provided with knockouts or other approved form of cable
entries, corresponding to the circuit capacity, together with a suitably
screened brass earthing stud.
The distribution boards shall be either double pole and neutral types as
required and shall be equipped with means to provide over load protection
to each circuit. This protection shall comprise moulded case circuit breaker.
14.3 CABLES
All cabling associated with the lighting and small power socket outlets
services shall be stranded annealed copper conductor, PVC insulated
galvanised steel wire or steel tape armoured and PVC sheathed as
appropriate or mineral insulated copper sheathed cable depending upon
the service required.
The Contractor shall select conductor sizes for the respective circuits to
fulfil the following conditions:
f. Plug Sockets
Plug sockets shall be located so that any point inside the GTG/STG
package, inside a building or outside in the high voltage areas can be
reached within the following distances from a plug socket.
Indoor - :10.0 m
Outdoor- :20.0 m
At least two plug sockets shall be installed within the vicinity of an indoor
The Contractor shall design DC/ UPS AC emergency lighting and power
supply system for the power station, and illumination level of emergency
lighting shall be as follows.
Location Illumination
Level (Lux)
Metal poles shall be either hot dip galvanised or covered with a bituminous
base protective area with the fitting erected and a safety factor of 2.5
allowed.
The rigid steel conduit pipes shall be galvanised and have a minimum
thickness of 2.3 mm and minimum inside diameter of 16 mm.
(5) Miscellaneous
All apparatus, accessories and materials which have not been specifically
mentioned but which are necessary for the completion of the work shall be
provided by the Contractor.
The Contractor shall design, manufacture, inspect, test, delivery to the site
and install of natural gas handling facilities (including gas booster
compressors) with all accessories as specified hereunder for the plant.
The gas turbine unit shall be furnished with a complete gas fuel system.
The gas handling system including Regulating Metering Station (RMS) shall
also be provided.
To forward the natural gas from the main gas supply header to the gas
turbine units and to adjust its supply pressure to normal operating pressure,
the Contractor shall furnish one (1) complete factory assembled skid
mounted gas pressure regulating unit including all accessories and
necessary pipe connections to the Board's gas supply header for gas
turbine unit.
Each gas handling unit shall comprise at least the following major items:
Each unit shall have guaranteed capacity, which matches or exceeds the
gas turbine needs under all load-operating conditions at site conditions.
16.1 General
16.2 Design Requirements
16.3 C02 Gas Fire Protection System
16.4 Hydrant System
16.4.1 Hydrant
16.4.2 Piping
16.5 Portable Equipment
16.1 GENERAL
The Contractor shall design, manufacture, deliver to the Site, install, test
and commission the fire fighting and fire detection equipment to protect the
steam & gas turbine, generating units and all associated equipment. In
particular, the following shall be included:
CO2 Gas fire protection system for the gas turbine packaged units.
Water hydrant system including motor & diesel engine driven pumps,
jockey pump, water main, hydrant stands, hoses etc.
The general design of the fire protection facilities shall take into account
that the basic operating policy for the power station will have the minimum
of personnel supervision for the gas turbines.
All fire protection installations shall comply with the requirements of the
codes of practice of the National Fire Protection Association, Boston,
Massachusetts, U.S.A., as appropriate for the respective systems, to the
approval of the Engineer. The codes and practice of the Japanese Fire
Protection may also be considered.
Facilities for alternative manual actuation of the fire protection system shall
also be provided such that, when the manual mode has been selected the
protection sequence will not proceed beyond the alarm stage without
manual action by an operator.
The fire protection system shall be segregated into separate zones so that
at least the protection for any one compartment can be selected to the
manual mode whilst, at the same time, retaining the automatic mode for the
remaining enclosures.
Audible and visual fire alarms shall be provided in all machinery en-,
closures, the local control cabs and in the control room of the control
building. Additional audible alarms shall also be provided external to the
turbine generator enclosures.
Particular areas of high fire risk such as confined spaces where lubricating
oil could possibly come into contact with high temperature ,surfaces shall
receive special consideration. Such areas shall be treated as separate fire
protection zones with detection and C02 gas injection facilities operating
independently of the system provided for the machinery enclosure
concerned.
16.4.1 HYDRANT
Hydrants shall be installed at required places around the gas & steam
turbine generating units, HRSG, Gas station, GBC, Chemical Plant
electrical building, Outdoor transformers and 230 kV switchyard. Each
hydrant stand shall be fitted with an isolating valve and approved type of
instantaneous hose complying 30-m hose with combined jet/water-fog
nozzle shall be provided in the cabinet adjacent to each hydrant.
16.4.2 PIPING
The fire fighting water mains shall consist of buried piping of at least 150
Communication Facilities
17.1 General
17.2 Internal Telephone System
17.2.1 Private Automatic Branch Exchange
17.2.2 Telephone Facilities
17.3 Paging System
17.3.1 General
17.3.2 Function
17.3.3 Equipment
17.3.4 Locations of Handsets and Speaker
17.1 GENERAL
The Contractor shall design, manufacture, deliver to the Site and install the
following communication facilities:
All internal telephone connections within the power station boundary shall
be the responsibility of the Contractor, but the interconnecting cables
between the PABX and the public telephone network shall not be the
responsibility of the Contractor except all facilities for the connection of this
service within the building.
(1) Functions
17.3.1 GENERAL
17.3.2 FUNCTION
Commanding Communication
Commanding and paging shall be made from any handsets through the lo-
cal speaker sets.
17.3.3 EQUIPMENT
(1) Handset
One set spare amplifier shall be furnished and it shall be put into operation
automatically when the normal use amplifier fails.
a. Relay Panel
Relays shall be provided for the starting and stopping amplifier and to
establish the commanding talk from the handsets. The talking shall be
indicated with a lamp on all handsets. The relays shall be of semi
conductor static type or wire spring relay with sulphuric acid proof type.
b. Change-over Panel
When one set amplifier fails, the failed amplifier's circuit shall be transferred
to the spare amplifier's circuit with relays. Manual change-over switch shall
also be provided.
c. Amplifier Protection
d. Test device
e. Terminal block
Sufficient length of the coaxial cables and cords with all the necessary
cable connectors shall be supplied to each station for making connections
between the coupling capacitors and the coupling filters, the coupling filters
and the line protective devices, and the line protective devices and the PLC
telephone terminals.
Communication & SCADA Equipment shall be comprised of but not limited to the
following:
a) Compatible Multiplexer with optical fiber
b) RTU (Remote Terminal Unit) with IEC60870-5-104 interoperability if ECS (Elec-
trical control system) with the protocol 104 is not present.
c) One IP telephone set (Cisco) with accessories.
d) Two general telephone sets for Administrative Telephone system with
accessories.
The camera pictures shall be displayed at the CCR where the camera view or
combination of views, selected by an operator shall be displayed on colour LCD
video monitors. A secondary CCTV display station shall be provided at the guard
house.
The complete system, as specified including, but not limited to the following :-
Control Room
Building gate entrance area.
electronic/computer rooms
turbine hall
GBC hall
switch gear rooms
switch yard
HRSG (e.g.drum level monitoring)
control building
C.W. pump House
store rooms
chemical plant
workshop
fire fighting station
water treatment plant
gas handling area
security gate
Maintenance Facilities
18.1.1 Scope
18.1.2 Extent of Supply
18.1.3 Type of Crane
18.1.4 Rating
18.1.5 Requirements for Characteristics
18.1.6 Requirements for Materials
18.1.7 Structural Design
18.1.8 Electrical Design
18.1.9 Gantry Structure, Rails and Girders
18.1.10 Site Tests
18.2 Mobile Cranes
18.2.1 General
18.2.2 Type and Rating
18.3 Tools
18.1.1 SCOPE
The Contractor shall provide and install four (4) Overhead electric crane (GT,
ST, CW Pump House, GBC house) complete with longitudinal gantry
structure, gantry rails, conductors, weather protection shed, control, power
supply etc. GT and ST EOT main hoist capacity minimum 125 ton and
auxiliary hoist capacity minimum 20 ton. All EOT crane must have capacity
required for lifting the heaviest single piece with 20% margin.
Main hoist: 120% of maximum heaviest item. Minimum 125 ton for
Turbine hall ( GT & ST)
Auxiliary hoist : For turbine hall crane 20 ton, for CWP house and
GBC house 5 ton
e. One (l) set of gantry structure, gantry rails, girders, holding down
bolts, securing plates, abutments, and weather protection shed.
f. One (l) set of power supply cables and trolley conductors complete
with supporting brackets and one (l) set of power supply indication
lamp
g. One (l) alarm bell
h. All lifting eyes, rings and bolts to facilitate erection and maintenance
k. All other equipment required for the safe and efficient operation of
the crane
The crane shall be of the semi-indoor/ indoor and low speed overhead
electric," travelling type equipped with single trolley, one(1) main and one
(l) auxiliary hoist.
18.1.4 RATING
Main hoist: 120% of maximum heaviest item. Minimum 125 ton for
Turbine hall ( GT & ST)
Auxiliary hoist : For turbine hall crane 20 ton, for CWP house and
GBC house 5 ton
a. Hoisting speed
Main hoist : 5 m/min
Auxiliary hoist : 10 m/min
b. Trolley travel : 15m/min
c. Bridge travel : 15 m/min
(1) The brake for hoisting shall be capable of stopping and holding 150% of the
rated capacity.
(2) Deflection of bridge girder under load on main hook at the centre of the
bridge girder shall not more than 1/500 of the span.
(3) The crane shall be capable of raising, lowering, holding and transporting
the rated load without damage to, or excessive deflection of any crane
parts,
(4) Operation of Hoists
Each hoist shall be controlled individually by the relevant controller
equipped in the operator's cab.
(1) All materials used for the crane shall be new and conform to the latest
revision of ISO or approved equivalent standards.
The bridge structures shall be of welded construction, but with all field
connections designed for high-strength bolting. The various parts of the
main structure of the crane shall be sub-assembled and the field
connections reamed.
The end truck frames shall be either one-piece steel castings or built-up
structural steel members.
Walkways shall be at least 0.70 m wide and provided with a substantial toe-
guard at least 0.10 m high and hand-railing not less than 1 m high over the
entire length and ends. Ladders shall be provided where required for
access between the walkways and operator's cab. The Contractor shall
prepare access from the floor to the operator’s cab.
The Contractor shall furnish and install all electrical equipment on the crane
including all motors, electrically operated brakes, air circuit breakers,
switches, contractors, controllers, resistors, control panels, relays, limit
switches, trolley travel conductors, current collectors, transformers,
complete lighting system, receptacles, conduit, wiring, cabling, insulators,
anchors and other electrical equipment necessary for the safe and proper
The Contractor shall also supply the main runway conductors, insulators,
brackets and associated accessories.
The main power supply shall have a short circuit capability of 25 kA.
All electrical equipment shall conform to the appropriate IEC.
Motors :
All electric motors shall be of the wound rotor, drip-proof, protected type
and tropicalized. They shall be in accordance with the latest edition of IEC
Standard for crane motors.
(2) Controller
The travel motion of the bridge and trolley shall be controlled by the
normal methods of acceleration, reversing and plugging the motor.
Multi-pole contactors may be used.
Within limits of each required speed, the drive shall be controlled to
provide substantially uniform speed regardless of load. The control
shall include all necessary relays, timers, and limit switches
required, for smooth and safe operation.
A main circuit contactor shall be provided in common for main power supply
circuit of main and auxiliary hoists, and for bridge and trolley travel.
The master switches for the main hoist, auxiliary hoist, trolley travel, and
bridge travel shall be on the cam operated type, with a contact operating
Automatic reset, totally enclosed, heavy duty, adjustable limit switches shall
be provided to limit the travel of the trolley and the bridge. The switches
shall disconnect power supply to the motor when either the bridge or the
trolley has travelled to within braking distance of its respective stop at either
end of the travel. A warning signal, preferably a buzzer installed in the cab,
shall alert the crane operator when the trolley approaches its stops. The
signal shall be activated ahead of the trolley's limit switch.
All power circuits to motors and all secondary circuits such as lighting shall
be placed in the panel. The panel shall also include all overload relays, low
voltage control, and all other necessary equipment recommended by the
Contractor.
(8) Cabling
All cabling, collector gear and power supply conductors required for the
operation of the crane shall be supplied by the Contractor. The crane shall
be capable of travelling the full length of the turbine area as shown on the
Drawing.
The assembled crane shall be load tested including overload test with
a load equal to 125% full lifting capacity after erection by the
Contractor and all tests shall be in accordance with the relevant IEC
Standard.
The Contractor shall supply all equipment including weights for the above
tests. The Contractor shall also be responsible for the disposal of the
materials used for the test load.
18.2.1 GENERAL
The Contractor shall provide the following mobile cranes which will be
utilised for erection works and for maintenance works after Taking over of
the Plant.
The crane shall be complete with all necessary appurtenances to ensure its
safe and efficient operation.
a. One (1) 30 ton self-propelled diesel engine driven mobile telescopic
crane.
b. One (1) 5 ton truck with 3 ton jib crane
18.6 TOOLS
18.6.1 GENERAL
The following tools and equipment shall be supplied under this Contract
and the Tenderer is required to give a full list with details in the Schedule of
Tools and Appliances when submitting his Tender.
Each set of tools and appliances shall be provided with conveniently sized,
robust, lockable boxes suitably inscribed with the name of the Plant for
which they are to be used.
The tools and appliances with the boxes shall be handed over to the Board
at the time of issue of the Taking Over Certificate.
One set of special tools, gauges and equipment required for the normal
maintenance of the whole of the Plant shall be provided by the Contractor.
One set of special lifting and handling appliances required for the normal
maintenance (such as lifting of turbine casing, lifting of rotor) of the whole
Plant and equipment shall be provided by the Contractor.
Special tool list with unit price shall be submitted with Tender.
18.6.3 HOIST
The hoist shall be of electrical or chain- block type and the capacity shall be
selected taking into consideration of weight of object. The hoist shall be
provided with the monorail, supporting materials for rail and anchor bolts.
The hoists shall be installed in the following area, but not be limited to, for
the convenience of maintenance:
EDG room, Water intake pump house, Fire fighting pump house,
Chemical plant.
19.1 General
19.2 Workshop Test
19.2.1 Gas Turbine
19.2.2 Generator
19.2.3 Exciter
19.2.4 Step-up Transformer
19.2.5 230 kV Switchgear Equipment
19.2.6 Control and Protection System
19.2.7 Other Materials and Equipment
19.3. Tests at Site
19.3.1 Tests and Completion
19.3.2 Field Inspections and Tests on Gas Turbine Units
19.3.3 Field Inspections and Tests on Switchgear Equipment
19.4. Acceptance and interim Operation
19.1 GENERAL
The Contractor shall perform all tests and inspections necessary to ensure
that the material and workmanship conform to the Contract and design
drawings. Those tests and inspections shall demonstrate that the
equipment will comply with the requirements of this Specification and meet
the specified guarantees.
The Board and the Engineer shall have a right to access the Contractor's or
sub-Contractor's works to determine or assess compliance with the
provisions of this Specification or to witness the Contractor's inspections or
tests.
(1) All plant shall be subjected to type, sample and routine tests at the
manufacturer's factory in accordance with these clauses and conditions of
the Contract.
(2) Type, sample and routine tests shall be to the relevant ISO and IEC
Standards or other approved standards for equipment where the test re-
quirements are not specified in these clauses.
(3) The Contractor may offer type test results for identical equipment in lieu of
the type tests specified, in which case the specified type tests may be
waived by the Engineer. If type test results for identical equipment are
offered in lieu of the specified type tests, the Contractor shall also provide
evidence as to the similarity of the equipment tested and the Contract
equipment.
(4) The Contractor shall submit evidence to the Engineer that the instruments
used for the testing shall have been calibrated at an approved testing
laboratory within a period of up to six months for a portable instrument and
twelve months for a fixed instrument.
- Vibration
- Lubrication system
- Fuel system
- Wheel space temperature
- Exhaust temperature
- Governor system
- Temperature control system
- Air system
- Over-speed trip
- Water system
- Individual accessories
The HRSG & ancillaries shall be tested on the factory, those tests shall
include, but not be limited to, the following:
1) Hydraulic tests:
Steam generator drum, header, boxes and other forged
components, high pressure steam valves & safety fittings shall be tested on
completion of welding and after heat treatment for a period of not less than
30 minutes.
2) Mechanical tests:
a) X-ray inspection throughout the length of welds.
b) Vibration or noise test on the auxiliary plant & all motors in
running condition.
3) Electrical tests:
a) Power frequency high voltage withstand test on small wiring of 2
KV.
b) On all motors as per relevant IEC.
The Steam Turbine and ancillaries shall be tested on the factory, those
tests shall include, but not be limited to, the following:
1) Hydraulic tests:
The following hydraulic tests shall be applied for a period of not less
than 30 minutes:
a) Turbine casing.
b) High pressure steam valves, chests, pipings etc.
c) Low pressure valves & pipings.
d) Oil coolers.
e) Water heat exchangers.
f) Condensers.
g) Air ejectors.
h) pumps.
2) Mechanical tests:
The Turbine rotor shall, after completion be tested to an overspeed
of 15% for 5 minutes.
19.2.4 GENERATOR
Each generator shall be operated at no-load on the factory test floor with
the following observations and respective data so reported and reference to
IEC Standard shall be made:-
19.2.5 EXCITER
Each exciter shall be operated at no-loads on the factory test floor with the
following observations and respective data so reported and reference to
IEC Standard should be made:-
a. Saturation run.
b. Mechanical balance.
c. Resistance.
d. Dielectric tests.
e. Insulation resistance of windings.
f. Exciter characteristics tests
a. General inspection
b. Measurements of Winding resistance
c. Voltage ratio measurement and check of polarity
d. Measurement of impedance voltages
C. Measurement of load loss
f. Measurement of no-load loss and current
g. Test of temperature rise
h. Induced over-voltage withstand test
i. Separate-source voltage-withstand test
- General inspection
- Insulation resistance measurement
- Dielectric withstand voltage test
- Operation test
In accordance with the requirements of IEC 56, details of the transient
recovery voltage to which the circuit breaker will be subjected during short
circuit testing shall be submitted to the Engineer for approval.
The Engineer may require in addition any of the following tests to be carried
out, the details of which will be agreed between the Engineer and the
Contractor:-
- General inspection
- Insulation resistance measurement
- Dielectric withstand voltage test
- Operation test
(3) Current Transformers
- General inspection
- Polarity test
- Insulation resistance measurement
- Dielectric withstand voltage test
- Characteristic test
- General inspection
- Power frequency spark-over voltage test
- Lightning impulse spark-over voltage test
- Measurement of leakage current and insulation resistance
a. Bus Supports
- General inspection
- Dielectric test of power frequency
- Tension proof test
a. The Contractor shall conduct the tests at the Site in accordance with
these clauses and the conditions of the Contract.
c. The Contractor shall prepare and submit to the Engineer at least three
months prior to the commencement of testing, schedules in approved
format for each test together with a programs provided by all Contractors.
The Engineer will also be responsible for overall co-ordination and safety
control of tests.
d. The Contractor shall submit one copy of the results of each of the tests at
the Site to the resident Engineer within one week of the tests being carried
out. Four copies of the certificates shall be provided to the Engineer within
one month of the tests being carried out.
f. The Contractor shall submit evidence to the Engineer that the instruments
used for the tests have been calibrated at an approved testing laboratory
within a period of up to six months.
The tests to be carried out and passed before taking over of the works by
the Board/Engineer shall be deemed to comprise two main stages of
testing as follows:
(1) The Contractor shall give to the Board and Engineer in writing twenty one
(21 ) day's notice of the date after which he will be ready to make the tests
on completion. Unless otherwise agreed, the tests shall take place within
ten (10) days after the said date, on such day or days as the Engineer shall
in writing notify the Contractor.
(2) If the Board and Engineer fail to appoint a time after having been asked to
do so or to attend at any time or place duly appointed for making the said
tests the Contractor shall be entitled to proceed in their absence, and the
said tests shall be deemed to have been made in the presence of the
Board/Engineer.
(3) If, in the opinion of the Board/Engineer, the tests are being unduly delayed
he may by notice in writing call upon. the Contractor to make such tests
within ten( 10) days from the receipt of the said notice and the Contractor
shall make the said tests on such day within the said ten (10) days as the
Contractor may fix and of which he shall give notice to the Engineer. If the
Contractor fails to make such tests within the time aforesaid the Engineer
may himself proceed to make the tests. All tests so made by the Engineer
shall be at the risk an expense of the Contractor unless the Contractor shall
establish that the tests were not being unduly delayed in which case tests
so made shall be at the risk and expense of the Board.
(4) The Board except where otherwise specified, shall provide free of charge,
such labour, materials, fuel, water, as may be requisite and as may be
reasonably demanded to carry out such tests efficiently. However all the
calibration devices, standard or sub-standard special test instruments,
stores, apparatus etc., required to conduct all the tests would be provided,
arranged and installed by the Contractor at his own cost and expenses.
The Contractor will pay all expenses including the custom duties etc. on the
import or export of all such instruments etc.
The following field inspections and tests will be carried out In the sequence
detailed below, and the successful performance and completion of all the
tests taken together shall constitute the Board's acceptance tests:-
Soon after the initial commercial operation tests have been run, per-
formance tests shall be run to determine whether the equipment complies
with the guarantee provided that unit is made ready for performance test by
the Contractor and certified by Engineer. The tests shall be conducted in
accordance with ISO 2314 or ASME PTC 22 and the latest ASME-IEEE
Power Test Codes using previously approved correction curves and
complying with the following special conditions unless otherwise specified.
The chemical analysis and lower heating values of the fuels shall be
determined in the Board's laboratory and two other laboratories to be
chosen respectively, one by the Board, the other by the Contractor.
The Board shall provide without charge such labour, material, fuel and
water as may be reasonably required to conduct the performance and
acceptance tests. The gross station efficiencies under different load
conditions established during a four (4) hours continuous test, shall be
calculated in a manner as approved by the Engineer. Power measurements
at the generator terminals and at the incoming circuit of unit motor control
centre shall be made with totalizing meters.
The gas turbine generator shall run at 25%, 50%, 75% and 100% of base
rating and peak load prior to placing the unit into commercial operation and
to prove that sudden load rejections from loads up to maximum capability
can be accommodated by the turbine without the speed rise being sufficient
to cause the over-speed trip to initiate.
The output and heat rate tests will be carried out on each unit in the
following manner:
Full load at the generator terminal for the purpose of the test will be
calculated from the guaranteed output according to the site ambient
installation conditions.
Correction factors for variations of test conditions from the specified design
conditions shall be stated in the Tender.
The Steam Turbine Generator shall run at 50%, 75% and 100% load
corresponding GT load rating prior to placing the STG into commercial
operation and to prove that sudden load rejections from loads up to max-
imum capability can be accommodated by the turbine without the speed
rise being sufficient to cause the over-speed trip to initiate. The load
rejection test of STG shall be carried out from 100% load, 75% load to
ensure i) both the GTG (s) are running at the same load that they were
running before load rejection ii) diverter dampers of both GT (s) are open to
bypass stack iii) LP/HP steam bypass are working perfectly with relevant
steam control valves & auxiliaries.
Full load at the generator terminal for the purpose of the test will be
calculated from the guaranteed output according to the site ambient
installation conditions.
Correction factors for variations of test conditions from the specified design
conditions shall be stated in the Tender.
The Contractor shall submit to the Engineer within three(3) months after the
signing of the Contract, the detailed procedure for the conductance of the
performance and acceptance tests for approval.
The procedure shall include the following for such test or group of tests:-
a. The time duration of each test at each load.
b. The number of test runs at each load.
c. The sequence of the tests to be conducted.
d. A list of instruments that will be used for each test.
f. Sample test reports or data sheets and all specific result sheet forms
that will be used for the test.
g. Written procedure and description of conducting the test.
h. All test data to be recorded by the Contractor and the Engineer.
a. Wiring
b. Mechanical Check
All relays shall be examined to ensure that they are in proper work-
ing condition and correctly adjusted, correctly labelled, and the relay
case, cover, glass and gaskets are in good order and properly
fitting.
c. Secondary Injection
a Primary Injection
(3) DC Operations
Tests shall be carried out to prove the correctness of all DC polarities, the
operating levels of DC relays and the correct functioning of DC relay
schemes, selection and control switching, indicating and alarms.
In view of the hazards inherent in these tests, they shall be carried out
under the direct supervision of the Engineer.
On load checks shall be made after the protection gear has been placed in
service to ensure that all connections and test links have been replaced
and test leads removed, as well as to confirm the integrity of the current
transformer circuits. Where necessary voltage readings shall be taken at
the terminals on each relay to ensure that loop connections between the
relays are complete. Special attention shall be paid to broken delta
voltages and residual current circuits where zero voltage or current
respectively may not be proof of the completeness of the circuit.
The above tests shall be recorded on approved test sheets, two signed
copies of which shall be forwarded to the Engineer immediately after a test
or series of tests has been completed.
a. General Check
A general check of all the main switchgear and ancillary equipment shall be
made and shall include a check of the completeness, correctness and
condition of earth connections, arcing ring and horn gaps, painted surfaces,
cables, wiring, pipework, valves, blanking plates and all other auxiliary and
ancillary items. Checks shall be made for oil and gas leaks and that
insulators are clean and free from external damage. A check shall be made
that loose items which are to be handed over the Board, e.g. blanking
plates3 tools, spares, are in order and are correctly stored or handed over.
b. Circuit Breakers
Checks shall be made of the local and remote indications and operation of
auxiliary contacts.
Motorised equipment shall be tested to prove the motor operation, including
local and remote operation. Timing tests shall also carried out.
Earth switches and maintenance earthing devices shall be tested to confirm
the opening and closing sequences and checks shall be made on the earth
mat, indications and manual locking devices.
d. Voltage Transformers
All voltage transformers shall be checked for polarity phasing and for
secondary output.
(7) Interlocking
Tests shall be made on the effectiveness of the bonding and earthing which
will include conductivity tests on selected joints, on the main earthing
system, and at the connections to equipment and structures. Checks shall
also be made on precautions taken to avoid corrosion attack on the
earthing system.
(9) Others
All other equipment and/or systems shall be tested in accordance with the
instruction by the Board and/or the Engineer.
(1) After the performance tests, if the equipment supplied by the Contractor is
found to meet the guarantees and any other specified requirement, and if
all other work called for hereunder has been completed, the Board's
acceptance will be forthcoming. This acceptance shall, however, not
relieve the Contractor of his responsibility for first inspection.
(2) Should the equipment furnished by the Contractor fail to operate as re-
quired, or in case of failure to meet any of its guarantees, the Board shall
have the right to operate the equipment, using the Contractor's supervisory
operating personnel, until such defects have been remedied and
guarantees met with. In the event that defects necessitate to the rejection
of the equipment or any part thereof, the Board shall have the right to
operate the equipment until such time as new equipment is provided to
replace the rejected equipment. Such operation shall not be deemed an
acceptance of any equipment.
Civil Works
20.1 General
20.1.1 General Requirement
20.1.2 Topographic Surveys
20.1.3 Site Investigation
20.1.4 Site Laboratory
20.1.5 Records and Drawings
20.1.6 Samples, Testing and Inspection
20.1.7 Standards and Codes of Practice
20.1.8 Preparation of Design and Drawings
20.2 Scope of Civil Works
20.3 Earthworks
20.3.1 General
20.3.2 Excavation
20.3.3 Filling
20.3.4 Backfilling
20.3.5 Measurement and Payment
20.4 Foundation
20.4.1 General
20.4.2 piling
20.4.3 Foundation of Gas Turbine Generator
20.4.4 Foundation for Building and Other Equipment
20.4.5 Hardcore
20.4.6 Replacement of Unsuitable Materials
20.5 Deleted.
20.6 Concrete Works
20.6.1 General
20.6.2 Composition
20.6.3 Tests
20.6.4 Cement
20.6.5 Admixture
20.6.6 Water
20.6.7 Aggregate
20.6.8 Standard Grading
20.6.9 Concrete Mixing
20.6.10 Placing
20.1 GENERAL
The Contractor shall upon examining the design of the foundations and
major structures incorporated in the bid drawings, develop and prepare the
detailed design and the construction drawings of all civil structures for the
approval of the Engineer which shall meet the equipment and structures
specification, to be supplied by the Contractor for the Project.
The Engineer shall reserve the right to examine the Contractor's design
and to instruct a change or modification by the Contractor.
Approval of the design by the Engineer shall not relieve the Contractor of
liability for the construction works.
The Tenderer shall familiarise himself with the site levels, subsoil and an
other data necessary to enable him to estimate the bearing capacity and
foundation requirements, for use in the preparation of his tender.
The Tenderer shall quote firm prices which shall remain valid through-out
the Contract Period on all items in the Price Schedule unless other-wise
stipulated.
The Contractor shall carry out surveys as are necessary for the proper
design and execution of the Works. The results of such additional surveys
together with the survey drawings shall be submitted to the Engineer for
approval.
The Contractor shall provide a site laboratory with a concrete floor space of
not less than 4m x 6m adequately equipped to carry out quality control tests
of material and workmanship in accordance with the procedures and tests
as described in the relevant ASTM Standard or other approved Standard.
He may as an alternative to the provision of laboratory equipment, make
arrangement for all necessary tests to be carried out by personnel with
relevant experience from an approved laboratory.
The Contractor shall keep at the Site accurate and upto-date records and
drawings of the Works, and shall submit these records to the Engineer at
tile end of every week. Such record shall include the amount of labour,
plant and materials employed upon the Site during that week.
The Engineer may request at any time to test or inspect sample of material
and workmanship proposed and the Contractor shall furnish these
immediately. When the Engineer has approved the samples, material, and
workmanship not corresponding in quality and character with the samples
approved shall be rejected. The costs of all sampling and testing to be
conducted either on the Site or in an approved laboratory shall be borne by
the Contractor.
The Civil Works shall be designed and constructed in accordance with the
Specifications, relevant Standards and Codes of Practice approved by the
Engineer. The Contractor shall submit together with his bid a schedule of
standards and codes of practice to be followed in the design and
construction of the Works. Copies of these codes and standards shall be
made available to the Engineer during the design and construction period.
In the case of the Standards and Codes not published in English, the
Contractor shall obtain English translations when required and send them
to the Engineer.
The Contractor shall prepare all designs and detailed working drawings as
deemed necessary for the execution and completion of the Works.
The Contractor shall be responsible for ensuring that the design satisfies
the requirements of all local and national authorities. Design calculations
shall be in accordance with an approved method and should take into
account the most critical combination of dead load, wind load, and seismic
load. Design calculations and detailed drawings shall be submitted to the
Engineer for approval. The Contractor may commence construction on the
Site only after drawings are approved by the Engineer.
The civil works shall include collection of site data, detailed design,
production of working drawings, provision of labour, supply of construction
plant and materials, construction and rectification of defects during the
Warranty Period of the Works.
The Scope of Work shall include, but not be necessarily limited to, the
following:
a) Site Works :Site clearance, excavation and filling of the Site to formation
level (0.8 meter above High Flood Level or 1.0 meter above
nearest Highway which one is higher) including running
surplus excavated materials to disposal area, sheet piling
work, site roads and surfacing, water supply, sewage
treatment cable ducting, pipe ducting, drainage,
landscaping, fencing and gates.
b) Foundation :For all plants and structures supplied under this Contract.
Suitable foundations shall be provided for the gas/ steam
turbine generating units, HRSG, Gas Booster Compressor,
230 kV switchgear, and elevated water tank, water/steam
supply system, cooling tower, overhead travelling crane,
buildings, equipment and structures.
20.3.1 GENERAL
The Contractor shall prepare the drawing necessary for his construction
purpose based on the attached drawings and the specification, and submit
them to the Engineer for approval. The Contractor shall be responsible for
and shall complete all the earthworks as shown on the approved drawings
or as directed by the Engineer.
20.3.2 EXCAVATION
Before commencing any excavation on the Site, the Contractor shall notify
the Engineer at least 48 hours before starting any additional surveys. He
shall carry out, where directed by the Engineer extra surveys required to
resolve any doubts which may arise as to correctness of any surveys or
record. Thereafter the decision of the Engineer regarding what shall be
recorded as the correct survey shall be final.
Excavations shall be carried out to the width, lengths and depths shown on
the approved drawings. The Contractor may excavate by any method he
considers suitable, subject to the approval of the Engineer.
Cut and fill slopes shall be designed for to be thorough stability. Unless
otherwise indicated On the Drawing the exposed surfaces of all cuttings
and embankments shall be soiled and turfed to the satisfaction of the
Engineer.
The Contractor shall take particular care during the excavation of the
foundation to avoid deterioration of the ground due to exposure to the
weather. The final 150 mm of excavation above formation level shall be
carried out by hand immediately before the next stage of construction is to
start. A similar method shall be adopted in the ease of the sides of
excavation against which the structure is to bear.
The Contractor shall provide all strutting and shoring necessary for the safe
execution of the Works and shall provide the necessary pumps, de-
watering facilities, and temporary drains to ensure that all excavation shall
be carried out in the dry.
The rates for excavation and filling shall be deemed to have included for
the full cost of excavation and filling of the materials including site clearing,
stripping of top soil, all pumping and temporary works necessary to keep
the excavation and filling free from water, temporary shoring and timbering,
trimming to line and level, stock-piling, handling, compaction, cutting, slope
protection, removing surplus excavated material to spoil tips, together with
all other costs incurred in com--plying with the contract requirements.
The area to be filled shall be cleared of vegetation and the top soil shall be
stripped and stockpiled. All soft yielding material shall be removed and
replaced with granular selected material. Where fill has to be deposited
against the hill slope, the Contractor shall take all necessary precautions to
ensure that a good bond is achieved between the fill and the original
ground.
No fill shall be deposited in the area to be filled until the Engineer has
inspected and given approval. Filling to the formation level shall be brought
up form the bottom in uniform compacted layers. Excavated material
obtained from the Site may be used for embankment construction and
filling.
Filling, levelling and compaction on the Site shall be carried out in layers
not exceeding 300mm thickness. The Contractor shall carry out all
necessary quality control works including in-situ soil density tests, moisture
content and other laboratory testing to ensure that all materials used in the
embankment or filling elsewhere are compacted in accordance with the
specified requirements.
The maximum dry density (MDD) for the purpose of this specification shall
be determined by the following procedures or equivalent.
The following standards tests (any one) shall be conducted for determi-
nation of MDD.
20.3.4 BACKFILLING
This section shall apply to the performance of all work in connection with
the required backfill for the permanent works.
(1) Material
20.4 FOUNDATION
20.4.1 GENERAL
The Contractor shall take full responsibility for the suitability of the type of
foundations he proposes to use and shall guarantee the performance of the
foundations.
20.4.2 PILING
(1) General
The Contractor shall supply, install and test at least one of the types of pile
specified herein, or in accordance with the approved design and the
drawing showing the piling arrangement. Each pile shall be suit existing the
sub-strata at the Site. The Engineer reserves the right to order additional
test piles at no extra cost if the type of pile or the sub-strata differs from the
one originally driven and tested.
The Contractor shall take full responsibility for the suitability of the type of
piles he proposes to use and shall guarantee that each pile will carry a test
load equal to twice the working load in accordance with this specification.
All concrete, reinforcement and other materials used for the manufacturing
of piles shall comply with the requirements of the relevant sections of the
Specification. Concrete may need to be made from sulphate resisting
cement where necessary.
The reinforcement for a pile shall be fabricated to form a rigid cage. The
main longitudinal reinforcement shall be in one continuous length except
where otherwise approved and shall be finished level and cut square at the
head of the pile, and shall bear against pile shoe. The minimum cover to
the main reinforcement shall be 65mm. The spacer blocks shall be made of
concrete of the same grade as that used in piles. Cast-in threaded
inserts or metal tubes of an approved type shall be used to form holes in
the piles where required.
Pile shoes shall be firmly fixed during concreting to prevent any dis-
placement. The whole of the concrete in any pile shall be poured
continuously. After a pile has been cast, the date of casting and reference
number shall be clearly inscribed near the pile head.
Piles shall not be lifted without permission of the Engineer and such
permission will not normally be given until the concrete in the pile has
All piles shall be kept continuously wet for a minimum 7 days from the date
of casting, or as directed by the Engineer.
No pile shall be driven until the concrete has reached the strength specified
on the drawings or as otherwise described.
The Contractor shall submit with his tender full details of the performance,
size and type of his driving plant together with information on the type of
hammer and the number of rigs he proposes to employ on the works.
Piles shall be adequately guided whilst being driven and the guides shall be
held rigidly in position down to the lowest level reached by the hammer.
The maximum departure of any pile head at cut-off level from the position
indicated on the drawings shall not exceed 75mm. The Maximum departure
from the vertical or the correct angle of rake shall not exceed 1 in 50.
The Contractor shall provide the Engineer with three copies of the driving
record for each pile, these records shall reach the Engineer’s
Representative not later than the day following the driving of the relevant
pile and shall contain details of the following
(a) Location
(b) Pile details such as reference number, date of casting, length, and
dimensions.
(f) Number of blows per 300mm over the last 3 meters of penetration.
(g) Number of blows per 50mm over the last 300mm of penetration.
Before commencing the piling, the Contractor shall submit details of the
type and number of rigs to be used for insitu piles.
The spoil from the pile holes and material remaining from the cutting of
piles shall be removed by the Contractor to a tip to be provided by him.
Before pouring concrete into the core, the reinforcement for each pile shall
be made up to form a rigid cage and lowered into the core. Arrangements
are to be made to ensure that the minimum cover to the main reinforcement
is 5Omm. The main longitudinal reinforcement shall be in one continuous
length except where otherwise approved and the main bars shall extend at
least 1 metre above cut-off level.
The concrete for the pile cores shall comply with the concrete specification.
Concrete may need to be made from sulphate resisting cement where
necessary. Concreting of the core shall not commence until the Engineer
has inspected.
The concrete shall be finished 4Omm above cut-off level. Concrete shall
not normally be placed in or through water. In particular circumstances
only, the Engineer may allow the Contractor at his own expense to place
concrete (using suitable mix) through water by means of a termite pipe. If
the Contractor's piling system does not normally exclude water during
concreting, he should allow in his tender for the use -of compressed air or
other method to keep the pile hole free' from water whilst the concrete is
being placed.
Details and jointing lengths- of piles will only be permitted with the
Engineer's approval. The type of joint and weld details shall be in ac
cordance with the pile manufactures recommendations.
(7) Testing
The Contractor shall install at least two piles solely for testing purposes and
shall submit a detailed driving record and other data as directed by the
Engineer for the purpose of proving the proposed pile design. If this pile
test does not satisfy the specified settlement, further piles shall be installed
and tested.
The Contractor shall provide all the equipment required for carrying out
load tests on piles together with the apparatus for measuring shall be to the
satisfaction of the Engineer.
The loading system shall incorporate a proving ring, load cell or other
apparatus capable of measuring the load to an accuracy with 2%.
The pile shall then be reloaded in one stage to the specified working load,
readings being taken every 15 minutes until displacement has again
ceased.
The load shall be then increased in equal increments up to twice the
specified working load, the same procedure being followed as stipulated for
the beginning of the test. The maximum load shall be maintained for 24
The settlement of the pile head under test load shall not exceed -the
following figures under the loads stated :
On completion of each pile test the Contractor shall supply the Engineer
with two copies of a complete report which shall include graphs of load-
settlement, load-time-settlement and recovery of the pile as the load is
removed.
If any pile is in any Fay unsatisfactory to the Engineer he reserves the right
to order the Contractor to install replacement piles at the locations selected
by the Engineer at no extra cost.
The following loads and external forces shall be considered for structural
analysis of the gas turbine generating unit foundations.
a. Concrete weight
b. Machine weight
C. Dynamic load (vertical direction)
d. Dynamic load (horizontal direction)
e. Short circuit force of generator
f Seismic load : 0.2 g (horizontal)
In following load cases, the worst case shall be selected for the design of
the gas turbine generating unit foundation.
- short term
a+b+e or a+b+c+f or a+b+d+f
20.4.5 HARDCORE
The Contractor shall place where required hardcore under the foundations
of the equipment. The material shall be crushed rock or natural rubble
stone not larger than 15cm in size containing suitable quantities of fines to
a grading and quality approved by the Engineer.
In a case where the in-situ soils are found unsuitable for proper
construction of the foundations, such materials shall be excavated and
replaced with sand or other suitable granular material to be approved by
the Engineer. The Contractor shall submit materials samples, laboratory
test results and the proposed method of compaction and construction to the
Engineer for approval prior to commence the construction.
Tenderer shall submit together with his tender the outlined drawings and
calculation sheet concerning the design of the steel sheet piling wall.
The contractor shall take full responsibility for the suitability of steel sheet
piling wall proposed for use in the project.
20.6.1 GENERAL
For the purpose of the Contract, this Specification shall be applicable to all
concrete works to be included in the civil engineering and building works.
20.6.2 COMPOSITION
The Contractor shall make trial mixes using samples of aggregates and
cements typical of those to be used at least four weeks before commencing
any concreting in the Works. The strength requirements for each grade of
concrete proposed in the design shall be determined by the Contractor by
means of trial mixes to satisfy the conditions specified in Table 20.1.
Maximum size of
aggregate (mm) 20 – 40 20 20
Maximum slump 7 - 10 7 7
(In cm)
Compressive strength
at 28th day cylinder 240 210 160
(kgf/sq. cm)
Approximate
Percentage of air
content 2±1 2±1 2±1
Fineness Modulus of
fine aggregate 2.3 - 2.4 2.3-2.4 1.8
20.6.3 TESTS
All cement shall be of normal Portland cement complying with BSTI or other
approved standard. When required by the Engineer, the Contractor shall
obtain for him the manufacturer's test certificate prior to any delivery. All
cement shall be stored dry in a well-ventilated and weatherproof building.
The cement shall be furnished either in bulk or in bags from the cement
factory approved by the Engineer.
20.6.5 ADMIXTURE
The Contractor may use water-reducing and set-retarding agents, but the
use of admixture must have the prior approval of the Engineer.
20.6.6 WATER
The water used for making concrete, mortar and grout shall be clean, fresh
and free from injurious amounts of oil, organic-matter or any other
deleterious substance.
20.6.7 AGGREGATE
The fine and coarse aggregates shall be durable, non-reactive hard mate-
rials complying with internationally accepted standards approved by the
Engineer. All aggregates shall be washed prior to use in order to remove
clay, silt, dust and adherent materials.
Coarse and fine aggregates shall be well graded within the standard limits
specified as follows.
a. Coarse aggregate
PERCENTAGE BY WEIGHT
Sieve size 50.8 38.1 31.7 25.4 19.1 15.9 9.52 4.72 2.38
Size of
b. Fine aggregate
9.52 100
4.76 90 - 100
2.38 80 100
1.19 50 90
0.595 25 65
0.297 10 35
0.149 2 20
20.6.10 PLACING
The concrete shall be fully compacted throughout the layer and it shall be
thoroughly worked against the formwork and round the reinforcement
without displacing theme Unless otherwise directed by the Engineer, ap-
proved power driven vibrators of the immersion type shall be used.
Vibrators shall penetrate to the full depth of the concrete layer and shall re-
vibrate that layer to ensure that the successive layers are well knitted
together. The placing of concrete shall not be permitted under the following
conditions unless specifically approved by the Engineer.
a. If it rains
b. If it is poorly illuminated during night work
C. If ordered to stop by the Engineer or his representative
Forms shall be removed without damage to the concrete. The use of form
oil or other release agents shall be approved by the Engineer.
The classes of finishes and the requirement for finishing concrete surfaces
shall be as specified in this clause or as shown on the approved drawings.
Surface irregularities in finishes shall be distinguished from construction
tolerances, which are allowable deviations from established lines, grades
and dimensions, as described herein.
d. Variation in locations of 10 mm
sleeves and sizes and loca-
tions of floor openings and
wall openings
The Contractor shall repair at his own expense the imperfections of con-
crete surfaces and the irregularities which do not meet the allowance
specified in the preceding item. Repairing works shall be performed and
completed within 24 hours after the removal of forms, in accordance with
the direction of the Engineer.
The reinforcement bars for the gas turbine generating units foundation
blocks shall be deformed steel bars. Dimension, shapes, tensile strength,
yield point and other mechanical properties of the reinforcement bars shall
comply with relevant approved standards. All reinforcement must be free
from oil, grease, paint, dirt, loose scale or rust at the time of concreting.
The physical properties of the reinforcement bar shall have the following
values
All costs associated with concrete work and reinforcing bar for equipment
foundations, duets, roads, buildings, drainage system and all other
structures shall be deemed to include in the lump sum price bid for the
respective work item in the Schedule. The lump sum price bid shall not be
modified or subject to any adjustment for design variations due to changes
of geological and other conditions.
20.7 ROADS AND SURFACINGS
The Contractor shall furnish all designs and construct the roads, yards,
paths, surfacing as necessary for the proper functioning of the power
station.
Maximum grade : 7%
Pavement width : as per approved Drawing
Turning radius : more than 10 m
The roads and yards shall be paved with reinforced cement concrete and
shall be designed in accordance with the procedures as outlined in the
AASHTO Standard or any other acceptable international standard or
Design of Pavement Structures or other internationally accepted methods
approved by the Engineer. Basic design conditions are as follows
The aggregate sub-base material shall be placed on the prepared and ap-
proved sub-grade. The deposition and spreading of the material shall bc as
directed by the Engineer. It shall start at the point farthest from the point of
loading, and shall progress continuously without breaks. The materials shall
be deposited and spread in a uniform layer and without segregation of size,
to such a loose depth of not more than 15cm each layer, making allowance
for any filler to be blended on the road, that when compacted, the layer
shall have the required thickness. Spreading shall be from spreader boxes
or from moving vehicles, or by placing in a windrow followed by spreading
to required depth and width by means of a blade grader. After the sub-
base material has been spread, it shall be bladed to a smooth surface
conforming to the cross section.
(1) Materials
(ii) Fine and coarse aggregates, and water shall conform to the appli-
cable Section of the Specification.
(iv) Dowel bars All dowel bars except at the expansion joints, shall be
deformed steel bars and shall conform to ASTM A6 15 Grade 60.
(v) Joint Sealer Concrete joint bituminous sealer for all joints shall
conform to ASTM Dl 850-67, "Specifications for Concrete Joint
Sealer, Cold-Application Type".
(i) Formwork
Before the mixing of concrete, forms shall have already been set for
a sufficient length well in advance of the forward end point where
the concrete is to be placed, but in no case less than the length
between expansion joints, except for closures which may require a
shorter length. Sufficient forms shall be provided so that it will not be
necessary to move those in place within twenty four (24) or more
hours after the concrete has been poured. All forms shall be
cleaned and oiled each time they are used. In the pouring of
sections, construction joints shall be located at expansion joints.
Should it be necessary to make construction joints beyond the
expansion joint, such construction joints shall be made at the
location of contraction joints.
(ii) Joints
(a) Longitudinal Joint: The longitudinal joint running at the centre line of
the pavement shall be formed in accordance with the section and
dimension shown on the approved drawings. Before concreting the
next lane, the longitudinal joint shall be painted with two (2) coats of
liquid asphalt applied at a temperature of 650 to 1350 Fahrenheit.
The asphalt should be completely dry before commencing pour to
the next lane.
(v) Finishing
After the concrete has been deposited, distributed and vibrated, the
concrete shall be struck off and screeded by mechanical means
approved by the Engineer. The finishing machine shall be of the
screeding and troweling type designed and operated both to strike
off and to compact. Hand finishing may be employed in limited
areas where finishing machines can not be operated. Finishing of
concrete shall be done, as directed to the satisfaction of the
Engineer. All finished surfaces shall be tested with a 3-meter
straight edge and it shall not vary more than 1cm in 3m from the
designed surface. Any variation of the surface from the desired
crown or cross-section shall be properly corrected.
All forms for concrete shall remain in place undisturbed for not less
than twenty-four (24) hours after the concrete is placed,
after which the forms may be removed. In the removal of formwork,
care should be taken so as not to break the edges of the pavement.
In case portions of the concrete are spalled, they shall be
immediately repaired, at the expense of the Contractor, with fresh
mortar mixed in the proportion of one (1) part cement to two (2)
parts clean sand. Major honeycombed area will be considered as
defective work and shall be removed and replaced at the expense
of the Contractor. Any area or section removed shall not be less
than 3 meters in length nor less than the full width of the lane
involved.
The Contractor shall repair at his own expense all imperfections, or
irregularities of the concrete pavement in accordance with the
direction of the Engineer.
(vii) Curing
As soon as the concrete has sufficiently set, and to prevent the
marring of the surface, the pavement shall be covered with burlap or
canvas, which shall be kept wet with clean water for a period of not
less than twenty-four (24) hours.
After removing the burlap, the pavement shall be covered immedi-
ately with either a layer of earth or sand four (4) centimetres in
thickness and shall be kept wet for a period of not less than fourteen
(14) days. Ponding of the surface of the pavement may also be
Turf shall be freshly cut approved carpet grass free from thorns and weeds.
The area to be turfed shall be provided with a layer of 20cm top soil
suitable for the growth of the lawn. The Contractor shall maintain and
replace all dead turf at his own expense until the end of maintenance
period.
The design of the storm water drainage system comprising the interceptor,
roadside and perimeter drains for buildings, powerhouse, and switchyard
shall be submitted to the Engineer for approval.
The Contractor shall carry out detailed designs of the storm water drains
using the rational method or other approved procedures. The work shall be
carried out in accordance with the rules and regulations of the local and
other authorities.
All drains or channels shall be concrete lined. Concrete sumps, silt traps,
screens and drain covers shall be incorporated in the design where it is
appropriate.
All trenches and drains are to be set out accurately to line and fall as
specified. Trenching for pipes shall be excavated with sufficient width to
allow adequate working space for pipe jointing. Backfilling of trenches to a
height 300 mm above the top of the pipes using selected materials shall be
hand packed and well rammed against the side of the pipes.
The laying of each length of drain is to be commenced at the lower end and
socketed pipes shall be laid with their sockets at the higher end Each pipe
is to be accurately levelled and securely held in position be fore the joint is
made.
All surface water channels shall be made from concrete grade B as de-
scribed in Section 20.6.
The Contractor shall keep sumps, drains, trenches and ditches free from
water at all times until, in the opinion of the Engineer, the concrete works
has hardened.
20.9.1 General
Pipes proposed for use in the sewer shall be approved by the Engineer,
cast iron pipes and fittings complying in all respects with B.S.78 and/or
B.S.437 shall be used. Manholes or inspection chambers with covers shall
be provided at every change in direction or gradient to satisfy the
requirement of the Local Authority.
The sewer shall be laid accurately to the design levels and gradient. Each
length of sewer shall be carefully water tested to the satisfaction of the
Engineer before the concrete haunching is placed and before the trench is
back filled. Septic tanks shall be constructed in accordance with the details
shown on the approved drawings.
All pipes, fittings, jointing materials and valves which are necessary for the
complete installation of the system shall be supplied and installed in
compliance with the approved standards and workmanship.
The Contractor shall supply all pipe, special fittings, valves, joints, jointing
materials and other necessary materials for the complete installation of the
system as shown on the approved drawings.
All metal, wooden and textile surfaces of materials furnished and installed
by the Contractor under this Section shall be painted in accordance with
Section 21.6, except as listed below. Performance of painting work shall be
as specified in the Section 21.6 of the Specifications.
(1) General
The Contractor shall provide plant, labour, material, equipment and perform
all operations in connection with the drilling, developing, placing of casings
and well screens, and pumping tests for the deep-well which shall be drilled
to a depth as indicated below.
(2) Drilling
A written record of the drilling information which is called a Well Log shall
be kept by the drillers and shall be available for examination by the
Engineer at any time during the work and a complete typewritten copy of
the well log shall be submitted to the Engineer within ten (10) days after
completion of the work. The well log shall show amongst other things the
type of materials encountered, colour of the return water, depth at which
circulation as lost, manner of drilling, length of casings installed, and other
pertinent drilling data.
The Contractor shall furnish and operate a pump for this purpose that is
capable of continuous operation at a sustained delivery of 380 lit/min or
more in a duration of at least five (5) hours of pumping test operation.
For a comprehensive test of the well, the pump shall be operated contin-
uously at about 1/3 of its capacity until pumping level is attained. After
making the necessary measurements, the pump rate is adjusted to about
2/3 of the pump capacity and measurements are repeated when the
pumping level becomes constant. By increasing the rate of pumpage to
produce maximum draw-down; or increasing it to the full capacity of the
pump and making measurements a third time when the pumping level be-
comes stable.
All the necessary equipment the measuring devices for testing the deep-
well shall be calibrated and provided by the Contractor at his own expense.
Upon completion of the drilling, the Contractor shall submit to the Engineer
the complete well-draw-down test results for check and determination of the
actual head and setting of the deep well pump.
A complete list and description of equipment, plant and tools for executing
the work in accordance with these Specifications and their location at the
time of opening of bids in order that they may be inspected by the
Engineer.
(1) General
The Contractor shall furnish, deliver, install and test motor-driven pumps (2
x 100% capacity) complete with accessories and housing at the top of the
well in accordance with these Specification.
The deep-well pump shall be a submersible type with a cast iron body,
bronze impeller, high-grade steel discharge column and stainless steel
shaft. The discharge pipe column and drive shaft of ample size shall be
supplied with interchangeable sections of not greater than 3.0 m in length.
The pump shall be guaranteed to circulate not less than the specified
quantity of water when pumping and without producing excessive vibration
and noise. The efficiency of the unit shall be as high as good engineering
practice will permit.
a) Pump Motor
The motor shall be submersible type, full voltage starting and with
torque-locked rotor current and slip characteristics conforming to
standard equivalent to those of the IEC Standard.
b) Control Equipment
When the water level of the deep-well goes down to the designated
level, the deep-well pump shall be stopped immediately, and the
other deep-well pump shall be started automatically. Breakdown of
deep-well pumps shall be connected to an alarmed on the control
board in the control room.
c) Control Board
d) Signal Indicators
Conduit piping and wiring for the work shall comply with the appli-
cable provisions of the Specification.
(5) Installation
The pumping unit and control equipment shall be housed for all weather
protection.
(6) Accessories
Sluice valve : 1 Pc
Check valve : 1 Pc
Air release valve : 1 Pc
Pressure gauge with cock : 1 Pc
Water pipe : Required Length
Well cover : 1 Pc
Submersible cable : Required Length
Flanges : 1 Set
Foundation bolts : 1 Set
Other necessary accessories : 1 lot
(8) Piping
20.11 Ducts
The concrete ducts to install cables and pipes shall be provided. The ducts
shall be covered with concrete or steel checkered plate, both having
The Contractor shall submit design drawing to the Engineer for approval.
20.12 FENCING AND GATES, FLAG POLES AND SITE BOUNDARY WALL
20.12.1 Fencing
Chain link fencing shall be installed as directed by the Engineer. The chain link
fencing shall be 2.4 m high with 3 strands of barbed wire at the top, generally
complying with B.S. 1722 or other approved Standards.
Posts and struts shall be fabricated from 100 mm x 100 mm x 6.5 mm thick an-
gles and set in concrete. The struts shall be fitted to all end and corner posts at
changes in direction or acute variations in levels and at intervals not exceeding 9
meters in straight lengths of fence. All posts shall be hot dip galvanised.
Prior to the supply and installation, the Contractor shall submit samples of fenc-
ing materials, structures and colour to be adopted to the Engineer for approval.
20.12.2 Gates
Sliding metal gates of 2.4 meter high and pedestrian swing gates of 2.0 meter
height shall be constructed at suitable locations as directed by the Engineer.
Decorative brick walls to be incorporated in the work next to the pedestrian gate
at the power station shall have the following dimensions:
The Contractor shall submit design drawings showing details of the gates for ap-
proval of the Engineer.
Three (3) flag poles shall be erected at locations as directed by the Engineer.
The poles shall be of tapered steel pipe, about 15 m in height with a diameter of
20 cm at the bottom. The pole shall be firmly held to a concrete foundation.
It shall be equipped with a brass pulley near the top and nylon rope for hoisting
the flag.
The pole shall be painted in accordance with the specification for painting to the
satisfaction of the Engineer.
The site boundary wall shall be installed around the power station as directed by
the Engineer. The site boundary wall shall be of brick wall with RCC frame in ac-
cordance with KPI Standard and 2.40 m high and 0.25 m thickness.
The contractor shall take full responsibility for the suitability of water intake
facilities and design the pump station in accordance with the requirements of the
specification.
The design of water intake facilities shall be submitted to the Engineer for
approval.
Building Works
21.1 General
21.1.1 Contractor's Responsibilities
21.1.2 Building Sub-contractor
21.1.3 Construction Schedule
21.1.4 Records
21.1.5 Samples Testing and Inspection
21.1.6 Temporary Services
21.2 Scope of The Works
21.3 Design of The Works
21.3.2 Standards and Codes of Practice
and Other Design Conditions....
21.3.3 Submission of Designs and Drawings
21.4 Building and Services
21.1 General
This is a turnkey contract which includes all building works and services.
The Tender shall cover all requirements of the Tender Documents and any
other items not specifically mentioned but which are deemed to be
necessary for the complete execution of the Works to the entire satisfaction
of the Engineer. No additional cost will be considered for any item which
the Contractor has over looked but are essential for the full completion of
the Project in every respect.
The Tender shall include the building works proposal complete with out-line
drawings indicating any variation or improvement which he deems
technically or financially justified for tile works shown on the Tender
Drawings, schedule of materials and finishes on which the tender has been
based. The Building shall generally conform to the sizes shown on the
Tender Drawings.
The Contractor shall perform the Works thoroughly in accordance with the
agreed construction schedule and direction to be made by the. Engineer
during the Contract Period.
The Contractor shall keep accurate and up-to-date records and drawings of
the Works at the Site and shall provide the Engineer with copies of these
records. The Contractor shall submit to the Engineer weekly reports of
labour, plant and materials employed on the Site.
The Contractor shall perform testing and inspection of materials and shall
submit sample materials, test certificates and workmanship details to the
Engineer for approval. The costs of all samples and testing shall be borne
by the Contractor.
The building works shall include collection of the Site information, detailed
design, production of working drawings, and provision of labour, plant and
materials, tests/inspection, construction and remedy of defects during the
Warranty Period. The Building shall generally conform to the sizes as
mentioned below.
The building works shall include collection of the Site information, detailed
design, production of working drawings, provision of labour, plant and
materials, tests/inspection, construction and remedy of defects during the
Warranty Period. The Building shall generally conform to the sizes as
mentioned below.
c. Live load for Ground floor area and Power house building: 1000kg/m2
The Contractor shall be required to produce full design calculations for the
foundations, building structures, and detailed working drawings and
reinforcement bar bending schedule etc. Design calculations shall be
prepared in accordance with an approved method of computation based on
the most unfavourable combination of dead load, live load or crane load
and wind load. The Contractor shall be responsible for the detailed design,
strength and safety of the structures, and ensuring that the design satisfies
(2) Windows:
Aluminium sash shall be provided. Window area shall be generally more
than 1/10 of the room floor area unless otherwise indicated. All windows
except toilet, store, and cable spread room windows shall be fitted with sun
blinds of approved made.
(3) Machines and utilities:
The Contractor may submit the layout to suit any particular requirement
subject to the approval of the Engineer.
All cast iron pipe works and fittings as are necessary for the complete
installation of the sanitary system shall be supplied and installed in
accordance with the requirement of the local authorities and other
standards approved by the Engineer.
(1) General
Structural steel, bolts and nuts shall comply with the requirement of an
approved standard and this Specification in all respects and those shall be
fabricated from hot rolled sections unless other wise specified or agreed in
writing by the Engineer. Design methodology (combination of Load) shall
be followed as per section 2.7 of BNBC (Bangladesh national building
code).
(2) Materials
The materials to be used shall be free from harmful defects and rust.
Samples of materials shall be tested, and copies of the test reports giving
physical and chemical properties shall be submitted to the Engineer for
approval. The Contractor shall carry out all necessary tests, at his own
expenses, to prove that the materials offered for the intended purpose are
in compliance with the approved Standard.
High strength bolts, anchor b6lts, ordinary bolts and shear connectors to be
supplied for the erection of structures shall conform to the Standard
approved by the Engineer and shall be of an approved manufacturer.
Specially devised high strength bolts, if used, shall tightened in accordance
with the manufacturer's instructions. Any bolt that has been fully, tightened
and then un-tightened shall not he used in the permanent Works.
(4) Fabrication
(5) Welding
Welding shall not be performed when the ambient temperature is less than
0 deg C; when surf aces are wet or exposed to rain, or strong wind; or
when welders are exposed to inclement weather conditions.
Surfaces to be welded shall be free from loose or thick scale, slag, rust,
moisture, grease and other foreign material that will prevent proper welding
or produce objectionable fumes. Welding shall be principally carried out in
workshops. Where necessary the Engineer may approve site welding,
subject to the satisfactory provision of effective protection and safeguards
for welding works by the Contractor.
Surface and edges to be welded shall be smooth, uniform, and free from
fins, tears, cracks, and other discontinuities, which will adversely affect the
quality or strength of the weld. In the preparation of the fusion faces,
shearing shall be limited to metal thickness not greater than 8 mm. All
fusion faces shall be prepared by machining shall be limited to metal shall
be prepared by machining or flame cutting, or where approved, by special
oxygen cutting apparatus. Fusion faces, angle of level, root radius, and the
like shall be properly prepared to give the approved weld forms. The parts
to be jointed by fillet welds shall be brought in-to contact as close as
practicable. The gap between parts shall normally not exceed 4.8 mm (3/16
in.). A butting parts to be joined by butt welds shall be carefully aligned and
the correct gap and alignment maintained during the welding operation.
Ends of the welds shall have full throat thickness by means of runoff tab.
Additional metal remaining after the removal of the tab shall be removed by
machining, or by other approved means. Ends and surfaces of the welds
shall be smoothly finished. All main butt welds shall have complete
penetration and, except on tubes or partial penetration Joint, shall be
welded from both sides. The back of the first run shall be suitably gouged
c. Intermittent Welds
(7) Paint
All rust, grease, mill scale and harmful matter shall be removed. The
surface shall be blast cleaned to:-
Painting shall be carried out in a clean, dry building where air temperature
shall not be allowed to drop below 5 deg.C. No paint shall be applied on the
steelwork with condensation. Painting shall not be carried out when the
relative humidity is over 90%, or if in the open, during rain, fog or mist. The
welded areas and the edges of site joints shall be cleaned down, primed
and painted' all in accordance with the standards specified, after erection.
Each coat of the paint will be applied in different colour. When paintwork is
damages it shall be cleaned and re-painted following the procedures as
approved by the Engineer. The manufacturer's instructions regarding inter-
coat intervals shall be strictly observed.
The whole of the steelwork shall be handled in such a manner that the
shape and surfaces of the section shall not be damaged during lifting and
transportation. The Contractor shall take all necessary measures, to ensure
that steelwork members shall be handled, stored and erected without their
being subject to stresses in excess of those for which they were designed.
Chains and hooks will not be used in contact with the steel work and lifting
slings shall be of nylon rope. Steel work shall be stored in clean, dry
conditions off the ground. Separate pieces of steelwork shall have spacer
blocks between them.
No permanent bolting and site welding shall be carried out until proper
alignment has been obtained.
21.5.2 Concrete
The aggregate for grouting shall consist of hard siliceous sand, and grained
chips, gravel or crushed stone, or other approved inert materials with
similar characteristics. The materials shall be clean, free from lumps, soft or
flaky particles, shale, crusher dust, silt, alkali, loam, organic
matter or other deleterious substances. The aggregate shall be of uniform
grading and shall be of such a size that 100% will pass through a 10 mm
mesh and not more than 10% will pass through a 150 micron mesh. A pre-
mixed non-shrink resin grout may he used. The manufacturer's instructions
on mixing and the placing of the grout shall be observed.
(2) Admixtures
An admixture which acts as a non-shrinking agent shall be added to the
grout only with the Engineer's approval. All proprietary admixtures shall be
added and mixed strictly in accordance with the manufacturer's
instructions.
(3) Surface Treatment
Concrete surface which is to be grouted shall be thoroughly cleaned and all
laitance removed from the surface by means of a hammer and chisel. A
power hammer shall not be used.
(4) Mixing
The Contractor shall submit @ to the Engineer for approval details of the
mix and the methods he intends to use, prior to the commencement of the
grouting.
(5) Placing
(1) Roofing
(2) Waterproofing
Waterproofing for reinforced concrete flat roofs shall be of lime concrete. The
minimum thickness of lime concrete shall be 10cm.
Mortar for use with brickwork shall be mixed in the proportions of 1:3
cement, sand or 1:2:5 cement, lime and sand by volume. Mortar may be
mixed by hand or machine. Hand mixing shall be carried out on a clean,
watertight platform. Cement shall be of a quality as described in the Section
20 for concrete. Sand shall be well-graded (2.5 mm down) hard and free
from deleterious substances. Lime for mortar shall be pure calcium
carbonate properly burned, then hydrated, and finely ground. All joints shall
be completely filled with mortar. The thickness of the horizontal mortar
Joints shall not exceed 40 mm to every four joints. The mortar shall be
used within 2 hours of mixing with water and any mortar not used then shall
be discarded.
The damp proof course shall be provided at joint and intersections laid on a
bed of cement sand (1:1), bedded in and coated on the upper surface with
liquid bitumen.
External fair faced wall shall be weather struck; faces or wall which are to
(5) Calking
The Contractor shall calk the joints to ensure water tightness of the building
structures. Prior to calking materials and working method shall be approved
by the Engineer.
(1) Timber
All timber shall be of best quality, perfectly dry and well seasoned, sawn die
square, free from sap, shakes, wanly edges, large loose or dead knots and
all other defects and shall be to the approval of the Engineer.
(2) Preservative
Timber to be used in shower rooms or in contact with the ground floor, shall
be treated with an approved preservative against rot or termite attack. The
backs or frames to be fixed to walls and all other bedding surfaces shall be
painted with two coats of preservative before fixing. All fixing blocks,
pallets, and other hidden timber shall be so treated prior to fixing.
All timber for Joinery fitting shall be of selected type properly seasoned and
dry to a agreed moisture content not exceeding 18%. The Engineer shall
have the right to check all timbering used and to reject any timber found to
have a moisture content exceeding 18%.
(4) Faults
Any defect in the wood works such as shrinks splits, fractures, etc shall be
removed and replaced to the satisfaction of the Engineer.
Prior to furnishing and installing, the Contractor shall submit the shop
drawings indicating shape, dimensions, material including hard wares and
locking method of doors and windows for all buildings for the approval of
the Engineer.
The standard requirements of doors and windows are as follows :
a. Steel doors
Frame and Stile Plates : more than 2.3 mm thick
Stile and Panel : more than l.6mmthick
Thickness : 80 mm
Hollow flush door shall be painted 2 coats of rust resistant paint and finish
coat. Hollow flush door shall be 9f the waterproof type.
c. Aluminium window : 70mm
Thickness : Aluminate
Finishing : double window 0.9 x 1.8 m e
Size single window 0.9 x 0.9 m or other
sizes as shown on the approved
drawing
Glass (tinted) : 6mm
d Aluminium swing doors
Frame and stile plate : More than 2.3 mm thick
Thickness : More than 45 mm
Size : As shown on the drawing
All other type of doors, windows which are shown on the drawings but not
specifically mentioned shall be provided to the satisfaction of the Engineer.
Upon completion of the works, glass shall be wiped clean and shall be
inspected by the Engineer.
(2) Materials
The materials to be used in the Works shall be free from defects and
conform to JIS Standard or relevant Standards approved by the Engineer,
(3) Workmanship
All plates and sections shall be true to form, free from twist and
straightened before any fabrication work is started on them. The works of
cutting, fabrication, welding, installation and painting shall be done in
accordance with this Specification and relevant Standard. If difference
quality metals are in contact with each other, these contact surfaces shall
be separated by means of bituminous paint, felt strip, rubber sheet and
other material to be approved by the Engineer.
PVC flooring shall be heat resisting vinyl tiles obtained from an approved
manufacturer. The tiles shall be not less than 2.4 mm thick and laid by an
specialist to a jointing layout approved by the Engineer. A matching PVC
cove-type skirting is to be used in conjunction with the floor tiles. The tiles
and skirting shall be laid on a flat, clean concrete floor, in strict accordance
with the manufacturers instructions, using the recommended adhesive.
The tiles shall be plain and of manufacture and colour approved by the
Engineer. The tiles shall be laid by experienced craftsman, on a concrete
slab accurately formed with a true, smooth surf ace. Joints shall be
accurately aligned in both directions and matching covered skirtings.
Expansion Joints shall be the same width as tile Joints, approximately 5
mm, and filled with approved filling material. The surface of the base shall
be cleaned of all dirt, grease, grit, etc. and the tiles shall be dry and clean.
In-situ terrazzo paving is to consist of2 1/2 parts 6.5 mm 9.5 mm approved
marble chippings, clean and free from dust, mixed with one part of
"concrete" or "snowcrete" or approved equivalent according to the
background required. The terrazzo shall be laid by a specialist.
(1) Materials
Cement, sand, hydrated lime, gypsum plaster, expanded metal lathing, flat
headed galvanised nails, galvanised staples and wire shall all comply with
approved standards. Materials shall be carefully store in a dry weatherproof
store until required for use.
Backgrounds for plaster work shall be carefully brushed out and removed
dust and other deleterious matter likely to impair the bond of the under coat
with the structure. When the background surface is dry and undue suction
occurs, this shall be sprinkled with water to, prevent drying the applied
plaster.
(3) Plasterwork
Approximately two days after the fixing of the tiles, all joints shall be pointed
with neat white grouting cement; the finish shall be flushed and free from all
voids and irregularities.
All wall faces shall be finished plumb and flush throughout free from
unevenness and irregularities of plain; all angles shall be straight and true.
The finished work shall be left clean and free from all materials, which will
scratch or in any way impair the finished work. Final polishing shall be done
with a dry cloth. The Contractor shall be responsible for the adequate
protection of the tiling from all damage until the handling over. Any damage
which does occur shall be made good by the Contractor at his own
expense. The whole of the work shall be left in a state satisfactory to the
Engineer.
(6) Suspended Ceiling
The stud partition shall be extended from floor to ceiling with variation in
heights to suit. Stud shall be formed of approximately 0.03 gauge cold
rolled steel with pre-punched holes in the web 150 mm on centre to allow
horizontal passage of utility lines. Studs shall be spaced 1000 mm on
centre with horizontal spacer channels and framing materials.
21.6.1 Materials
(unit:kg/sq.m)
Mixed paint Synthetic resin emulsion
Metal Wood Concrete Brick
First paint
(Rust inhibitive paint) 0.14 0.09 0.13
Second paint 0.08 0.11 0.13
Finishing paint 0.04 0.09 0.13
Note: Rust inhibitive paint shall be either red lead or zinc rich lead
type.
Prior to painting, the dust, grease, injurious adherent substance, rust shall
be removed from the surface to be painted. The planed grain, interlocked
grain, fluff in wood shall be ridded with sandpaper and all cracks, manholes
open; duct and other imperfection shall be made good with hard stopping
consisting of paste white lead and gold size stiffened with whiting. Cracks
and holes on the concrete surface shall be flattened with cement paste,
mortar, or cement filler.
21.6.3 Workmanship
All painting and decoration shall be carried out by skilled workmen ac-
cording to the best current practice in accordance with manufacturer's
instructions.
All materials shall be applied by brush unless otherwise specified or
approved.
21.6.4 Priming
All joinery, metal works to be painted shall be primed using appropriate and
approved primer before delivery assembly or fixing. No primer is required
on surfaces to be distempered or emulsion painted unless otherwise
specified.
21.6.6 Storage
The Contractor shall furnish an exclusive place for storing the combustible
paints. The place for storage shall be fully ventilated. Adequate measures
shall be taken against the ingress of dust and direct rays of the sun.
Spare Parts
22.2 Spares & Service during Long Term Service agreement (LTSA)
The Contractor shall submit a list of spare parts with OEM Part No. and consumables
(lube. oils, greases, air & oil filters, chemicals etc.) to be necessary for day to day opera-
tion and maintenance of the generating units and other plant equipment inclusive of emer-
gency use that takes place in the course of operation (according to the Manufacture's rec-
ommendation and guideline) during the Warranty period (24 months). During the warranty
period of 24 months, the Contractor shall supply all necessary equipment, spare parts,
materials/consumables etc. at his own cost and whether it is listed or not in their list. In
preparation of the list the tenderer have to consider plant factor as 80%. During the war-
ranty period the Contractor have to conduct (providing all required spare parts and ser-
vice) at least 1(One) CI for Gas Turbine and at least one Inspection for other equipment
and any other maintenance work for force outage. 1 (one) HGPI spares is also included.
Spare parts & consumables to be supplied for warranty period under the Contract must be
made available at site before start of testing.
The Contractor shall provide the essential spare parts, which are specified in this Tender.
[Schedule F of Volume 2 of 2 Part B].
22.2 Spares & Service during Long Term Service agreement (LTSA)
The tenderer have to provide a price quotation from GT Original Equipment Manufacturer
with confirmation that they agree to provide LTSA for GT for 5 years after the warranty
period within the terms and condition of the quotation, which will be attached along with
the tender. BPDB will sign a separate contract with OEM for GT on the basis of quotation
related LTSA. Without such confirmed quotation the tender will be rejected. It is to be
noted that the price quoted for LTSA of GT will not be considered in the evaluation. The
tenderer have to provide all spares consumables and service during warranty period as
stated in clause 22.1 volume 2 of 2 part A.
For gas turbine maintenance at least 1 (One) CI, 1 (One) HGPI and 1 (One) MI within the
LTSA period have to be considered.
Note:
All spare parts shall be subject to the same specification, tests and conditions as similar
material supplied under the inter-changeable and suitable for use in place of the corre-
sponding parts supplied with the plant and must be suitably marked and number for identi-
fication and prepared for storage by greasing or painting to prevent deterioration.
All spare parts shall be delivered in cases or containers suitable for storing such parts
over a period of years without deterioration under the atmospheric conditions existing in
Bangladesh. The cases shall remain the property of the Board.
Each case or container shall be marked with the appropriate contract details and a list of
the parts contained therein with identification references given of the outside of the enclo-
sure.
Provision for expert services and spare parts for smooth operation (including all
inspection/overhauling/ major overhauling of Gas Turbine, for Five (5) years after
expiry of warrantee period under 'Long Term Service Agreement (LTSA)' from the
original equipment manufacturer (OEM) of GT for GHORASAL 300 - 450 MW GAS
BASED COMBINED CYCLE POWER PLANT PROJECT
The Operation & Day to Day Maintenance (O & M) is expected to be performed by BPDB
personnel, but a O&M Contracting Firms may be engaged. But LTSA provider will be re-
sponsible for all other scheduled and forced maintenance of GTG unit(s) and other essen-
tial auxiliaries during the LTSA period.
The manufacturer of GTG will have the requisite potential to furnish detailed technical &
financial proposal for LTSA for the Power Plants covering all major maintenances of GTG
units and essential BOP equipment for a period of 5 (five) years after the expiry of war-
ranty period of the Generating units.
2. SOURCE OF FUND
The remuneration of expert services, the cost of spares and other expenditures under the
LTSA shall be borne by BPDB
3. SUBMISSION OF BID
The bid shall be submitted as part of the tender for the project and shown under Sched-
ule F, Volume 3 of 3.
Scope of work of Expert Service required for overhauling (CI, HGPI and major)
of GTG units and other essential auxiliaries of Ghorasal 300-450 MW gas based
Combined Cycle power plant project
Before starting minor, intermediate and major overhauling (CI, HGPI, MI etc) of GTG units
and other essential auxiliaries, all the parameters, Data of the control system and Vibra-
B. Scope of services:
SCHEDULED OUTAGES
Scheduled maintenance outages shall be carried out at such time as set out in the table
below or as per GTG manufacturer's guidelines.
The Experts proposed shall supervise and carry out the scheduled CI/HGPI /
MI & overhauling, maintenances of essential BOP equipment, testing & com-
missioning work of the followings (indicative, but not limited to):
During LTSA period, it shall also be the responsibility of the LTSA provider to train
up (by on job training) BPDB personnel adequately and properly in a planned
manner so that they can take over the responsibility of operation and inspection/
maintenance of the plant and equipment independently.
LTSA provider will provide overseas training to BPDB personnel and they (BPDB
personnel) will witness manufacturing process and tests of the materials and
spares (to be supplied under LTSA) at manufacturers' works:
For HGPI materials/ spares: 03 person, 30 person-days (each person 10 days ex-
cluding travel time);
Necessary spares required for the CI, HGPI, major inspection / overhauling work (e,g; 1st
& 2nd stage Nozzles, Buckets, Shroud with hardware as per OEM guidelines) and all other
day to day maintenance spares of GTG units will be provided by the L TSA provider. List
of such spares with price offer shall be provided in the Proposal. Normal tools/tackles as
available at the Power Station site will be provided.
Special tools/tackles & Instruments required for the proposed services shall have to be
arranged by the L TSA provider at their own arrangement.
All necessary spares required for the Electrical protection system and Control system (DCS
or GTG control system) like relays, electronic cards, pick-ups, monitors, micro switches.
sensors, switches, oil seals, etc., which shall be provided by the LTSA provider.
All necessary spares required for the Electrical system/ equipment (HV/MV/LV) including
transformers, switchgears etc., shall be provided by the LTSA provider
All necessary spares required for the maintenance work relating to other BOP equipment
/ machinery (fuel handling, cooling, lubricating system etc).
After the CI, HGPI, major overhauling of Gas Turbine Generating units and proper check-
ing of control system, testing, calibration of various equipment etc, the machine should be
commissioned and gradually loaded up to full capacity. During commissioning, note all the
parameters, data and vibrations, temp, pressure and compare those with the data noted
before and after overhauling. If requires, subsequent correction measure should be ac-
complished.
A complete report shall be submitted; immediately after completion of the CI, HGPI, ma-
jor overhauling of Gas Turbine units to the Plant Manager, Ghorasal 300-450 MW CCPP.
After completion of CI / HGPI / overhauling work, the Experts (of LTSA pro-
vider) shall be responsible for testing & commissioning and putting back the
GTG units into successful normal operation & guarantee the load output and
the other normal operation parameters of the GTG, Maximum load test shall be
performed after commissioning of each unit. Uninterrupted continuous opera-
tion of 168 hours of each GTG unit shall have to be carried out jointly by both O
& M personnel and LTSA provider. If the unit trips for its own troubles/ faults
within this period, then the unit shall have to be started after necessary correc-
tive measures and put the unit into operation for 168 hours again. If the unit
trips for external faults / troubles (e.g. Grid problem) within this period, then
the balance running time will be added to the period already run by the unit.
1. GENERAL
1.1 The terms or conditions of Contract shall not be binding upon the LTSA pro-
vider unless agreed and accepted in writing by the duly authorized representa-
tive of the LTSA provider.
2. SPECIFICATIONS
Services and supply of spares shall be supplied in accordance with the conditions
and the specification set out in the Contract and both LTSA provider and the 0 & M
contractor is responsible for satisfying itself to their suitability for the Procuring en-
tity's application.
3. BASIS OF PRICE
3.1 Basis of price for this Contract shall be according to the actual service required
during a particular period, as mentioned in the scope of work and number of Su-
pervisors to be provided.
3.2 Basis of price for this Contract shall be according to the actual supply of spares/
equipment to be required against each service (inspection & overhaul) during a
particular period, as mentioned in the scope of work.
3.3 Supervisory Service fee shall include base rate, holiday rate, traveling day rate,
overtime rate, air fare, food and any other expenditure whatsoever necessary
should be included in the man day rate of supervising service fee.
3.4 Accommodation of Experts may be provided by the Manager of the Power Station
site subject to the availability of the same. The rate of such accommodation shall
have to 'be paid by the LTSA provider as per BPDB rules applicable to LTSA pro-
vider /consultant's personnel.
4.1 The Procuring entity shall provide in time any approval, instruction, material, civil
works, access to site or other thing which may be required in relation to the per-
formance of the LTSA provider's obligations and which is not expressly stated to
be the LTSA provider's responsibility.
4.2 Procuring entity will assist the LTSA provider to obtain any authorization required
by any authority in the country of installation to allow the LTSA provider to per-
form this Contract in due time.
5.1 Unless provided otherwise in the Contract, no variation to the Contract may be
made unless agreed in writing by the LTSA provider and the Procuring entity.
5.2 If any variation of work increases or reduces the cost of the LTSA provider for per-
forming the work satisfactorily then the Contract price shall be adjusted accord-
ingly.
5.3 The time for performance of the Contract shall be extended in order to take into
account the consequences of any variation.
5.4 A variation will not be effective until an agreement on price and delivery is reached
6.1 LTSA provider warrants to the Procuring entity that the services part of the Con-
tract will be performed in a competent manner (International standard practice or
appropriate maintenance guideline). If any failure to meet the foregoing warranty
appears within one (1) year counted from the date of particular work (inspec-
tion/overhauling) performed and subsequent issuance of Provisional Acceptance
Certificate (PAC) by a Committee to be constituted by the BPDB and if promptly
notified in writing thereof, LTSA provider will re-perform the service to the same
extent as the original service or either (at its option) repair any damage part of the
equipment or make available ex-works the repaired part or replacement for the
part which was damaged as a result of the poor performance of the service with-
out any demand of payment .
6.2 The liability of LTSA provider to the Procuring entity whether on warranty, contract
or negligence and the repair or replacement of any damaged part of the equip-
ment resulting from poor workmanship shall be re-performed by the LTSA provider
at their own responsibility. In such cases the liability regarding warranty shall be
extended by the both LTSA provider beyond one (1) year by proportioned weight
of the reperformed service counted from the date of issuance of PAC.
6.3 The provisions of this Clause shall not apply to any component parts or consum-
able items or materials the nature and purpose of which is such that it would be
reasonable to expect their replacement or repair in carrying out routine mainte-
nance operations during the period of guarantee stated herein or where such re-
placement or repair might reasonably be expected as a result of proper use, wear
and tear during the said period.
7.1 BPDB shall retain the ownership of its studies, drawings, software models and any
documents issued and communicated to Procuring entity, or of which Procuring
entity may have had knowledge in fulfillment of the Contract. Such information
and documents may be used only by Procuring entity and exclusively for execution
of the Contract and operation, maintaining, adjusting and repairing of the works.
These documents and information shall be treated as confidential and shall not be
distributed, published or generally communicated to any third parties without prior
permission of BPDB.
8.1 The total liability of the Contract on all claims of any kind for any loss or damage
resulting from performance or lack of performance by the LTSA provider under the
Contract shall be an amount up to the maximum of the Contract price.
8.2.1 For the purpose of this clause the LTSA provider is or shall be deemed to be acting
as agent or trustee on behalf of and for the benefit of all persons, firms or compa-
nies who are or may from time to time become Sub-LTSA provider's employees or
agents as aforesaid and to such extent all such persons firms or companies shall
be, or be deemed to be parties to the LTSA provider
If the LTSA provider fails to meet the delivery date (Completion time) as specified
in the Contract, then the LTSA provider shall pay to the Procuring entity liquidated
damages for that delay calculated on the Contract price of the delayed services at
a rate of 0.5% per week of the respective service (inspection/overhauling) cost of
the delayed services or such other rate as may be specified in the Contract.
10.1 If performance of any obligation under the Contract (other than the obligation of
the Procuring entity to make payment) is prevented, restricted or delayed by any
force majeure event. The party whose performance is affected shall be executed
from and shall not be liable for failure in performance to the extent of that pre-
vention, restriction or delay and the time for performance shall be extended ac-
cordingly.
10.2 Force majeure shall be defined as any circumstances beyond the reasonable con-
trol of the parties including but not limited to :
10.3 In case one party considers that an event shall be considered as force majeure
case and he shall inform the other party within a period of ten (10) working days
counted from the date he was informed of the event.
In case of force majeure case, the guaranteed delivery time shall be extended by
the delay time due to force majeure (including time to restart the work).
10.4 Any reasonable additional costs due to a force majeure case incurred by the LTSA
provider to continue to perform his obligations under the Contract so far as rea-
sonably practicable shall be certified and added to Contract value.
If the Contract is terminated under sub-clause 10.5 here above, the LTSA provider
shall be entitled to receive:
10.6.1 The outstanding balance of the value of the services which have
been delivered or performed.
10.6.2 The costs incurred by the LTSA provider up to the date of notice of
termination in performing services which are not then in a deliver-
able state.
Termination of the Contract in whole or in part however occasioned shall not af-
fect or prejudice the provisions of the clause, the Ownership and Confidentiality of
Technical information Clause or Limitation of Liability Clause above or the Law and
Arbitration Clause.
10.7 If as a consequence of force majeure and under the law governing the Contract,
the LTSA provider is released to perform the Contract. The sum payable by the
Procuring entity to the LTSA provider shall be as stated in 10.6.
11.1 The Procuring entity may by giving 30 days notice be entitled to terminate the
contract for LTSA provider's default in the following cases:
The LTSA provider repeatedly neglects to perform his Contractual obligations and
fail to comply within a reasonable time with the Procuring entity notice to make
good such neglects, or
The LTSA provider assigns the whole of work of the Contract to sub-LTSA provider
s without the employer's consent.
11.2 In case of termination (Art. 11.1) by the Procuring entity, the LTSA provider shall
not be paid further. The Contract value of the services which have already been
delivered or performed and the costs incurred by the LTSA provider up to the date
of notice of termination against which payment has been made by BPDB shall be
realized / recovered.
12.1 The LTSA provider may by giving 30 (Thirty) days notice be entitled to suspend
and / or terminate the Contract when the Procuring entity is :
- Failing to pay the LTSA provider in due time.
12.2 In case of termination by the LTSA provider. the Procuring entity shall pay to the
LTSA provider an amulet calculated as below:
12.2.1 The outstanding balance of the Contract value of the services which have
been delivered or performed and those goods which have been shipped
for delivery, and
12.2.2 The costs incurred by the LTSA provider up to the date of notice of termi-
nation in performing services which are not then in a deliverable state
plus a reasonable margin to be agreed between the parties
Termination of the Contract in whole or in part however occasioned shall not affect
or prejudice the provisions of the clause, the Ownership and Confidentiality of
Technical information Clause or Limitation of Liability Clause above or the Law and
Arbitration Clause.
13.1 Termination of the Contract in whole or in part however occasioned shall not affect
or prejudice the provisions of this Clause, the Ownership and Confidentiality of
technical Information Clause or limitation of Limitation of liability Clause above or
the Law and Arbitration Clause.
13.2 In case of termination, the LTSA provider shall be entitled to remove immediately
all equipment belonging to the LTSA provider, which is on site.
14. ARBITRATION
Any dispute arising out of the interpretation of application of the terms of this
agreement shall unless mutually settled by direct negotiation between the parties
of the agreement, be resolved through arbitration in accordance with rules of 'Ar-
bitration Act'-200 I of Bangladesh. The venue shall be in Dhaka, Bangladesh.
Payment of contract price for individual service / supply shall be made through ir-
revocable letter of credit established in favor of the LTSA provider advised by the
BOARD.
All bank charges outside Bangladesh shall be borne by the LTSA provider and in-
side Bangladesh by BPDB.
The LTSA provider shall have to bear all such charges inside and outside Bangla-
desh in case of extension of L/C if done at the request of the LTSA provider.
a) Contract signing: Contract will be signed separately for each of the individ-
ual services along with relevant supply of spares against inspec-
tion/overhauling of units/BOP.
b) Contract effectiveness: The contract shall come into force from the date of
receiving confirmed unconditional & irrevocable Bank Guarantee against
predominance security @ 10% of quoted price of the service and supply of
spares to be required for the units’/BOPs’ scheduled maintenance immedi-
ately after expiry of EPC contractor's warranty period.
17. INSURANCE
The insurance including all personal accident insurance for the expert will be ar-
ranged by the LTSA provider.
b) During payment of invoices by BPDB to the LTSA provider, IT and VAT (as per
regulations and approved rates of National Board of Revenue during the pe-
riod. of particular services) will be deducted at source from the contract price.
The LTSA provider shall indicate IT and VAT separately in the proposal.
LTSA provider shall be well conversant with the prevailing rules of the
Government of Bangladesh relating to income tax, VAT.
For HGPI materials/ spares: 03 person, 30 person-days (each person 10 days ex-
cluding travel time);
09(nine) round trip air fares from Dhaka, Bangladesh to the Manufacturer's
factory, meals, lodging costs transport expenses of the BPDB personnel during the
period of training including incidental expenses or medical expenses or Medical
Insurance from time to time will be covered by the LTSA provider. In addition,
pocket expenses will be US dollar 100 per day per person.
Appendices
1. Chemical Composition
a. Methane (CH4) 92 to 97 Percent by volume
b. Ethane (C2H6) 0 to 6.00 Percent by volume
c. Propane (C3H8) 0 to 1.00 Percent by volume
d. Butane (C4H4) 0 to 1.00 Percent by volume
e. Pentane (C5H12) & higher HC 0 to 2.00 Percent by volume
f. Hydrogen Sulphide (H2S) 0.5 grains per 10 S. Cu. ft.
g. Carbon Dioxide (CO2) 0 to 0.80 Percent by volume
h. Nitrogen (N2) 0 to 0.60 Percent by volume
i. Oxygen (O2) 0 to 1.00 Percent by volume
j. Inert Gas 0 to 5.00 Percent by volume
2. Physical Properties
a. Calorific Value (LHV) 900 Btu/ S. Cu. ft.
b. Temperature Range 150 c to 600C
c. Total Sulphur 20 grains or less in per 100
SCF gas
d. Solid Substances Free from solid material
beyond 5 microns in size
e. Specific Gravity (air=1) 0.55 to 0.67
f. Water content 7 lbs per 100,000 SCF
g. Liquefiable Hydrocarbons Not more than 2 American
gallons per 100,000 SCF
h. Pressure Range 80 - 150 Psig
SCOPE OF INSPECTION:
230 KV BUS
15.75/230 KV
15.75/230 KV 15.75/230 KV
Note: Generator Circuit Breaker & Unit Auxiliary Transformer are required to install with Steam Turbine Generator.
Ghorasal 300-450 MW CCPP Project (Vol-2A of 2) 303
Annexure-5
Environmental Standards
Gaseous Emission